ISUZU 4JJ1 4JK1 4JX1 TURBO Diesel Engine Workshop Manual

PAGE Section 6A Engine Mechanical .................................................................................... 1361 Section 6B Engine Cooling .......................................................................................... 1524 Section 6C Fuel System ............................................................................................... 1542 Section 6D Engine Electrical ....................................................................................... 1589 Section 6E Engine Control System ............................................................................ 1618 Section 6F Exhaust System ........................................................................................ 1986 Section 6H Engine Speed Control System ................................................................ 1998 SECTION 6 ENGINE TABLE OF CONTENTS ENGINE 6 4JK1/4JJ1 MODELS

ENGINE MECHANICAL (4JK1/4JJ1) 6A-1 SECTION 6A ENGINE MECHANICAL (4JK1/4JJ1) TABLE OF CONTENTS ISUZU DIESEL ENGINE (4JK1/4JJ1) ................ 6A-3 Service Precautions ........................................ 6A-3 Trouble Shooting ............................................. 6A-8 Main Data and Specifications .......................... 6A-13 Special Tools ................................................... 6A-14 Engine Assembly................................................ 6A-15 Removal .......................................................... 6A-15 Installation ....................................................... 6A-17 Special Tools ................................................... 6A-19 Engine Mount ..................................................... 6A-20 Components .................................................... 6A-20 Removal .......................................................... 6A-21 Installation ....................................................... 6A-21 Torque Specifications...................................... 6A-22 Special Tools ................................................... 6A-22 Cylinder Head Cover .......................................... 6A-23 Components .................................................... 6A-23 Removal .......................................................... 6A-24 Installation ....................................................... 6A-25 Intake Manifold ................................................... 6A-27 Components (Standard Output) ...................... 6A-27 Components (High Output) ............................. 6A-28 Removal .......................................................... 6A-29 Installation ....................................................... 6A-31 Torque Specifications...................................... 6A-32 Turbocharger and Exhaust Manifold (Standard Output) ........................................... 6A-33 Components .................................................... 6A-33 Removal .......................................................... 6A-34 Inspection ........................................................ 6A-36 Installation ....................................................... 6A-37 Torque Specifications...................................... 6A-40 Turbocharger (High Output) ............................... 6A-41 Components .................................................... 6A-41 Removal .......................................................... 6A-42 Inspection ........................................................ 6A-43 Installation ....................................................... 6A-44 Torque Specifications...................................... 6A-45 Exhaust Manifold (High Output) ......................... 6A-46 Components .................................................... 6A-46 Removal .......................................................... 6A-47 Inspection ........................................................ 6A-47 Installation ....................................................... 6A-47 Torque Specifications...................................... 6A-49 Timing Gear Train .............................................. 6A-50 Components .................................................... 6A-50 Removal .......................................................... 6A-51 Disassembly .................................................... 6A-53 Reassembly .................................................... 6A-53 Inspection ........................................................ 6A-54 Installation ....................................................... 6A-55 Torque Specifications...................................... 6A-58 Camshaft Assembly ........................................... 6A-59 Components .................................................... 6A-59 Removal .......................................................... 6A-60 Disassembly .................................................... 6A-61 Reassembly .................................................... 6A-63 Installation ....................................................... 6A-64 Torque Specifications...................................... 6A-66 Special Tools................................................... 6A-66 Valve Stem Seal and Valve Spring .................... 6A-67 Components .................................................... 6A-67 Removal .......................................................... 6A-68 Inspection ........................................................ 6A-69 Installation ....................................................... 6A-70 Special Tools................................................... 6A-71 Cylinder Head..................................................... 6A-72 Components .................................................... 6A-72 Removal .......................................................... 6A-72 Disassembly .................................................... 6A-81 Inspection ........................................................ 6A-83 Reassembly .................................................... 6A-87 Installation ....................................................... 6A-89 Torque Specifications...................................... 6A-100 Special Tools................................................... 6A-100 Piston and Connecting Rod................................ 6A-101 Components .................................................... 6A-101 Removal .......................................................... 6A-101 Disassembly .................................................... 6A-102 Reassembly .................................................... 6A-107 Installation ....................................................... 6A-108 Torque Specifications...................................... 6A-110

