Isuzu 4LE2, Workshop Manual

Page 1: ...INDUSTRIAL DIESEL ENGINE 4LE2 MODEL 2003 ISUZU MOTORS LIMITED WORKSHOP MANUAL ...

Page 2: ... necessary maintenance service and repair procedures on applicable Isuzu industrial engines Information contained in this Workshop Manual is the latest available at the time of publication Isuzu reserves the right to make changes at any time without prior notice ...

Page 3: ...CTION 1 GENERAL INFORMATION 1 SECTION 2 ENGINE 27 SECTION 3 LUBRICATING SYSTEM 79 SECTION 4 COOLING SYSTEM 83 SECTION 5 FUEL SYSTEM 89 SECTION 6 TROUBLESHOOTING 101 SECTION 7 SPECIAL TOOL 107 SECTION 8 CONVERSION TABLE 109 ...

Page 4: ...ERAL REPAIR INSTRUCTIONS 2 NOTES ON THE FORMAT OF THIS MANUAL 2 APPEARANCE 5 MAIN DATA AND SPECIFICATIONS 6 TIGHTENING TORQUE SPECIFICATIONS 7 ANGULAR NUT AND BOLT TIGHTENING METHOD 9 TIGHTENING TORQUE ON MAJOR COMPONENTS 11 GASKET LOCATION 17 MAINTENANCE 20 RECOMMENDED LUBRICATING OIL 25 ...

Page 5: ...should be carefully followed 10 Always release the air pressure from any machine mounted air tank s before dismounting the engine or disconnecting pipes and hoses 11 Always check and recheck your work No service operation is complete until you have done this 12 Information contained in the Main Data and Specifications of the Workshop Manual and the Instruc tion Book may differ In this case the inf...

Page 6: ...dard and limit A measurement falling within the standard range indicates that the applicable part or parts are ser viceable Limit should be thought of as an absolute value A measurement which is outside the limit indicates that the applicable part or parts must be either repaired or replaced 8 Components and parts are listed in the singular form throughout the Manual Fig 1 Water Outlet Pipe 5 Pack...

Page 7: ...ease Sealant 10 Direction used in this Manual are as follows Front The cooling fan side of the engine viewed from the flywheel Right The injection pump side of the engine Left The exhaust manifold side of the engine Rear The flywheel side of the engine Cylinder numbers are counted from the front of the engine The front most cylinder is No 1 and rear most cylinder is No The engine s direction of ro...

Page 8: ...GENERAL INFORMATION 5 APPEARANCE 1 MODEL 4LE2 1 Left side view 2 Right side view Fig 2 Fig 3 ...

Page 9: ...sion pressure MPa kg cm2 psi 3 31 440 or more 250 min 1 Valve clearance cold Intake 0 4 0 0157 mm in Exhaust 0 4 0 0157 Intake valve Open BTDC 15 Valve Close ABDC 29 operating Exhaust valve Open BBDC 40 timing Close ATDC 16 Injection pump Bosch type Governor Mechanical type Nozzle Multi hole type Injection pressure MPa kg cm2 psi 17 7 180 2560 Oil pump Trochoid type Oil filter Cartridge type Lubri...

Page 10: ...15 4 23 0 151 0 226 0 15 4 23 0 206 0 310 0 21 0 31 6 190 0 286 0 19 4 29 2 251 0 414 0 25 6 42 2 218 0 328 0 22 2 33 4 359 0 540 0 36 6 55 0 338 0 507 0 34 5 51 7 004 9 009 8 00 5 01 0 011 8 022 6 01 2 02 3 027 5 046 1 02 8 04 7 027 5 045 1 02 8 04 6 060 8 091 2 06 2 09 3 056 9 084 4 05 8 08 6 093 2 139 0 09 5 14 2 088 3 131 0 09 0 13 4 135 0 204 0 13 8 20 8 129 0 194 0 13 2 19 8 195 0 293 0 19 9...

Page 11: ...3 03 8 054 9 082 3 05 6 08 4 051 0 076 5 05 2 07 8 083 0 125 0 08 5 12 7 077 2 116 0 07 9 11 8 116 0 173 0 11 8 17 7 109 0 164 0 11 2 16 7 006 6 012 2 00 6 01 2 015 3 028 4 01 6 02 9 035 4 058 9 03 6 06 1 034 5 057 5 03 5 05 8 077 7 117 0 07 9 11 9 071 4 107 0 07 3 10 9 115 0 172 0 11 7 17 6 108 0 162 0 11 1 16 6 171 0 257 0 17 4 26 2 163 0 244 0 16 6 24 9 018 1 033 6 02 1 03 4 042 3 070 5 04 3 07...

Page 12: ... of molybdenum disulfide grease to the threads and setting faces of the nuts and bolts 3 Tighten the nuts and bolts to the specified torque snug torque with a torque wrench Snug torque 4 Draw a line A B across the center of each bolt Center line ANGULAR NUT AND BOLT TIGHTENING METHOD Fig 4 Fig 5 Fig 6 ...

