Isuzu Truck repair manual, workshop manual, maintenance, electrical wiring diagrams, Isuzu N series engine repair manual, specifications. Manuals for Isuzu Diesel Engines Owner and Workshop Manuals are important documents that should be. Workshop Manual 4H Serie s. Workshop Manual 4JA1-NA.
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- 2Table of Contents
- 3General Information
- 4General Repair Instructions
- 6Symbols Used in the Manual
- 8Main Data and Specifications
- 11Design Features and General Outline
- 11Main Engine Parts and Their Function
- 11Cylinder Head
- 12Cylinder Body
- 12Crankshaft
- 13Pistons
- 13Valve Mechanism
- 14Tightening Torque Specifications
- 15Angular Nut and Bolt Tightening Method
- 17Major Part Fixing Nuts and Bolts
- 17Cylinder Head and Cover
- 18Cylinder Body Diagram
- 19Oil Pan and Dipstick Diagram
- 20Camshaft and Rocker Arm Diagram
- 21Crankshaft, Piston and Flywheel Diagram
- 22Thermostat and Thermostat Housing Diagram
- 23Intake and Exhaust Manifold Diagram
- 24Timing Gear Case and Flywheel Housing Diagram
- 25Oil Cooler, Oil Filter, and Oil Pump Diagram
- 26Fuel System Diagram
- 27Turbocharger Diagram
- 28Identifications
- 28Engine Serial Number
- 28Injection Pump Number
- 29Maintenance
- 30Lubricating System Maintenance
- 30Main Oil Filter Replacement
- 30Center Bolt Type Removal/Installation
- 30Cartridge (Spin-on) Type Removal/Installation
- 31Fuel System Maintenance
- 31Fuel Filter Replacement
- 32Injection Nozzle Maintenance
- 33Spray Condition Check (During Injection Nozzle Tester Operation)
- 34Water Separator (Water Sedimentor) Check
- 34Air Bleeding Check
- 35Cooling System Maintenance
- 35Valve Clearance and Adjustment
- 35Cooling Fan Drive Belt Adjustment
- 35Thermostat Inspection
- 37Injection Timing
- 37Flange Mounted Injection Pump Injection Timing Checking and Adjustment
- 38Injection Timing Checking Procedure
- 41Coupling Driven Injection Pump Timing Adjustment
- 43Compression Pressure Measurement
- 44Turbocharger Inspection
- 45Engine Repair-kit (For Non-turbocharged Engines) Diagram
- 46Engine Repair Kit (For Turbocharged Engines) Diagram
- 47Recommended Lubricants
- 47Engine Oil Viscosity Chart
- 49Engine Assembly I (Disassembly)
- 50External Parts Disassembly Steps
- 50Model 6BD1T Right Side View/Disassembly Steps
- 51Model 4BD1T View/Disassembly Steps
- 52Injection Pump With Injection Pump Gear
- 52Flange Mounted Injection Pump Removal
- 52Coupling Mounted Injection Pump Removal
- 52Remove of the Air Compressor (If Equipped)
- 53Model 6BD1T Left Side View/Disassembly Steps
- 54Model 4BD1T Left Side View/Disassembly Steps
- 55Major Components/Disassembly Steps
- 56Rocker Arm Shaft
- 56Cylinder Head Bolts
- 56Crankshaft Pulley Nut
- 57Taper Bushing (6B Series Only)
- 57Flywheel
- 58Major Components II/Disassembly Steps
- 59Idler Gear
- 59Cam Shaft
- 59Crankshaft Bearing Cap
- 60Rocker Arm and Rocker Arm Shaft View/disassembly Steps
- 61Cylinder Head View/Disassembly Steps
- 61Split Collar Removal
- 62Piston and Connecting Rod View/Disassembly Steps
- 63Piston Rings Removal
- 63Snap Ring and Piston Pin Removal
- 65Engine Assembly II (Inspection and Repair)
- 66Cylinder Head Lower Face Warpage Check
- 66Water Jacket Water Pressure Test
- 67Valve Stem and Valve Guide Clearance
- 67Valve Guide Replacement/Removal
- 68Valve Depression
- 68Valve Contact Width
- 68Valve Seat Insert Replacement/Removal
- 69Valve Seat Installation
- 69Valve Seat Insert Correction
- 70Valve Spring Free Length Measurement
- 71Valve Spring Inclination
- 71Valve Spring Tension
- 71Tappet (Cam Follower or Valve Lifter) Inspection
- 72Push Rod Inspection
- 72Rocker Arm Correction
