Isuzu A-4JA1 Manuals

Manuals and User Guides for Isuzu A-4JA1. We have 1 Isuzu A-4JA1 manual available for free PDF download: Workshop Manual

Isuzu A-4JA1 Workshop Manual

Isuzu A-4JA1 Workshop Manual (232 pages)

INDUSTRIAL DIESEL ENGINE

Brand: Isuzu | Category: Engine | Size: 5.91 MB

Table of Contents

Table of Contents
3
General Information
4
General Repair Instructions
5
Notes on the Format of this Manual
5
General Information
7
Main Data and Specifications
9
Standard Bolt
10
Tightening Torque Specifications
10
Maintenance
20
- Engine Serial Number
  21
- Injection Pump Identification
  21
- Lubricating System
  21
- Main Oil Filter
  21
- Model Identification
  21
- Fuel Filter
  22
- Fuel System
  22
  - Air Bleeding
    23
  - Water Separator (Water Sedimentor)
    23
  - Injection Nozzle
    24
  - Injection Nozzle Adjustment
    24
  - Injection Nozzle Inspection
    24
  - Spray Condition
    24
  - Cooling Fan Drive Belt
    25
- Cooling System
  25
  - Operating Test
    25
  - Thermostat
    25
- Valve Clearance Adjustment
  26
- In-Line Type Injection Pump
  27
- Injection Timing
  27
- Compression Pressure Measurement
  29
  - Engine Oil Viscosity Chart
    30
  - Engine Oil Viscosity Grade – Ambient Temperature
    30
- Recommended Lubricants
  30
- Engine Repair Kit
  31
Section 3. Engine Assembly (1)
32
Engine Assembly (1)
32
Disassembly
34
- Fuel Injection Pipe with Clip
  35
- Injection Pump
  35
- Exhaust Manifold
  35
- Injection Nozzle Holder
  38
- Rocker Arm Shaft and Rocker Arm
  38
- Cylinder Head
  38
- Crankshaft Damper Pulley with Dust Seal
  39
- Idler Gear
  39
- Timing Gear Backlash Measurement
  39
- Idler Gear “A” End Play Measurement
  39
- Piston and Connecting Rod with Upper Bearing
  40
- Connecting Rod Cap with Lower Bearing
  40
- Camshaft with Camshaft Timing Gear and Thrust Plate
  40
- Flywheel
  40
- Crankshaft Bearing Cap with Lower Bearing
  41
- Crankshaft Upper Bearing
  41
- Tappet
  41
- Crankshaft Rear Oil Seal
  41
- Single Unit
  42
- Rocker Arm Shaft Bracket
  43
- Rocker Arm Shaft Snap Ring
  43
- Split Collar
  45
- Intake and Exhaust Valve
  45
- Piston and Connecting Rod
  46
- Connecting Rod Bearing
  47
- Piston Ring
  47
- Piston Pin Snap Ring
  47
- Piston Pin
  47
- Camshaft, Camshaft Timing Gear, and Thrust Plate
  48
- Camshaft Timing Gear
  49
- Thrust Plate
  49
Engine Assembly (2)
50
Inspection and Repair
51
- Valve Guide
  52
- Manifold Fitting Face Warpage
  52
- Valve Stem and Valve Guide Clearance
  52
- Valve Guide Replacement
  52
- Valve and Valve Seat Insert
  53
- Valve Guide Installation
  53
- Valve Stem Outside Diameter
  53
- Valve Thickness
  53
- Valve Seat Insert Removal
  54
- Valve Seat Insert Replacement
  54
- Valve Depression
  54
- Valve Contact Width
  54
- Valve Seat Insert Installation
  55
- Valve Seat Insert Correction
  55
- Valve Spring
  56
- Valve Spring Free Height
  56
- Valve Spring Inclination
  56
- Valve Spring Tension
  56
- Rocker Arm Shaft and Rocker Arm Clearance
  57
- Rocker Arm Shaft Run-Out
  57
- Rocker Arm Shaft Outside Diameter
  57
- Rocker Arm Correction
  58
- Cylinder Body
  58
- Cylinder Body Upper Face Warpage
  58
- Cylinder Liner Bore Measurement
  59
- Cylinder Liner Projection Inspection
  59
- Cylinder Body Bore Measurement
  60
- Cylinder Liner Removal
  60
- Cylinder Liner Grade Selection
  60
- Cylinder Liner Replacement
  60
- Cylinder Liner Installation
  61
- Piston Selection
  62
- Piston Grade Selection
  63
- Piston Grade
  63
- Cylinder Liner and Piston Clearance
  63
- Tappet and Push Rod
  64
- Tappet Outside Diameter
  64
- Push Rod Curvature
  65
- Tappet and Cylinder Body Clearance
  65
- Camshaft
  65
- Camshaft Journal Diameter
  65
- Camshaft and Camshaft Bearing
  66
- Camshaft Bearing Replacement
  66
- Camshaft Run-Out
  66
- Cam Height
  66
- Camshaft Bearing Installation
  67
- Camshaft End Play
  67
- Thrust Plate Replacement
  67
- Thrust Plate Removal
  67
- Crankshaft and Bearing
  68
- Crankshaft Tufftriding Inspection
  68
- Judgment
  68
- Crankshaft Journal and Crankpin Diameter
  69
- Crankshaft Run-Out
  69
- Bearing Tension
  69
- Crankshaft Journal and Bearing Clearance
  70
- Connecting Rod Bearing Inside Diameter
  70
- Crankpin and Bearing Clearance
  71
- Crankshaft Timing Gear Replacement
  73
- Crankshaft Timing Gear Removal
  73
- Crankshaft Timing Gear Installation
  73
- Crankshaft Pilot Bearing Installation
  74
- Crankshaft Pilot Bearing Replacement
