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WORKSHOP MANUAL 2011 SERIES - ENGINE 4JJ1 MODEL (ISUZU)
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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 theyare installed properly.
CONTENTS:
ISUZU DIESEL ENGINE (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-26
Components.................................................... 6A-26
Removal .......................................................... 6A-27
Installation ....................................................... 6A-28
Torque Specifications...................................... 6A-30
Turbocharger and Exhaust Manifold .................. 6A-31
Components.................................................... 6A-31
Removal .......................................................... 6A-32
Inspection........................................................ 6A-34
Installation ....................................................... 6A-35
Torque Specifications...................................... 6A-38
Timing Gear Train .............................................. 6A-39
Components.................................................... 6A-39
Removal .......................................................... 6A-40
Disassembly.................................................... 6A-42
Reassembly..................................................... 6A-42
Inspection........................................................ 6A-43
Installation ....................................................... 6A-44
Torque Specifications...................................... 6A-47
Camshaft Assembly ........................................... 6A-48
Components.................................................... 6A-48
Removal .......................................................... 6A-49
Disassembly.................................................... 6A-50
Reassembly .................................................... 6A-52
Installation ....................................................... 6A-53
Torque Specifications...................................... 6A-55
Special Tools................................................... 6A-55
Valve Stem Seal and Valve Spring .................... 6A-56
Components.................................................... 6A-56
Removal .......................................................... 6A-57
Inspection........................................................ 6A-58
Installation ....................................................... 6A-59
Special Tools................................................... 6A-60
Cylinder Head..................................................... 6A-61
Components.................................................... 6A-61
Removal .......................................................... 6A-61
Disassembly.................................................... 6A-69
Inspection........................................................ 6A-71
Reassembly .................................................... 6A-76
Installation ....................................................... 6A-77
Torque Specifications...................................... 6A-88
Special Tools................................................... 6A-88
Piston and Connecting Rod................................ 6A-89
Components.................................................... 6A-89
Removal .......................................................... 6A-89
Disassembly.................................................... 6A-90
Reassembly .................................................... 6A-94
Installation ....................................................... 6A-95
Torque Specifications...................................... 6A-97
Special Tools................................................... 6A-97
Flywheel ............................................................. 6A-98
Components.................................................... 6A-98
Removal .......................................................... 6A-98
Inspection........................................................6A-100
Installation .......................................................6A-100
Torque Specifications......................................6A-102
Special Tools...................................................6A-102
Gear Case Assembly .........................................6A-103
Components....................................................6A-103
Removal ..........................................................6A-104
Installation .......................................................6A-105
Torque Specifications......................................6A-107
6A-2 ENGINE MECHANICAL (4JJ1)
Crankshaft Front Oil Seal...................................6A-108
Components....................................................6A-108
Removal ..........................................................6A-108
Installation .......................................................6A-109
Torque Specifications......................................6A-110
Special Tools...................................................6A-110
Crankshaft Rear Oil Seal ...................................6A-111
Components....................................................6A-111
Removal ..........................................................6A-112
Installation .......................................................6A-112
Special Tools...................................................6A-113
Crankshaft..........................................................6A-114
Components....................................................6A-114
Removal ..........................................................6A-115
Disassembly....................................................6A-116
Reassembly.....................................................6A-116
Inspection........................................................6A-116
Installation .......................................................6A-120
Torque Specifications......................................6A-123
Cylinder Block ....................................................6A-124
Components....................................................6A-124
Removal ..........................................................6A-124
Inspection........................................................6A-125
Installation .......................................................6A-126
Lubrication System.............................................6A-128
Service Precautions ........................................6A-128
Functional Check ............................................6A-129
Oil Filter Cartridge ..............................................6A-131
Components....................................................6A-131
Removal ..........................................................6A-131
Installation .......................................................6A-131
Special Tools...................................................6A-132
Oil Filter Assembly and Oil Cooler .....................6A-133
Components....................................................6A-133
Removal ..........................................................6A-133
Installation .......................................................6A-135
Crank Case and Oil Pan.....................................6A-137
Components....................................................6A-137
Removal ..........................................................6A-138
Disassembly....................................................6A-139
Reassembly.....................................................6A-139
Installation .......................................................6A-140
Torque Specifications......................................6A-142
Oil Pump ............................................................6A-143
Components....................................................6A-143
Removal ..........................................................6A-143
Disassembly....................................................6A-145
Reassembly ....................................................6A-145
Inspection........................................................6A-145
Installation .......................................................6A-146
Oil Pressure SW ................................................6A-149
Components....................................................6A-149
Removal ..........................................................6A-150
Inspection........................................................6A-150
Installation .......................................................6A-150
Circuit check....................................................6A-150
Air Cleaner Element ...........................................6A-151
Removal ..........................................................6A-151
Cleaning ..........................................................6A-151
Installation .......................................................6A-151
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 theyare installed properly.