Page 13: ...n of the specified angle Q across the center E of the nut or bolt Specified angle Q Coinciding line E F G 7 Use a socket wrench to tighten each nut or bolt to the point where the line A B is aligned with the line F G A B C D F G Tighten Example Specified Angle and Tightening Rotation A 30 1 12 of a turn B 60 1 6 of a turn C 90 1 4 of a turn D 180 1 2 of a turn E 360 One full turn A B C D E Fig 7 F...

Page 14: ...OMPONENTS 1 COOLING FAN AND WATER PUMP N m kgf m ft lb Fig 11 19 28 1 9 2 9 14 21 12 18 1 2 1 8 9 13 12 18 1 2 1 8 9 13 19 28 1 9 2 9 14 21 To cylinder head 19 28 1 9 2 9 14 21 To cylinder head 19 28 1 9 2 9 14 21 34 46 3 5 4 7 25 34 19 28 1 9 2 9 14 21 ...

Page 15: ... 2 4 0 2 0 4 1 4 2 9 8 12 0 8 1 2 6 9 8 12 0 8 1 2 6 9 8 12 0 8 1 2 6 8 Apply sealant 83 93 8 5 9 5 61 69 60 90 Apply engine oil 19 28 1 9 2 9 14 21 15 20 1 5 2 0 11 14 0 9 1 1 0 09 0 11 0 6 0 8 19 28 1 9 2 9 14 21 25 34 2 5 3 5 18 25 Apply Locktite No 262 to this part Apply engine oil ...

Page 16: ......

Page 17: ... 20 25 2 0 2 5 15 18 19 28 1 9 2 9 14 21 8 12 0 8 1 2 6 9 8 12 0 8 1 2 5 8 8 7 19 28 1 9 2 9 14 21 69 88 7 0 9 0 51 65 21 30 2 1 3 1 15 22 Apply engine oil 19 28 1 9 2 9 14 21 Positioning pin 19 28 1 9 2 9 14 21 8 12 0 8 1 2 6 9 10 14 1 0 1 4 7 10 15 25 1 5 2 5 11 18 31 41 3 2 4 2 23 30 ...

Page 18: ... 12 0 8 1 2 6 9 12 16 1 2 1 6 9 12 Rotate 3 4 turn after contacted with sealing surface Apply Locktite No 262 2 locations 8 12 0 8 1 2 6 9 1 5 25 1 5 2 5 11 18 8 12 0 8 1 2 6 9 8 12 0 8 1 2 6 9 19 28 1 9 2 9 14 21 19 28 1 9 2 9 14 21 8 12 0 8 1 2 6 9 41 55 4 2 5 6 30 41 With PTO provided ...

Page 19: ...6 TURBOCHARGER N m kgf m ft lb 16 GENERAL INFORMATION Fig 16 19 28 1 9 2 9 14 21 ...

Page 20: ... be applied Packin water outlet pipe Packin idle spring set screw O ring fuel cut lever Seal valve Gasket cylinder head Oil seal crankshaft rear Gasket exhaust manifold Gasket exhaust silencer O ring Oil drain plug O ring Oil strainer O ring Oil pump Oil seal crankshaft front O ring angleich cover O ring control lever Packin governor cover Packin rear cover PTO O ring Gasket ...

Page 21: ...tions 1 Always use the above brandnames or an equivalent as the sealant 2 Since Loctite FMD127 and Three Bond 1386 are anaerobic do not use them in case a gap exceeding 0 25 mm is occurring between the metallic mating surfaces since satisfactory effects cannot be expected 3 Always use the optimum quantity of sealant Observe the handling precautions designated for respective products When applying ...

Page 22: ...d bead width Reference Anaerobic 2 3 mm Others 2 6 mm Types Colors Work procedures 1 Wipe the thoroughly remove oil grease and moisture from the mating surfaces such as the bolt surface bolt hole thread surface of the nut 2 Apply Locktite 3 Tighten the bolt at the specified torque Caution After tightening the bolt do not apply excessive torque or vibrations for about an hour until the applied Loct...

Page 23: ... is at TDC on the compression stroke Adjust the circle or double circle marked valves as shown in Fig 22 while the No 1 or the No 4 cylin der is at TDC on compression stroke mm in Intake and Exhaust Valve Clearance cold 0 40 0 05 0 015 0 002 3 Loosen each valve clearance adjusting screw as shown in the illustration 4 Insert a 0 40 mm 0 015 in feeler gauge between the rocker arm and the valve stem ...