  74
- Crankshaft Pilot Bearing
  74
- Flywheel and Ring Gear
  75
- Ring Gear
  75
- Ring Gear Installation
  76
- Piston
  76
- Piston Ring Gap
  76
- Piston Ring and Piston Ring Groove Clearance
  77
- Piston Ring and Piston Ring Groove
  77
- Piston Pin Diameter
  78
- Piston Pin and Piston Clearance
  78
- Connecting Rod Bushing Removal
  78
- Connecting Rod Bushing Installation
  79
- Connecting Rod Alignment
  79
- Idler Gear Shaft and Idler Gear
  80
- Connecting Rod Side Face Clearance
  80
- Idler Gear Shaft Outside Diameter
  80
- Crankshaft Front Oil Seal Replacement
  81
- Idler Gear “A” Inside Diameter
  81
- Timing Gear Case Cover
  81
- Oil Seal Installation
  82
Engine Assembly (3)
84
Reassembly
85
- Rocker Arm Shaft
  86
- Valve Stem Oil Seal
  88
- Crankcase
  100
- Oil Pump with Oil Pipe
  101
- Flywheel Housing
  101
- Flywheel Housing Bolt Torque
  101
- Oil Pan
  102
- Intake Manifold
  108
Lubricating System
112
- Item
  113
- Main Data and Specifications
  113
- General Description
  114
- Lubricating Oil Flow
  114
- Oil Pump
  117
- Vane and Pump Body Clearance
  118
- Oil Filter with Built-In Oil Cooler
  120
- Rotor and Vane Clearance
  118
- Vane, Rotor, and Cover Clearance
  118
- Relief Valve
  121
- Oil Cooler
  121
- Relief Vale
  123
Cooling System
124
- Item
  125
- Main Data and Specifications
  125
- Coolant Flow
  126
- General Description
  126
- Water Pump
  127
- Water Pump
  128
  - Bearing Unit
    130
  - Cooling Fan Center
    132
  - Impeller and Seal Unit
    132
  - Set Screw
    132
- Thermostat
  134
Fuel System
136
- Item
  137
- Main Data and Specifications
  137
- General Description
  138
- Fuel Filter and Water Separator
  140
- Injection Nozzle
  141
- Injection Pump Data
  146
- Injection Volume Adjustment
  146
- Governor Adjustment
  147
- Injection Quantity
  147
- Full Adjustment
  147
- Speed Lever Angle
  148
- Section 9. Engine Electricals
  150
Engine Electricals
150
- Starter Identification
  151
- Armature
  157
- Armature Short Circuit Test
  157
- Armature Winding Ground Test
  157
- Armature Winding Continuity Test
  157
- Commutator Run-Out Test
  158
- Commutator Outside Diameter Measurement
  158
- Commutator Outside Diameter
  158
- Segment Mica Depth Measurement
  158
- Field Winding Continuity Test
  159
- Brush and Brush Holder
  159
- Field Winding Ground Test
  159
- Yoke
  159
- Brush Spring Inspection
  160
- Brush Holder Insulation Test
  160
- Pinion Clutch
  160
- Pinion Inspection
  160
- Pinion
  163
- Dust Cover
  163
- Shift Lever
  163
- Torsion Spring
  163
- Through Bolt
  164
- Lead Wire
  164
- Inspection after Reassembly
  164
- When Pinion Gap Deviates from Specified Value
  164
- Alternator
  165
- Alternator Identification
  165
- Rectifier with Brush Holder
  169
- Rotor and Bearing
  169
- Front Cover
  169
- Pulley and Fan
  169
- Ball Bearing
  170
- Rotor Coil Continuity Test
  171
- Rotor Coil Ground Test
  171
- Stator Coil Continuity Test
  171
- Stator Coil Ground Test
  172
- Rectifier (Positive Diode) Continuity Test
  172
- Rectifier (Negative Diode) Continuity Test
  173
- Rectifier Assembly Replacement Procedure
  173
- Brush
  174
Section 10. Troubleshooting
178
- Hard Starting
  180
- Unstable Idling
  184
- Unstable Idling
  186
- Insufficient Power
  187
- Excessive Fuel Consumption
  191
- Excessive Oil Consumption
  193
- Overheating
  194
- White Exhaust Smoke
  196
- Dark Exhaust Smoke
  197
- Oil Pressure Does Not Rise
  198
- Abnormal Engine Noise
  200
- Engine Knocking
  200
- Continuous Noise
  201
- Gas Leakage Noise
  201
- Slapping Noise
  202
Section 11. Special Tool List
204
- Special Tool List
  205
- General Rules
  208
Section 12. Repair Standards
208
- Millimeters to Inches
  222
- Inches to Millimeters
  222
Section 13. Conversion Table
222
- Feet to Meters
  223
- Length
  223
  - Meters to Feet
    223
  - Miles to Kilometers
    223
- Area
  224
- Volume
  224
  - Gallons (Imp.) to Liters
    225
  - Gallons (U.s.) to Liters
    225
  - Liters to Gallons (Imp.)
    225
  - Liters to Gallons (U.s.)
    225
  - Kilograms to Newton
    226
  - Kilograms to Pounds
    226
- Mass
  226
- Pressure
  227
  - Foot Pounds to Kilogrammeters
    228
  - Kilogrammeters to Foot Pounds
    228
  - Kilogrammeters to Newtonmeters
    228
- Torque
  228
- Temperature
  229
- Fahrenheit to Centigrade
  229
- Centigrade to Fahrenheit
  229

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