Isuzu NPR 4J Series Manuals

Manuals and User Guides for Isuzu NPR 4J Series. We have 1 Isuzu NPR 4J Series manual available for free PDF download: Workshop Manual

Isuzu NPR 4J Series Workshop Manual

Isuzu NPR 4J Series Workshop Manual (407 pages)

Brand: Isuzu | Category: Engine | Size: 9.56 MB

Table of Contents

Table of Contents
4
Service Information Contents
5
Table of Contents
5
Troubleshooting Contents
6
Hard Starting
7
Unstable Idling
10
Insufficient Power
11
Excessive Fuel Consumption
13
Excessive Oil Consumption
13
Overheating
14
White Exhaust Smoke
14
Dark Exhaust Smoke
15
Oil Pressure Does Not Rise
15
Abnormal Engine Noise
16
- Engine Knocking
  16
- Gas Leakage Noise
  16
- Continuous Noise
  16
- Slapping Noise
  17
Engine Cooling Trouble
18
Engine Electrical Part Trouble
19
Engine Has Less than Normal Power
24
Turbocharger
24
Lubrication Chart
33
Main Data and Specifications
34
- Engine Cooling
  36
- Starting System
  36
- Charging System
  37
Engine Mechanical
38
Service Standard
38
- Model Identification
  42
- Air Cleaner
  42
- Dust Fouled Element
  42
Servicing
42
Fuel System
44
Fixing Torque
55
Special Tools
64
- General Engine Mechanical Contents
  68
- Cylinder Head
  69
- Valve Spring, Valve Guide Oil Seal, Valve Guide, Push Rod
  77
- Camshaft, Tappet
  84
  - Camshaft, Tappet Disassembly
    84
  - Camshaft, Tappet Inspection and Repair
    85
  - Camshaft Bearing Replacement
    86
  - Tappet
    87
  - Tappet Reassembly
    87
- Rocker Arm Assembly
  91
- Oil Pump
  94
  - Oil Pump Disassembly
    94
  - Oil Pump Inspection and Repair
    95
  - Oil Pump Reassembly
    96
- Crankshaft
  98
  - Crankshaft Disassembly
    98
  - Crankshaft Inspection and Repair
    99
  - Run-Out
    101
  - Crankshaft Bearing Selection
    102
  - Crankshaft Reassembly
    103
  - Timing Belt
    108
  - Crankshaft Damper Pulley
    110
  - Injection Pump
    112
- Piston and Connecting Rod
  114
- Cylinder Block
  123
  - Cylinder Block Disassembly
    123
  - Cylinder Block Inspection and Repair
    124
  - Cylinder Liner Projection Inspection
    124
  - Flatness
    124
  - Cylinder Liner Bore Measurement
    125
  - Cylinder Liner Grade Selection
    125
  - Cylinder Body Bore Measurement
    126
  - Cylinder Liner Installation
    127
  - Cylinder Block Reassembly
    128
  - 4JB1/4JB1T/4JB1TC/4JG2-Engine Contents
    136
- General Description
  137
- Engine Mount (RH)
  139
  - Engine Mount (RH) Removal
    139
  - Engine Mount (RH) Installation
    140
- Engine Mount (LH)
  141
  - Engine Mount (LH) Removal
    141
  - Engine Mount (LH) Installation
    142
- Inlet Manifold
  143
  - Inlet Manifold Removal
    143
  - Inlet Manifold Installation
    144
- Exhaust Manifold
  145
  - Exhaust Manifold Removal
    145
  - Exhaust Manifold Installation
    146
- Oil Cooler
  147
  - Oil Cooler Removal
    147
  - Oil Cooler Inspection
    148
  - Oil Cooler Installation
    148
- Oil Filter Cartridge
  149
  - Oil Filter Cartridge Installation
    149
  - Oil Filter Cartridge Removal
    149
- Cylinder Head Cover
  150
  - Cylinder Head Cover Installation
    150
  - Cylinder Head Cover Removal
    150
- Rocker Arm Shaft Assembly
  152
  - Rocker Arm Shaft Installation
    152
  - Rocker Arm Shaft Removal
    152
- Valvestem Oil Controller and Valve Spring