CONTENTS:
ISUZU DIESEL ENGINE (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-26
Components.................................................... 6A-26
Removal .......................................................... 6A-27
Installation ....................................................... 6A-28
Torque Specifications...................................... 6A-30
Turbocharger and Exhaust Manifold .................. 6A-31
Components.................................................... 6A-31
Removal .......................................................... 6A-32
Inspection........................................................ 6A-34
Installation ....................................................... 6A-35
Torque Specifications...................................... 6A-38
Timing Gear Train .............................................. 6A-39
Components.................................................... 6A-39
Removal .......................................................... 6A-40
Disassembly.................................................... 6A-42
Reassembly..................................................... 6A-42
Inspection........................................................ 6A-43
Installation ....................................................... 6A-44
Torque Specifications...................................... 6A-47
Camshaft Assembly ........................................... 6A-48
Components.................................................... 6A-48
Removal .......................................................... 6A-49
Disassembly.................................................... 6A-50
Reassembly .................................................... 6A-52
Installation ....................................................... 6A-53
Torque Specifications...................................... 6A-55
Special Tools................................................... 6A-55
Valve Stem Seal and Valve Spring .................... 6A-56
Components.................................................... 6A-56
Removal .......................................................... 6A-57
Inspection........................................................ 6A-58
Installation ....................................................... 6A-59
Special Tools................................................... 6A-60
Cylinder Head..................................................... 6A-61
Components.................................................... 6A-61
Removal .......................................................... 6A-61
Disassembly.................................................... 6A-69
Inspection........................................................ 6A-71
Reassembly .................................................... 6A-76
Installation ....................................................... 6A-77
Torque Specifications...................................... 6A-88
Special Tools................................................... 6A-88
Piston and Connecting Rod................................ 6A-89
Components.................................................... 6A-89
Removal .......................................................... 6A-89
Disassembly.................................................... 6A-90
Reassembly .................................................... 6A-94
Installation ....................................................... 6A-95
Torque Specifications...................................... 6A-97
Special Tools................................................... 6A-97
Flywheel ............................................................. 6A-98
Components.................................................... 6A-98
Removal .......................................................... 6A-98
Inspection........................................................6A-100
Installation .......................................................6A-100
Torque Specifications......................................6A-102
Special Tools...................................................6A-102
Gear Case Assembly .........................................6A-103
Components....................................................6A-103
Removal ..........................................................6A-104
Installation .......................................................6A-105
Torque Specifications......................................6A-107
6A-2 ENGINE MECHANICAL (4JJ1)
Crankshaft Front Oil Seal...................................6A-108
Components....................................................6A-108
Removal ..........................................................6A-108
Installation .......................................................6A-109
Torque Specifications......................................6A-110
Special Tools...................................................6A-110
Crankshaft Rear Oil Seal ...................................6A-111
Components....................................................6A-111
Removal ..........................................................6A-112
Installation .......................................................6A-112
Special Tools...................................................6A-113
Crankshaft..........................................................6A-114
Components....................................................6A-114
Removal ..........................................................6A-115
Disassembly....................................................6A-116
Reassembly.....................................................6A-116
Inspection........................................................6A-116
Installation .......................................................6A-120
Torque Specifications......................................6A-123
Cylinder Block ....................................................6A-124
Components....................................................6A-124
Removal ..........................................................6A-124
Inspection........................................................6A-125
Installation .......................................................6A-126
Lubrication System.............................................6A-128
Service Precautions ........................................6A-128
Functional Check ............................................6A-129
Oil Filter Cartridge ..............................................6A-131
Components....................................................6A-131
Removal ..........................................................6A-131
Installation .......................................................6A-131
Special Tools...................................................6A-132
Oil Filter Assembly and Oil Cooler .....................6A-133
Components....................................................6A-133
Removal ..........................................................6A-133
Installation .......................................................6A-135
Crank Case and Oil Pan.....................................6A-137
Components....................................................6A-137
Removal ..........................................................6A-138
Disassembly....................................................6A-139
Reassembly.....................................................6A-139
Installation .......................................................6A-140
Torque Specifications......................................6A-142
Oil Pump ............................................................6A-143
Components....................................................6A-143
Removal ..........................................................6A-143
Disassembly....................................................6A-145
Reassembly ....................................................6A-145
Inspection........................................................6A-145
Installation .......................................................6A-146
Oil Pressure SW ................................................6A-149
Components....................................................6A-149
Removal ..........................................................6A-150
Inspection........................................................6A-150
Installation .......................................................6A-150
Circuit check....................................................6A-150
Air Cleaner Element ...........................................6A-151
Removal ..........................................................6A-151
Cleaning ..........................................................6A-151
Installation .......................................................6A-151
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