Page 24: ...level and replenish to the speci fied level if required 6 Start the engine and check for oil leakage from the oil filter 2 LUBRICATIN SYSTEM 3 COOLING SYSTEM Cartridge Cooling Fan Drive Belt Adjustment 1 Check the cooling fan drive belt for cracking and other damage 2 Check the drive belt tension by exerting a force of 98 N 10 kg midway between the Fan pulley 1 and the Generator pulley 2 3 Adjust ...

Page 25: ...oid entry of dust or foreign particles into the pump interior when the timing adjustment is made Injection timing BTDC 14 6 Adjust the injection timing with a shim between the injection pump and the cylinder block Shim is available in the following 9 types and iden tification mark is stamped or imprinted on the top face Identification mark of shim and its thickness mm Injection pump Cylinder block...

Page 26: ...ugs and the injection pipes 3 Attach a compression gauge to the No 1 cylinder glow plug installation threads Note Compression pressure may be measured starting at any cylinder and in no particular cylinder order However it is very important that the compression pressure be measured in each cylinder Therefore start at the No 1 cylinder and work back In this way you will be sure to measure the compr...

Page 27: ... will facilitate air bleeding 3 Turn in the new fuel filter until the filter O ring is fit ted against the sealing face 4 Use the filter wrench to turn in the fuel filter an addi tional 2 3 of a turn Injection nozzle Check to see if the spray condition and the injection pressure are normal Adjust them to the specified value respectively when they don t meet the standard valve Spray Condition 1 Cor...

Page 28: ... LUBRICANTS API DIESEL ENGINE OIL CC OR CD GRADE Fig 34 ENGINE OIL VISCOSITY GRADE AMBIENT TEMPERATURE Single grade 0 C 32 F 15 C 59 F 25 C 77 F 30 C 86 F 15 C 5 F 25 C 13 F Multi grade SAE 40 SAE 20 20W SAE 10W SAE 10W 30 SAE 15W 40 20W 40 20 C 4 F SAE 5W 20 SAE 30 Ambient temperature ...

Page 29: ...MEMO ...

Page 30: ...ENGINE 27 SECTION 2 ENGINE TABLE OF CONTENTS CONTENTS PAGE DISASSEMBLY 28 INSPECTION AND REPAIR 42 REASSEMBLY 56 ...

Page 31: ... 4 5 6 7 8 9 10 11 1 Exhaust silencer 2 Exhaust pipe 3 Cooling fan and spacer 4 Fan belt 5 Fan pulley 6 Generator 7 Starter 8 Exhaust manifold and gasket 9 Cylinder head cover and air intake pipe 10 Water outlet pipe and thermostat 11 Water pump assembly Fig 35 ...

Page 32: ...and side 12 13 14 15 16 17 18 19 20 12 Injection pipe 4 pcs 13 Fuel hose 14 Fuel leak off pipe 15 Fuel pipe 16 Engine stop solenoid 17 Injection pump housing cover 18 Injection pump and shim 4 set 19 Oil filter 20 Oil level gauge Fig 36 ...

Page 33: ...on pump housing cover 1 Remove the bolts and nut 2 Install the bolts M8 x 1 25 to the replacer hole 3 Tighten the bolts and then remove housing cover Fig 37 Injection pump 1 Align the hole of the fuel cut lever with the hole of the governor cover and then insert a pin 6ø into this hole to hold the fuel cut lever 2 Check to see if the pin groove of the control link is at the center of the injection...

Page 34: ...058 0 115 0 0023 0 0045 0 2 0 0079 CRANKSHAFT END PLAY mm in STANDARD LIMIT 0 058 0 208 0 0023 0 0082 0 3 0 0118 NOTE 1 Mark each injection pump as to which cylinder it was removed from 2 Do not reuse the shim replace it with the same thickness that was removed Control link Injection pump center position Injection pump rack pin Injection pump ASM Shim Cylinder block Stud Fig 42 Fig 43 ...

Page 35: ... Head Assembly 6 Cylinder Head Gasket 7 Tappets 8 Oil Pan 9 Oil Strainer 10 Oil Pipe 11 Crank Pulley 12 Flywheel 13 Flywheel Housing 14 Timing Gear Case without PTO 15 Oil Pump Assembly 16 Idler Gear and Shaft 17 Cam Gear 18 Camshaft 19 Rear Seal Retainer 20 Piston Assemblies 21 Crankshaft 3 INTERNAL PARTS ...

Page 36: ...ENGINE 33 Internal Parts 1 3 1 3 2 7 4 5 17 18 6 15 16 14 Fig 44 ...

Page 37: ...34 ENGINE Internal Parts 2 3 Fig 45 Do not pull out this bolt 20 13 12 9 10 11 8 19 Rear 21 ...

Page 38: ...ENGINE 35 14 1 14 2 15 Internal Parts 3 3 When provided with PTO Fig 46 ...

