2011-2013 Isuzu Q Series Truck Service & Repair Manual

WORKSHOP MANUAL ENGINE (4JB1 model) 2011MY

This Workshop Manual deals only with the screen toned section(s) in the table below. Section Sub Section 0 GENERAL INFORMATION 0A GENERAL INFORMATION 0B MAINTENANCE AND LUBRICATION 1 HEATING AND AIR CONDITIONING 00 SERVICE INFORMATION 1A HEATING AND VENTILATION 2 FRAME AND CAB 00 SERVICE INFORMATION 2 CAB AND FRAME 3 STEERING, SUSPENSION, WHEELS 00 SERVICE INFORMATION AND TIRES 3A FRONT END ALIGNMENT 3B1 POWER STEERING 3B2 MANUAL STEERING 3B3 STEERING LINKAGE 3B4 STEERING COLUMN 3C FRONT SUSPENSION 3D REAR SUSPENSION 3E WHEELS AND TIRES 4 PROPELLER SHAFT AND AXLE 00 SERVICE INFORMATION 4A PROPELLER SHAFT 4B REAR AXLE 4C FRONT AXLE 5 BRAKES 00 SERVICE INFORMATION 5A HYDRAULIC BRAKES 5C PARKING BRAKES 5E EXHAUST BRAKE 6 ENGINE 00 SERVICE INFORMATION 6A GENERAL ENGINE MECHANICAL 6A1 4JB1/4JB1-TC-ENGINE 6B ENGINE COOLING 6C ENGINE FUEL 6D ENGINE ELECTRICAL 6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM 6F ENGINE EXHAUST 6G TURBOCHARGER 7 MANUAL TRANSMISSION AND CLUTCH 00 SERVICE INFORMATION 7B MANUAL TRANSMISSION 7C CLUTCH 8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL (LEFT HAND DRIVE MODEL) 8 CAB AND CHASSIS ELECTRICAL 8 CAB AND CHASSIS ELECTRICAL (RIGHT HAND DRIVE MODEL) 9 SEAT BELT, SRS AIRBAG 9A SEAT BELT

SERVICE INFORMATION 00-1 ENGINE SECTION 00 SERVICE INFORMATION Contents TROUBLE SHOOTING ......................................... 00-2 Hard Starting ..................................................... 00-2 Unstable Idling ................................................... 00-5 Insufficient Power .............................................. 00-6 Excessive Fuel Consumption ............................ 00-7 Excessive Oil Consumption ............................... 00-7 Overheating ....................................................... 00-7 White Exhaust Smoke ....................................... 00-8 Dark Exhaust Smoke ......................................... 00-8 Oil Pressure Does Not Rise............................... 00-8 Abnormal Engine Noise ..................................... 00-9 Engine Cooling Trouble ................................... 00-10 Engine Electrical Part Trouble ......................... 00-11 Turbocharger ................................................... 00-16 Lubrication Chart ............................................. 00-23 MAIN DATA AND SPECIFICATIONS ................. 00-24 Main Data and Specifications .......................... 00-24 Engine Cooling ................................................ 00-26 Starting System ............................................... 00-26 Charging system.............................................. 00-27 SERVICE STANDARD........................................ 00-28 Engine Mechanical .......................................... 00-28 SERVICING ........................................................ 00-31 Model Identification.......................................... 00-31 Air Cleaner....................................................... 00-31 Lubricating System .......................................... 00-32 Fuel System..................................................... 00-32 Cooling System ............................................... 00-34 Engine Control ................................................. 00-37 Compression Pressure Measure-ment ............ 00-42 Quick-On Start II System................................. 00-43 FIXING TORQUE ................................................ 00-44 Cylinder Head Cover, Cylinder Head, Rocker Arm Shaft......................................................... 00-44 Crankshaft, Bearing Cap, Connecting Rod Cap, Crankshaft Damper Pulley, Flywheel, Oil Pan ............................................................. 00-45 Timing Pulley Housing, Timing Pulley, Timing Gear, Camshaft Oil Seal Retainer ................... 00-46 Cooling System and Lubrication System......... 00-47 Intake Manifold, Exhaust Manifold, Exhaust Pipe ................................................................. 00-48 Engine Electricals ............................................ 00-50 Engine Fuel ..................................................... 00-51 Engine Mounting Bracket ................................ 00-52 SPECIAL TOOLS ................................................ 00-53

00-2 SERVICE INFORMATION TROUBLE SHOOTING Hard Starting 1. Starter Inoperative 2. Starter Motor Operates But Engine Does Not Turn Over Checkpoint Possible cause Correction Battery Loose battery cable terminal poor connections due to rusting Clean and/or retighten the battery cable terminal Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt Fusible link Fusible link shorted Replace the fusible link Starter switch Defective starter switch or starter relay Replace the starter switch or the starter relay Starter motor Defective magnetic switch or starter relay Repair or replace the magnetic switch Defective starter motor Repair or replace the starter motor Checkpoint Possible cause Correction Battery Loose battery cable terminal Clean and/or retighten the battery cable terminal Poor connections due to rusting Recharge or replace the battery Battery discharged or weak Recharge or replace the battery Fan belt loose or broken Adjust or replace the fan belt Starter Defective pinion gear Replace the pinion gear Defective magnetic switch Repair or replace the magnetic switch Brush wear, Weak brush spring Replace the brush and/or the brush spring Engine Piston, crank bearing seizure, or other damage Repair or replace the related parts

2011-2013 Isuzu Q Series Truck Service & Repair Manual

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