  155
- Cylinder Head Assembly and Gasket
  172
  - Cylinder Head and Gasket Installation
    176
  - Tension Adjustment
    181
- Oil Pan
  183
  - Oil Pan Removal
    183
  - Oil Pan Installation
    185
- Oil Pump Assembly
  186
  - Oil Pump Removal
    186
  - Oil Pump Installation
    188
- Piston, Piston Ring and Connecting Rod
  189
  - Piston, Piston Ring and Connecting Rod Removal
    189
  - Piston, Piston Ring and Connecting Rod Installation
    192
- Camshaft and Tappet
  198
  - Camshaft and Tappet Removal
    198
  - Camshaft and Tappet Installation
    203
- Crankshaft Front Oil Seal (Gear Drive Type)
  206
  - Crankshaft Front Oil Seal (Gear Drive Type) Removal
    206
  - Crankshaft Front Oil Seal (Gear Drive Type) Installation
    207
- Crankshaft Front Oil Seal (Belt Drive Type)
  208
  - Crankshaft Front Oil Seal (Belt Drive Type) Removal
    208
  - Crankshaft Front Oil Seal (Belt Drive Type) Installation
    209
- Crankshaft Rear Oil Seal (Gear & Belt Drive Type)
  211
  - Crankshaft Rear Oil Seal (Gear & Belt Drive Type) Removal
    211
  - Crankshaft Rear Oil Seal (Gear & Belt Drive Type) Installation
    215
- Flywheel and Pilot Bearing
  218
  - Flywheel and Pilot Bearing Removal
    218
  - Flywheel and Pilot Bearing Installation
    219
- Crankshaft and Main Bearings
  220
  - Crankshaft and Main Bearings Removal
    221
  - Crankshaft and Main Bearings Installation
    225
- Engine Assembly
  231
  - Engine Removal
    231
  - Engine Installation
    238
  - Engine Cooling Contents
    244
  - Engine Cooling General Description
    244
  - Radiator
    245
  - Thermostat
    245
  - Water Pump
    245
  - Anti-Freeze Solution
    248
- On-Vehicle Service
  249
  - Water Pump Removal
    249
  - Water Pump Inspection
    250
  - Water Pump Installation
    251
  - Thermostat Inspection
    253
  - Thermostat Removal
    253
  - Thermostat Installation
    254
  - Radiator Removal
    255
  - Radiator Inspection
    256
  - Radiator Installation
    257
  - Drive Belt Adjustment Inspection
    258
  - Engine Fuel Contents
    260
- General Description
  261
  - Fuel Flow
    262
  - Injection Pump
    263
  - Fuel Filter and Water Separator
    264
  - Injection Nozzle
    265
- Fuel Filter Assembly
  266
  - Fuel Filter Installation
    266
  - Fuel Filter Removal
    266
- On-Vehicle Service
  266
- Fuel Filter Cartrige
  267
- Injection Pump Assembly (Gear Drive Type)
  286
- Injection Pump Asm (4JB1/4JB1T, 4JG2 Gear Drive Type) Installation
  287
- Injection Pump Assembly (Belt Drive Type)
  287
- Injection Timing Adjustment
  300
- Adjustment of Idling Speed
  301
- Injection Pump Data
  302
  - Test Conditions
    302
  - Identification Plate and Number
    303
- Injection Volume and Governor Performance Diagram
  304
- Fuel Tank
  314
  - Fuel Tank Removal
    314
  - Fuel Tank Installation
    315
- Fuel Gauge Unit
  316
  - Fuel Gauge Unit Installation
    316
  - Fuel Gauge Unit Removal
    316
- Accelerator Control Cable
  317
  - Accelerator Control Removal
    317
  - Accelerator Control Inspection
    318
  - Accelerator Control Installation
    318
- Accelerator Pedal
  319
  - Accelerator Pedal Installation
    319
  - Accelerator Pedal Removal
    319
- Idling Control Cable
  321