Page 39: ...d front hangers 2 When removing the cylinder head bolts loosen them slowly a little at a time starting with the outside working in a circular pattern inward 3 Remove the cylinder head assembly and the head gasket 4 Pull out the tappet from the cylinder body Rear hanger Cylinder head ASM M8 Head bolt M12 Head gasket Front hanger 5 4 3 2 1 8 9 7 6 12 13 14 10 15 11 Fig 47 Fig 48 Fig 49 Rocker Bracke...

Page 40: ...ent Do not pull them out 5 locations Split collar 4 Spring seat 5 Valve spring 6 Valve 7 Hot plug Seat valve insert Valve mechanism 1 Before disassembling the valve mechanism remove the connector glow plug and nozzle holder as sembly 2 Compressing the valve spring remove the split col lar spring seat valve spring and valve Fig 50 ...

Page 41: ... Bearing Wear ring Cam shaft 8 Pin Bearing Snap ring 7 Cam gear 6 Fly weight ASM 5 Sleeve 4 Lock nut Shaft idle gear 3 Idle gear 2 Thrust collar Crankshaft Key Crank gear Crank pulley 1 Washer Timing Gear Fig 51 ...

Page 42: ... Remove the lock nut of the cam shaft gear and then remove the flyweight assembly and the cam gear Camshaft 1 Remove the snap ring which holds down the front bearing of the cam shaft from the ring groove of the cylinder block 2 Pull out the cam shaft from the cylinder block together with the bearing Crankshaft Snap ring Fig 52 ...

Page 43: ... assembly upward out of the cylinder block Notes 1 Before removing the piston scrape the carbon deposit off the cylinder wall 2 When pushing out the piston assembly care should be taken not to damage the cylinder wall 3 Attach a tag with a cylinder number to the removed caps and bearings to keep them in order Fig 53 Fig 54 Snap Pipe 5 Bush The drawing out of the bush must be limited to only when r...

Page 44: ... 1 85221 029 0 Piston pin 1 Remove the snap rings with a commercially avail able tool 2 With a brass bar attached to the piston pin push it out by hammering it lightly Note Keep the pistons piston pins and connecting rods in order for each cylinder Fig 55 Fig 56 Brass bar Piston pin ...

Page 45: ... covered during inspection Y X X 1 CYLINDER BLOCK Cylinder block Check the cylinder block for wear damage or any other defects Use the hydraulic gauge to check the water jacket water pressure Apply water pressure to the water jacket at 5 kg cm2 71 1 psi for three minutes Cylinder bore Measurement position 13mm below the top Measure in X X and Y Y directions Near the No 1 compression ring mm in Sta...

Page 46: ...d values exceed the maximum grinding allowance the cylinder body must be replaced Cylinder Body Upper Face Warpage mm in Standard Limit Maximum Grinding Allowance 0 075 0 0029 0 15 0 0059 0 3 0 0118 If the measured value is less than the limit the cylinder body may be reground A B C D E F Cylinder Body Height H Reference mm in Engine Standard 307 94 308 06 4LE2 12 123 12 128 H Engine Bore Diameter...

Page 47: ...ind the cylinder head lower face if the mea sured values are greater than the specified limit but less than the maximum grinding allowance If the measured values exceed the maximum grinding allowance the cylinder head must be replaced Cylinder Head Lower Face Warpage mm in Standard Limit Maximum Grinding Allwance 0 075 0 0029 0 15 0 0059 0 3 0 0118 A B C D E F Cylinder Head Height H Reference mm i...

Page 48: ...6 85 0 2756 0 2697 Exhaust Valve 7 0 6 80 0 2756 0 2677 Valve thickness Nominal Limit Repair method 1 0 0 7 IN 0 03937 0 0276 0 8 0 5 Replace EX 0 0315 0 0197 3 VALVE VALVE SEAT INSERT AND VALVE SEAL Inspection of valve seat 1 A Contact width 2 B Valve depression mm in Cylinder head Valve A B 45 Standard Limit Contact width 2 0 0 0787 2 5 0 0984 Valve depression IN 0 7 0 0276 1 2 0 0427 EX 0 9 0 0...

Page 49: ...chment must contact the valve seat insert 2 Use a bench press 3 to gradually apply pressure to the attachment and press the valve seat insert into place 4 000 kg 8 819 lbs Note Do not apply an excessive amount of pressure with the bench press Damage to the valve seat insert will result 3 1 2 Valve Seat Insert Correction 1 Remove the carbon from the valve seat insert sur face 2 Use a valve cutter 1...

Page 50: ...on If the measured value exceeds the specified limit the valve spring must be replaced mm in Standard Limit Valve Spring 1 8 2 5 Inclination 0 0709 0 0984 Valve Spring Tension Use a spring tester to measure the valve spring tension If the measured value is less than the specified limit the valve spring must be replaced mm in Standard Limit Valve Spring 17 0 15 0 Tension at 29 9 mm 37 479 33 069 Se...