- 72Rocker Arm Shaft and Rocker Arm Inspection
- 72Rocker Arm Shaft Outside Diameter Measurement
- 73Idler Gear and Idler Gear Shaft Inspection
- 73Rocker Arm Shaft and Rocker Arm Clearance Check
- 74Camshaft Inspection
- 75Cylinder Liner Bore Measurement
- 76Cylinder Liner Projection Inspection
- 76Cylinder Liner Replacement
- 77Cylinder Bore Measurement
- 77Cylinder Liner Grade Selection
- 77Cylinder Body Inside Diameter Measurement
- 78Cylinder Liner Outside Diameter Measurement
- 78Cylinder Bore and Cylinder Liner Outside Diameter Combinations
- 79Cylinder Liner Installation
- 79Piston Grade Selection
- 80Cylinder Liner Bore Measurement/Piston Outside Diameter
- 81Cylinder Liner Bore and Piston Clearance
- 82Piston Ring and Piston Ring Groove Clearance
- 82Piston Ring and Piston Groove Clearance
- 82Piston Ring Gap
- 83Piston Pin Outside Diameter
- 83Piston Pin and Piston Clearance
- 83Piston Pin and Piston Pin Hole Clearance
- 84Connecting Rod Alignment
- 84Piston Pin and Connecting Rod Small End Bushing Clearance
- 84Connecting Rod Bushing Replacement
- 85Connecting Rod Bearing Inspection
- 86Crankshaft and Bearing Inspection
- 86Crankshaft Journal and Crankpin Outside Diameter
- 87Crankshaft Journal and Bearing Clearances
- 88Crankshaft Journal Bearing Inside Diameter
- 88Connecting Rod Bearing Inside Diameter
- 89Crankshaft Run-Out
- 89Main Bearing and Connecting Rod Bearing Tension
- 89Crankshaft Regrinding
- 90Crankshaft Regrinding Procedure
- 90Crankshaft Grinding Limit
- 91Plastigage Clearance Measurement
- 91Crankshaft Journal Bearing Clearance
- 92Crankshaft Pin Bearing Clearance
- 92Crankshaft Tufftriding Inspection
- 93Oil Seal Wear Ring Replacement (6BD1T, 6BG1, 6BG1T)
- 93Crankshaft Gear Inspection
- 94Crankshaft Gear Replacement
- 94Flywheel and Flywheel Housing (Rear Oil Seal) Inspection
- 94Rear Gear Inspection/Replacement/Installation
- 94Flywheel Housing Oil Seal Replacement
- 95Timing Gear Case Cover Inspection
- 95Crankshaft Front Oil Seal Replacement
- 97Engine Assembly III (Reassembly)
- 98Piston and Connecting Rod Reassembly Steps - Minor Component
- 99Pistons Heating/ Connecting Rod Installation
- 99Piston Pin Snap Ring Installation
- 99Piston Ring Installation
- 99Connecting Rod Bearing Installation
- 100Cylinder Head Reassembly Steps
- 101Valve Stem Oil Seal Installation
- 101Intake and Exhaust Valves Installation
- 101Intake and Exhaust Valve Springs Installation
- 101Spring Seat Split Collar Installation
- 102Intake Manifold and Gasket Installation
- 102Exhaust Manifold and Gasket Installation
- 104Rocker Arm and Rocker Arm Shaft Reassembly Steps
- 105Major Component Reassembly Steps I
- 106Oil Jet Installation
- 106Crankshaft Bearing Configuration
- 106Crankshaft Installation
- 106Thrust Bearing Installation
- 107Crankshaft Bearing Cap Installation
- 107Timing Gear Case Installation
- 107Camshaft/Thrust Plate Bolts Tightening
- 107Idler Gear Shaft Installation
- 108Idler Gear Installation
- 108Piston and Connecting Rod Installation
- 109Oil Pump and Coupling Installation
- 109Flywheel Housing Installation
- 110Oil Pan Installation
- 110Oil Cooler Installation
- 111Major Component Reassembly Steps II
- 112Flywheel Installation
- 112Injection Pump and Injection Pump Gear Assembly
- 112Air Compressor Installation
- 113Tappet Chamber Cover Installation
- 113Water Pump Installation
- 113Cylinder Head Gasket/Bolt Installation
- 115Rocker Arm and Rocker Arm Shaft Installation
- 116External Parts Reassembly Steps (Left-hand Side)
- 117Cylinder Head Cover Installation
- 117Fan Belt Adjustment
- 117Starter Motor Installation
- 118Turbocharger Mounting Flange Gasket Positioning