6A-2 ENGINE MECHANICAL (4JK1/4JJ1) Special Tools ................................................... 6A-110 Flywheel ............................................................. 6A-111 Components .................................................... 6A-111 Removal .......................................................... 6A-111 Inspection ........................................................ 6A-113 Installation ....................................................... 6A-113 Torque Specifications...................................... 6A-115 Special Tools ................................................... 6A-115 Gear Case Assembly ......................................... 6A-116 Components .................................................... 6A-116 Removal .......................................................... 6A-117 Installation ....................................................... 6A-118 Torque Specifications...................................... 6A-119 Crankshaft Front Oil Seal ................................... 6A-120 Components .................................................... 6A-120 Removal .......................................................... 6A-120 Installation ....................................................... 6A-121 Torque Specifications...................................... 6A-122 Special Tools ................................................... 6A-122 Crankshaft Rear Oil Seal ................................... 6A-123 Components .................................................... 6A-123 Removal .......................................................... 6A-124 Installation ....................................................... 6A-124 Special Tools ................................................... 6A-125 Crankshaft .......................................................... 6A-126 Components .................................................... 6A-126 Removal .......................................................... 6A-127 Disassembly .................................................... 6A-127 Reassembly..................................................... 6A-128 Inspection ........................................................ 6A-128 Installation ....................................................... 6A-132 Torque Specifications...................................... 6A-135 Cylinder Block .................................................... 6A-136 Components .................................................... 6A-136 Removal .......................................................... 6A-136 Inspection ........................................................ 6A-137 Installation ....................................................... 6A-139 Lubrication System ............................................. 6A-140 Service Precautions ........................................ 6A-140 Functional Check ............................................ 6A-141 Oil Filter Cartridge .............................................. 6A-143 Components .................................................... 6A-143 Removal .......................................................... 6A-143 Installation ....................................................... 6A-143 Special Tools ................................................... 6A-144 Oil Filter Assembly and Oil Cooler ..................... 6A-145 Components .................................................... 6A-145 Removal .......................................................... 6A-145 Disassembly .................................................... 6A-146 Reassembly..................................................... 6A-147 Installation ....................................................... 6A-147 Crank Case and Oil Pan .................................... 6A-150 Components .................................................... 6A-150 Removal .......................................................... 6A-151 Disassembly .................................................... 6A-152 Reassembly .................................................... 6A-152 Installation ....................................................... 6A-153 Torque Specifications...................................... 6A-155 Oil Pump ............................................................ 6A-156 Components .................................................... 6A-156 Removal .......................................................... 6A-156 Disassembly .................................................... 6A-157 Reassembly .................................................... 6A-158 Inspection ........................................................ 6A-158 Installation ....................................................... 6A-159 Oil Pressure SW ................................................ 6A-161 Components .................................................... 6A-161 Removal .......................................................... 6A-162 Inspection ........................................................ 6A-162 Installation ....................................................... 6A-162 Circuit check.................................................... 6A-162 Air Cleaner Element ........................................... 6A-163 Removal .......................................................... 6A-163 Cleaning .......................................................... 6A-163 Installation ....................................................... 6A-163

ENGINE MECHANICAL (4JK1/4JJ1) 6A-3 ISUZU DIESEL ENGINE (4JK1/4JJ1) Service Precautions Matters that require attention in terms of maintenance To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in maintaining the engine: • When lifting up or supporting the engine, do not apply a jack on the oil pan. When taking down the engine on the ground, do not make the bearing surface of the oil pan touch the ground directly. Use a wooden frame, for example, to support the engine with the engine foot and the flywheel housing. Because there is only a small clearance between the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer. • When the air duct or air cleaner is removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If it gets contaminated, it can considerably damage the cylinder and others while the engine is operating. • When maintaining the engine, never fail to remove the battery earth cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others. • Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started. • When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them. • When installing them, put them back in the same location they were removed from. • Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled. • As for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust is clinging to them. Then, apply the designated liquid gasket to each place anew before assembly. • Surfaces covered with liquid gasket must be assembled within 5 minutes of gasket application. If more than 5 minutes has elapsed, remove the existing liquid gasket and apply a new liquid gasket. • When assembling or installing parts, fasten them with the prescribed tightening torque so that they are installed properly. Matters that require attention in specifically dealing with this engine. Holes or clearances in the fuel system, which serve as a passage of fuel, including the inside of the injector, are made with extreme precision. For this reason, they are highly sensitive to foreign matter and, if it gets in, it can lead to an accident on the road, for instance; thus, make sure that foreign matter is prevented from getting in. When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system. • Before beginning the service procedure, wash the fuel line and the surrounding area. • Perform the service procedures with clean hands. Do not wear work gloves. • Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe. • If parts are to be replaced (fuel hose, fuel pipe, etc.) do not open the new part packaging until installation. Work procedure • The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and fuel rail. • The eyebolts and gasket must be stored in a clean parts box with a lid to prevent adhesion of foreign matter. • Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.