Page 51: ...asure the clearance between the tappet and cylinder body tappet travelling bore mm in Standard Limit Tappet and Tappet Travelling Bore 0 020 0 054 0 08 Clearance 0 00079 0 00213 0 00315 PUSH ROD Use a filler gauge to measure the valve push rod runout Roll the push rod along a smooth flat surface illustra tion mm in Limit Push Rod Run Out 0 3 0 0118 5 TAPPET Cam Follower or Valve Lifter AND PUSH RO...

Page 52: ...ylinder block pressed in with roller bearings as the center bearing check to see if the camshaft rotates smoothly with no play at each bearing Camshaft Standard Limit Repair method Intake 6 13 5 83 Replace 0 2413 0 2295 Exhaust 6 43 6 13 Replace 0 2531 0 2413 Nominal Limit Repair method 52 ø 51 92 ø Replace 2 0472 2 0441 4 Runout of cam shaft mm in Nominal Limit Repair method 0 02 0 1 0 004 Replac...

Page 53: ...e a vernier caliper to measure the rocker arm bushing inside diameter mm in Standard Rocker Arm Bushing 11 960 11 980 Inside Diameter 0 4709 0 4717 2 Measure the rocker arm shaft outside diameter Replace either the rocker arm or the rocker arm shaft if the clearance exceeds the specified limit mm in Standard Limit Rocker Arm Bushing and Rocker Arm 0 005 0 045 0 2 Shaft Clearance 0 0002 0 0018 0 00...

Page 54: ...ston and cylinder bore 1 Measure the outside diameter of the piston at about 64 mm from the top in a right angle to the piston pin in the unit of 1 1 000 mm 2 Calculate the clearance based on the measurements of the cylinder bore and the outside diameter of the piston mm in Model Outside diameter of piston Grade 84 945 84 960 4LE2 3 3443 3 3449 NON Nominal Limit Remarks 25 0 24 97 Replace if worn ...

Page 55: ...ace the rings mm in Standard Limit 1st 0 2 0 35 compression ring 0 0079 0 0138 1 5 2nd compression 0 35 0 5 0 0590 ring 0 0138 0 0197 Oil ring 0 2 0 4 1 0 0 0079 0 0157 0 03937 Clearance between piston ring groove and ring Measure clearance at several places on the circumfer ence If worn beyond the limit replace the rings or piston 4LE2 mm in Standard Limit 1st 0 085 0 105 0 2 compression ring 0 0...

Page 56: ... 0003 0 0008 0 0020 Inside diameter 25 0 9843 Connecting Rod Bearing Inspection 1 Fit the connecting rod bearing lower half into the connecting rod bearing cap 2 Check the connecting rod bearing lower half tension If the tension is insufficient the bearing must be replaced 3 Tighten the connecting rod and the bearing cap to the specified torque N m kgf m ft lb Tightening torque 74 83 7 5 8 5 54 61...

Page 57: ... 2 3622 59 86 2 3567 Crank pin mm in Standard Limit 4LE2 49 0 1 9291 48 87 1 9240 Standard Limit Clearance 0 029 0 072 0 11 0 0011 0 0028 0 0043 Runout of crankshaft Replace if beyond limit mm in Standard Limit 0 025 0 001 0 05 0 002 Crankshaft gear Check the crankshaft gear visually for damage and any other defects Fig 98 Fig 99 Fig 100 Fig 101 Note When there occurs an uneven wear to the cranksh...

Page 58: ...al Strike around the edges of the ring gear with a hammer and chisel to remove it Ring Gear Installation 1 Heat the ring gear evenly with a gas burner to invite thermal expansion Do not allow the temperature of the gas burner to exceed 200 C 390 F 2 Use a hammer to install the ring gear when it is suf ficiently heated 12 TIMING GEAR 11 FLYWHEEL AND RING GEAR Uneven wear of idle gear shaft mm in Cl...

Page 59: ...d valve stem sealing area with engine oil 2 Use a valve stem oil seal installer to install the oil seal Valve Stem Oil Seal Installer 5 8840 9033 0 REASSEMBLY 1 CYLINDER HEAD ASSEMBLY Important Operations Intake and Exhaust Valves 1 Place the cylinder head on a flat wooden surface 2 Lubricate valve stems with engine oil 3 Install the valves to the intake or exhaust guides Install the valves to the...

Page 60: ... the nozzle holder assembly check to see if the spray condition and the spray pressure of the injection nozzle are appropriate Refer to INSPECTION AND SERVICE Assemble to the cylinder head the gasket Install the nozzle holder assembly and then tighten it to the specified torque N m kgf m ft lb Gasket Nozzle holder ASM Bolt Eye bolt Bracket Tightening torque 31 41 3 2 4 2 23 30 Glow plug and connec...