  - Idling Control Cable Installation
    321
  - Idling Control Cable Removal
    321
- Air Cleaner Element
  323
  - Air Cleaner Element Removal
    323
  - Air Cleaner Element Installation
    324
  - Battery Contents
    326
  - Engine Electrical Contents
    326
- Battery
  327
- Diagnosis
  327
- Fluid Level Check
  327
- General Description
  327
  - Visual Inspection
    327
  - Voltage Check
    327
  - Load Test
    328
- Battery Charging
  329
- On-Vehicle Service
  329
- Jump Starting
  330
  - Jump Starting with an Auxiliary (Booster) Battery
    330
  - Jump Starting Procedure
    331
- Main Data and Specifications
  332
- Removal and Installation of Battery
  332
  - Starting Circuit
    334
  - Starting System Contents
    334
  - Starting System Installation
    336
  - Starting System Removal
    336
  - Starting System Disassembly
    338
  - Unit Repair
    338
  - Armature
    341
  - Starting System Inspection and Repair
    341
  - Yoke
    342
  - Bearing
    343
  - Brush and Brush Holder
    343
  - Overrunning Clutch
    343
  - Starting System Reassembly
    344
  - Magnetic Switch
    345
  - Charging System Contents
    346
  - Generator
    347
  - Charging Circuit
    348
  - General On-Vehicle Inspection
    349
  - Generator Removal
    350
  - Generator Installation
    351
  - Generator Disassembly
    354
  - Generator Inspection and Repair
    355
  - Rotor
    356
  - Stator Coil
    356
  - Brush
    357
  - Diode
    357
  - IC Regulator
    358
  - Vacuum Pump
    359
  - Generator Reassembly
    360
  - Charging System Disassembly
    362
  - Charging System Inspection and Repair
    364
  - Charging System Reassembly
    366
  - Output Characteristic
    366
  - QOSII Preheating System (4JB1/4JB1T/4JB1TC Only)
    368
  - QOS II Timing Chart
    369
  - System Diagram
    369
  - Gow Plug
    370
  - Inspection on QOSII System Operation Thermo Switch
    370
  - QOSII System Troubleshooting
    371
  - QOSIII Preheating System (4JG2 Only) Contents
    374
  - QOS III Flow Chart
    376
  - QOS III Block Chart
    377
  - Inspection on QOSIII System Operation
    378
  - Glow Plug
    379
  - Thermo Sensor
    379
  - Charge Relay
    380
  - Dropping Resistor
    380
  - Glow Plug Relay
    380
  - Exhaust Gas Recirculation (EGR) System Contents
    382
- General Description
  383
- EGR System Operation
  384
- EGR System Wiring Diagram
  384
  - Exhaust Gas Recirculation (EGR) System Check
    385
  - EGR System Inspection
    386
  - Engine Exhaust Contents
    388
- General Description
  389
  - General Export
    389
  - Model ’91/542B (Euro 2)
    389
- Three Way Catalytic Converter
  390
- Front Exhaust Pipe
  391
- Front Exhaust Pipe Removal
  391
- On-Vehicle Service
  391
  - Exhaust Brake Unit Inspection
    392
  - Front Exhaust Pipe Installation
    392
  - Turbocharger Contents
    394
  - Turbocharger Main Data and Specifications
    395
- General Description
  396
- Identification of Unit
  397
- Precautions
  397
- Turbocharger Servicing
  397
  - Disassembly Steps
    398
  - Turbocharger Disassembly
    398
  - Turbocharger Inspection and Repair
    400
  - Reassembly Steps
    402
  - Turbocharger Reassembly
    402
- Ihi Service Network
  404

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