- 118Turbocharger Nuts Tightening
- 118Oil Drain Pipe Installation
- 119Oil Feed Pipe Installation
- 119Turbo Adaptor Tightening
- 120External Parts Reassembly Steps (Right-hand Side) - Model 6BD1T
- 121Injection Nozzle Installation
- 121Fuel Injection Pipe and Fuel Leak Off Pipe Installation
- 121Oil Filter Installation
- 122Fuel Pipe, Fuel Return Pipe, Intake Pipe Installation
- 122Injection Timing Adjustment
- 123Engine Tuning Operation
- 125Engine Sectional View
- 127Lubricating System
- 128Lubricating System - General Description
- 129Oil Pump Disassembly
- 130Oil Pump Drive Gear Inspection
- 130Oil Pump Driven Gear Inspection
- 131Main Oil Filter Disassembly/Inspection and Repair
- 132Lubricating System Reassembly
- 132Center Bolt and Drain Plug Installation
- 133Oil Cooler Disassembly, Inspection and Repair
- 134Lubricating System Reassembly Steps
- 134Oil Cooler Element Installation
- 135Cooling System
- 136Cooling System - General Description
- 137Water Pump Disassembly Steps
- 138Impeller/Pulley Center/Snap Ring Removal
- 138Spindle, Bearing, Spacer/Seal Unit, Washer and Seal Removal
- 139Bearing Replacement
- 140Cooling System Reassembly Steps
- 141Spindle, Bearing, and Spacer Installation
- 141Snap Ring/Pulley Center Installation
- 141Seal Unit, Washer and Seal Installation
- 142Impeller/Pulley Installaton
- 142Thermostat Inspection and Repair
- 143Fuel System
- 144Fuel System - General Description
- 145Fuel Filter Disassembly/Inspection and Repair
- 147Injection Nozzle Disassembly
- 148Push Rod Spring Check
- 148Nozzle Holder Push Rod Check
- 148Injection Nozzle Check
- 149Fuel Filter Reassembly Steps
- 150Injection Pipe Connector/Injection Nozzle/Retaining Nut Check
- 150Injection Starting Pressure Adjustment
- 151Nozzle Holder Cap Nut Check
- 152Injection Pump Calibration Data
- 152Identification Plate and Product Serial Number
- 152Test Conditions Required for the Fuel Injection Amount Adjustment
- 153Inj. Pump Calibration Data
- 154Governor Adjustment
- 155Turbocharger
- 156Turbocharger - General Description
- 157Turbocharger Identification
- 158Rotor Shaft Play Inspection
- 158Rotor Shaft Axial Play Measurement
- 159Air Compressor
- 160Air Compressor Sectional View/Main Data
- 161Air Compressor Disassembly Steps
- 162Air Compressor Inspection and Repair
- 164Air Compressor Reassembly Steps
- 165Connecting Rod/Bearing Cover Installation
- 165Cylinder Body/Cylinder Head Installation
- 167Engine Electricals
- 168Starter Motor Identification
- 168Nikko Identification Plate
- 168Hitachi Identification Plate
- 169Starter Motor Main Data and Specifications
- 171Starter Motor Sectional View
- 172Starter Motor Exploded View
- 173Alternator Identification
- 174Alternator Main Data and Specifications
- 176Regulator Main Data and Specifications
- 177Alternator Sectional View
- 178Alternator Exploded View
- 179Troubleshooting
- 180Hard Starting
- 180Starter Inoperative
- 181Starter Motor Operates but Engine Does Not Turn Over
- 182Engine Turns Over but Does Not Start, Fuel Is Being Delivered to the Injection Pump
- 183Engine Turns Over but Does Not Start
- 184Unstable Low Idling
- 187Unsufficient Power
- 190Excessive Fuel Consumption
- 193Overheating
- 195White Exhaust Smoke
- 196Dark Exhaust Smoke
- 197Oil Pressure Does Not Rise
- 199Abnormal Engine Noise
- 199Engine Knocking
- 199Gas Leakage Noise
- 200Continuous Noise
- 201Slapping Noise
- 203Special Tool List
- 207Conversion Table
- 207Length Conversion Table
- 209Area Conversion Table
- 209Volume Conversion Table
- 211Mass Conversion Table
- 212Pressure Conversion Table
- 213Torque Conversion Table
- 214Temperature Conversion Table