Page 61: ...e piston with setting the marks as illustrated 2 Install the piston pin into the piston and the connect ing rod bushing Conventional piston heater Fig 114 Fig 115 Fig 116 Rod bolt removed for clarity Snap Pipe 4 Bush 2 Piston ring 5 Piston 1 Piston pin 3 Connecting rod 2 Cap 7 Cap nut 8 Bearing 6 Hot plug side Front mark Engine front direction Isuzu mark Cylinder number stamped side ...

Page 62: ...stall the piston rings in the following order 1 Oil ring 2 2nd compression ring 3 1st compression ring The marked side of the two compression rings must be facing up The undercut side of the second compression ring will be facing down As the oil ring has no any facing mark it may face in either direction 2 Lubricate the piston ring surfaces with engine oil 3 Check that the piston rings rotate smoo...

Page 63: ...ear 6 Idler gear and Shaft 7 Oil Pump Assembly 8 Timing Gear Case Without PTO 9 Flywheel Housing 10 Flywheel 11 Crank Pulley 12 Oil Pipe 13 Oil Strainer 14 Oil Pan 15 Tappets 16 Cylinder Head Gasket 17 Cylinder Head Assembly 18 Push Rods 19 Rocker Bracket Assembly 20 Engine Hangers 3 INTERNAL PARTS ...

Page 64: ...ENGINE 61 Internal Parts 1 3 Fig 119 Rear 3 14 2 13 12 11 1 10 9 ...

Page 65: ...62 ENGINE 19 20 18 17 4 5 15 20 7 6 16 8 Internal Parts 2 3 Fig 120 ...

Page 66: ...ENGINE 63 8 1 8 2 7 Internal Parts 3 3 Fig 121 ...

Page 67: ...aft install the thrust bearings with the groove facing the crankshaft Crankshaft Bearing Cap 1 Lubricate the bearing cap bolts with engine oil 2 Install the bearing caps to the crankshaft The arrow mark must be pointing to the front of the engine 3 Tighten the bearing cap bolts to the specified torque a little at a time in the numerical order shown in the illustration N m kgf m ft lb Crankshaft Be...

Page 68: ...il the crankpin reaches its highest point Special tool Front mark Set the bearing cap cylinder number marks and the con necting rod cylinder number marks The marks must be facing the injection pump side N m kgf m ft lb Note After installation confirm that the crankshaft rotates smoothly Cylinder No Installation of retainer After applying engine oil to the lip of the oil seal install the retainer A...

Page 69: ...o the shaft of the sleeve and the slide of the flyweight 4 With the lip of the sleeve placed in the cavity of the flyweight insert the shaft of the sleeve into the tip end of the camshaft Note Check to see if the sleeve moves smoothly Cam gear Timing point Sleeve Fly weight Lock nut Tightening torque 69 88 7 0 9 0 51 65 Idle Gear Install the idler gear shaft with the oil hole facing up ward Lubric...

Page 70: ...1 2 6 9 Front plate only for those provided with PTO Apply sealant to the front plate incorporated with the oil pump before installing it to the cylinder block N m kgf m ft lb Front plate with PTO Tightening torque 19 28 1 9 2 9 14 21 Timing gear case Front oil seal Front oil seal Install the front oil seal to the timing gear case Installation is made according to the L dimension shown in the figu...

Page 71: ...t to the cylinder block or the front plate N m kgf m ft lb 4 Assemble the gasket and the governor cover to the top of the gear case and then tighten them to the specified torque N m kgf m ft lb Governor cover Timing gear case Front oil seal Case tightening torque 19 28 1 9 2 9 14 21 Cover tightening torque 8 12 0 8 1 2 6 9 Tightening torque 41 55 4 2 5 6 30 40 Flywheel housing Install the flywheel...

Page 72: ...n the front bolt N m kgf m ft lb Crankshaft Front oil seal Crank pulley Washer Tightening torque 167 186 17 19 123 137 Tightening torque 19 28 1 9 2 9 14 21 Oil pipe To 2nd bearing cap Oil strainer Oil pan 1 Apply sealant to the oil pan 2 Install the oil pan to the cylinder block and tighten fixing bolts evenly N m kgf m ft lb Tightening torque 8 12 0 8 1 2 6 9 Tappet and head gasket 1 Install the...

Page 73: ... bracket assembly Apply liquid gasket to the the bottom of the rocker arm bracket assembly being careful not to get any in the groove around the oil galley as shown in the illustration Install the rocker arm bracket assembly making sure the push rods align with the rocker arms and tighten to the specified torque N m kgf m ft lb Rocker arm bracket Rocker arm Rocker spring Rocker bracket bottom surf...

Page 74: ...learance Front hanger and rear hanger Tighten them to the specified torque shown below N m kgf m ft lb Refer to Section General Information Maintenance on page 20 Rear hanger Front hanger Tightening torque 19 28 1 9 2 9 14 21 Fig 147 ...