6A-4 ENGINE MECHANICAL (4JK1/4JJ1) How to read the model (This illustration is 4JK1 engine) RTW56ALF004701 Legend 1. Engine Model (Stamped) 2. Engine Number (Stamped) 3. Front Explanation of functions and operations Electronic engine control With the control unit, the range from injection to air intake/exhaust, including fuel injection quantity, injection timing, intake air restriction, EGR, and idling rpm, is controlled. Piston The piston is aluminum-alloy and a thermal flow piston with a strut cast, while the combustion chamber is a round reentrant type. Cylinder head The cylinder head is aluminum-alloy and there are 4 valves per cylinder. The angular tightening method of the cylinder head bolt further increases reliability and durability.

ENGINE MECHANICAL (4JK1/4JJ1) 6A-5 EGR system Based upon data, including water temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it. Its main components include an EGR valve, an EGR cooler and various sensors. Connecting rod cap bolt The angular tightening method of the connecting rod cap bolt further increases reliability and durability. Fuel rail-type electronic control injection system The fuel rail-type electronic control injection system is composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a fuel rail that measures such high-pressure fuel and a fuel injector that turns it into a fine spray and injects it. Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition. Fuel injector The fuel injector is a 6-hole nozzle that adjusts fuel injection quantity or injection timing by opening or closing an electromagnetic valve on the head of the fuel injector. ECM corrects the dispersion of fuel injection quantity between fuel injector according to ID code data in memory. At the replacement of fuel injector, ID code data should be stored in ECM. Fuel filter with sedimenter It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water, which comes with an indicator that notifies you that it is filled with water. Preheating system The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and makes the engine easy to start. Lubrication system It is an oil filter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston. Functional inspection Inspection/adjustment of valve clearance 1. Inspection of valve clearance • Remove the fuel injector harness assembly. • Remove the leak off hose. • Remove the cylinder head cover. • Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC). RTW76ASH001301 Legend 1. TDC

6A-6 ENGINE MECHANICAL (4JK1/4JJ1) • Insert a 0.15 mm (0.006 in) thickness gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm. Valve clearance mm (in) Intake valve 0.15 (0.006) Exhaust valve 0.15 (0.006) Note: Adjust while cold. 2. Adjustment of valve clearance • Loosen each adjusting screw of the rocker arm completely. RTW56ASH003701 Legend 1. Screwdriver 2. Ring Spanner 3. Valve Clearance Adjust Nut Wrench Special tool Valve clearance adjust nut wrench: 5-8840-2822-0 • Insert a 0.15 mm (0.006 in) thickness gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm. LHW71BSH001201 Legend 1. Cam; Exhaust 2. Cam; Intake 3. Roller; Intake 4. Roller; Exhaust Tightening torque: Rocker arm adjustment screw nut 18 N⋅m (1.8 kg⋅m/ 13 lb ft) Adjustment table Cylinder No. 1 2 3 4 Valve arrangement IN EX IN EX IN EX IN EX No. 1 cylinder Compression TDC No. 4 cylinder Compression TDC × × ×× • If the No.1 cylinder is the compression TDC, adjust a valve clearance with mark given on the table and if the No. 4 cylinder is the compression TDC, adjust that with × mark. • Install the cylinder head cover. Refer to "Cylinder Head Cover." • Install the leak off hose. • Install the fuel injector harness assembly. Compression pressure inspection • Warm up the engine. • Disconnect the negative battery cable.