Page 75: ...72 ENGINE 8 7 6 5 4 3 2 1 4 EXTERNAL PARTS Right hand Side 1 Dipstick 2 Oil Filter 3 Injection Pump 4 Injection Pump Housing Cover 5 Fuel Pipe 6 Leak Off Pipe 7 Fuel Hose 8 Injection Pipe Fig 148 ...

Page 76: ... 10 9 5 EXTERNAL PARTS Left hand Side 9 Water Pump 10 Thermostat and Water Outlet Pipe 11 Cylinder Head Cover 12 Exhaust Manifold 13 Starter 14 Generator 15 Fan Pulley 16 Fan Belt 17 Cooling Fan 18 Exhaust Pipe 19 Exhaust Silencer Fig 149 ...

Page 77: ...r and hold the control link for the installa tion of the injection pumps Injection pump center position Control link Fuel cut lever Pin 6 φ Install a new shim with the same thickness as the one that was removed Refer to the maintenance section on shim selection Injection pump ASM Shim Cylinder block Injection pump center position Rack pin Control link Install the injection pump making sure the rac...

Page 78: ...the cylinder block the rear of the No 3 injection pump rack and then tighten it to the specified torque N m kgf m ft lb Note The areas of the housing cover to which liquid gasket is applied are about 4 mm in width from the cover edge and about 2 mm around the bolts Housing cover Apply potion of sealant About 4mm in width from the cover edge About 2mm around the bolt hole Solenoid ASM Solenoid ASM ...

Page 79: ...ection pipe to the injection pump and the nozzle holder and tighten them up with sleeve nuts N m kgf m ft lb Injection pipe Nozzle holder Injection pump Tightening torque 15 25 1 5 2 5 11 18 Water pump assembly 1 Put sealant on the water pump where it contacts the block and head 2 Tighten to the specified torque N m kgf m ft lb L 60 L 40 Tighten together with adjusting plate Tightening torque 19 2...

Page 80: ... 4 1 4 2 9 Air inlet pipe 1 Apply sealant TB1207C to the surface in which the air inlet pipe is installed 2 Install the air inlet pipe to the cylinder head cover and tighten it to the specified torque N m kgf m ft lb Cylinder head cover Air inlet pipe Tightening torque 8 12 0 8 1 2 6 9 Exhaust manifold Assemble the gasket to the cylinder head install the exhaust manifold along the stud bolts and t...

Page 81: ... belt 1 Install the fan pulley to the water pump and then tighten it up 2 locations 2 Set the fan belt to each pulley Fan pulley Water pump Fan belt Fan belt tension Adjust the alternator as specified and tighten to the specified torque mm in mm in Cooling fan 1 Assemble the spacer before tightening the cooling fan 2 Tighten it to the specified torque 4 locations Cooling fan Spacer Deflection amou...

Page 82: ...LUBRICATING SYSTEM 79 SECTION 3 LUBRICATING SYSTEM TABLE OF CONTENTS CONTENTS PAGE LUBRICATING OIL CIRCULATION SYSTEM DIAGRAM 80 OIL PUMP 81 ...

Page 83: ...ening pressure 98 kPa 1kgf cm2 Oil filter Oil gallery Main bearing Crankshaft Connecting rod Idle gear bush Timing gear Governor Cylinder head Rocker arm bracket Rocker shaft Rocker arm Valve opening pressure 440 kPa 4 5kgf cm2 Oil pump Strainer Piston Injection pump Piston pin boss Tappet Valve stem end Fig 170 ...

Page 84: ... Without PTO Body Oil pump With PTO Front plate Body integral structure OIL PUMP Clearance between the outer rotor or inner rotor and the pump cover mm in Clearance between the periphery of the outer rotor and the pump body mm in Clearance between the inner rotor and the outer rotor mm in Standard Limit 0 040 0 085 0 0016 0 0033 0 15 0 0059 Standard Limit 0 10 0 185 0 0039 0 0073 0 4 0 0157 Standa...

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Page 86: ...COOLING SYSTEM 83 SECTION 4 COOLING SYSTEM TABLE OF CONTENTS CONTENTS PAGE COOLING WATER CIRCULATION SYSTEM DIAGRAM 84 WATER PUMP 85 THERMOSTAT 87 ...

Page 87: ...84 COOLING SYSTEM COOLING WATER CIRCULATION SYSTEM DIAGRAM Radiator Bottom bypass type thermostat Cyliner head Cylinder block bypass circuit Water pump Fig 172 ...

Page 88: ...r Cover 1 Loosen the set screw 2 Remove the cover Note The cover is applied with sealant TB1207B When re moving the cover much care should be taken not to deform it by applying an excessive force to it Cover Setscrew Fan center Impeller Seal unit Bearing unit Bearing unit Impeller Seal unit Fig 173 Fig 174 Fig 175 ...