ENGINE MECHANICAL (4JK1/4JJ1) 6A-7 • Remove the all glow plugs. Note: When the harness connector is removed, ECM judges that it broke down and DTC is recorded. Upon completion of measurement, never fail to clear the memory of the ECM. (For how to clear the memory of the ECM, refer to “ENGINE CONTROL SYSTEM” Section) • Connect the negative battery cable. • Turn on the starter to emit foreign matter within the cylinders. • Install an adapter and a gauge of a compression gauge of the special tool. RTW56ASH003801 Compression gauge: 5-8840-2675-0 Gauge adapter: 5-8840-2815-0 • Turn on the starter to inspect compression pressure. Compression pressure MPa(psi)/200rpm Standard 2.84 − 3.24 (412 − 469) Limit 1.96 (284) Differences among the cylinders 294 kPa (43) • Measure each cylinder one by one. Note: To keep engine speed at 200 rpm or more, use fully charged batteries. • Remove a compression gauge of the special tool. • Disconnect the negative battery cable. • Install the glow plugs. • Connect the negative battery cable. A list of defective phenomena • Engine does not turn over. • Engine turns over but does not start. • Excessive black exhaust smoke. • Excessive white exhaust smoke. • Engine knocking. • Abnormal engine rotation. • Abnormal battery charging. • Turbocharger trouble shooting.

6A-8 ENGINE MECHANICAL (4JK1/4JJ1) Trouble Shooting Engine does not turn over Condition Possible Cause Correction Dead or weak battery Charge battery Replace battery Incomplete circuit Connect Repair Starter motor brushes stuck, worn, or broken Replace brushes Starter motor does not rotate Starter motor internal damage Repair motor Ring gear abrasion Replace ring gear Starter motor not meshed with flywheel Magnetic switch (starter motor) not properly adjusted Adjust Dead or weak battery Charge battery Replace battery Insufficient contact pressure between starter motor brushes and commutator Adjust pressure Armature (starter motor) stuck Repair armature Starter motor pinion meshed with ring gear but does not rotate Engine internal damage (Seizure) Repair engine Engine turns over but does not start Condition Possible Cause Correction Air in fuel system Bleed air from fuel system Air entering fuel pipe Replace pipe and bleed air from fuel system Empty fuel tank Replenish fuel Clogged strainer (fuel suction) Clean or replace strainer Clogged fuel pipe Clean or replace pipe Feed pump malfunction Replace pump Use of wrong fuel for prevailing temperatures Drain existing fuel and replace with appropriate fuel Fuel is not delivered to fuel supply pump Clogged fuel filter Replace filter Loose injection pipe connections Tighten connections Loose or broken electrical connectors Tighten and/or replace connectors Bad rotational sensor Replace sensor Fuel is delivered to fuel supply pump Engine control system malfunction System diagnosis Air in fuel system Bleed air from fuel system Feed pump malfunction Repair pump Loose or broken electrical connectors Tighten and/or replace connectors Clogged fuel filter Replace filter Insufficient or unstable fuel delivery volume Engine control system malfunction System diagnosis

ENGINE MECHANICAL (4JK1/4JJ1) 6A-9 Excessive black exhaust smoke Condition Possible Cause Correction Bad injection timing Engine control system malfunction System diagnosis Carbon deposit at nozzle tip Clean fuel injector assembly Sticking nozzle Replace fuel injector assembly Bad fuel injector condition Engine control system malfunction System diagnosis Excessive valve clearance Adjust clearance Sticking valve stem (valve open) Repair or replace valve Damaged valve spring Replace spring Valve seat abrasion Repair valve seat Compression leakage due to damaged piston ring Replace piston ring Damaged gasket Replace gasket Insufficient compression pressure Piston scoring Replace piston Water in fuel Drain existing fuel and replace with new fuel Fuel condition Poor fuel quality Drain existing fuel and replace with new fuel Clogged intake pipes Clean or replace pipes Poor engine aspiration Clogged air cleaner element Clean or replace element Defective sensor Replace sensor Malfunction detected by engine control system Engine control system malfunction System diagnosis Intake throttle valve sticking Repair or replace valve EGR valve sticking Repair or replace valve EGR valve and/or intake throttle valve malfunction Engine control system malfunction System diagnosis Damaged turbocharger blade Replace turbocharger Rough turbocharger shaft rotation Replace turbocharger Oil leakage from oil seal Replace turbocharger Turbocharger malfunction Broken actuator Replace turbocharger

ISUZU 4JJ1 4JK1 4JX1 TURBO Diesel Engine Workshop Manual

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