Page 89: ...e clearance between the pump impeller and the body gets to the specified value Impeller Seal unit Cover 1 Apply sealant to the surface to which the cover is installed and then install the cover 2 Apply Screw lock to the cover installation screws and then tighten them Cover Clearance play and tightening allowance between parts 1 Clearance between the pump impeller and the body mm in 2 Play in the w...

Page 90: ...replacement Replace the thermostat when there is wear damages or any other defects found Opening temp 80 5 83 5 C 177 182 F Valve lift mm in 8mm or more at 95 C 0 31 inch or more at 203 F Thermometer Thermostat Wooden piece Agitating rod Fig 179 ...

Page 91: ...MEMO ...

Page 92: ...FUEL SYSTEM 89 SECTION 5 FUEL SYSTEM TABLE OF CONTENTS CONTENTS PAGE FUEL CIRCULATION SYSTEM DIAGRAM 90 GOVERNOR 91 NOZZLE HOLDER ASSEMBLY 99 ...

Page 93: ...90 FUEL SYSTEM FUEL CIRCULATION SYSTEM DIAGRAM Nozzle Nozzle holder Injection pump Fuel filter Fuel tank Fig 180 ...

Page 94: ...ever B Angleich Full load stopper Sleeve Flyweight Shifter Camshaft Main spring lever Main spring Floating lever 1 The adjustments of the governor related parts require the engine performance test 2 Before disassembling the governor measure the dimensions A and B given in the structural drawing to ensure the same dimensions in reassembly 3 Do not disassemble the governor when the performance test ...

Page 95: ...ting Floating lever Shifter shaft Shifter Cap nut Setscrew Fuel cut lever Return spring Fuel cut shaft O ring Idle spring Speed control screw O ring Lever bush Control lever Timing gear case Bracket start spring Shaft Lever bush Return spring Angleich Tensioner lever Main spring Lever main spring Sleeve Cam gear Flyweight Full load setscrew Fig 182 ...

Page 96: ...ough the shaft of the lever main spring 3 Assemble the bushes Assemble the bush of the lever main spring first and then the control lever bush Note When assembling the bushes apply Loctite 601 to the periphery of the bushes 4 Hook both ends of the return spring control lever securely to the protrusion and the pin of the lever main spring respectively Lever Main spring Bush Apply Loctite No 601 to ...

Page 97: ...tening up the control lever with a nut Bush O ring Washer Groove Control lever Spring washer Nut N m kgf m ft lb Control lever tightening torque 12 18 1 2 1 8 9 13 Notes 1 Tighten the control lever after locking the control lever firmly Do not tighten the control lever after locking the main spring lever 2 After assembly confirm that the control lever moves smoothly Fig 184 ...

Page 98: ...Assemble the shifter to the guide lever put the shaft through it and then assemble the snap ring 2 After assembly confirm that the shaft moves smoothly 3 Also confirm that the shifter shakes smoothly Guide lever Shifter Snap ring Shaft Fig 185 ...

Page 99: ...ring securely to the notched groove at the bottom of the cover and the bent up arm of the lever respectively 3 After reassembling the governor cover confirm that the governor moves smoothly 4 When assembling the timing gear case to the gover nor cover tighten the A dimension shown in the illustration to 2 3 mm temporarily The parts given in the square indicated by are assem bled after performance ...

Page 100: ...FUEL SYSTEM 97 6 Reassembly of full load stopper Install the full load stopper to the timing gear case and then tighten it with a nut temporarily Timing gear case Full load stopper Nut setscrew Fig 188 ...

Page 101: ...assembling governor related components 1 When assembling components apply engine oil to each slide such as the end face of the lever the hole in the shaft and the periphery of the shaft 2 Install the set spring securely to the groove of the pin connecting the floating lever with much care to its assembling direction 3 Confirm that each lever moves by its dead weight before installing the start spr...

Page 102: ...n the clean light oil disas semble it into the nozzle body and the needle valve and clean them thoroughly Then check to see if the valve moves smoothly in the body When it does not move smoothly repair or replace the nozzle Adjustment For the adjustment of the injection pressure and the spray condition of fuel refer to Section 1 INSPECTION AND SERVICE Light oil NOZZLE ASSEMBLY Fig 190 Fig 191 ...

Page 103: ...MEMO ...

Page 104: ...ce Defective injection pump Bring it to a specialty shop for repair Normal operation of glow plug control resistance OK No fuel injected Check if fuel comes to fuel pump Check for air mixing Air mixed Retighten it replace packing bleed air Check fuel filter Clogged Clean Check compression ratio Low compression ratio Defective valve spring gasket etc Overhaul Check starter switch Defective Replace ...

Page 105: ...efective Repair or replace Check cylinder for uneven compression pressure Uneven compression pressure Adjust Defective injection pump Bring it to a specialty shop for repair Unstable rotation at high speed Check fuel for air mixing Air mixed Bleed air mixing Check fuel filter for clogging Clogged Clean or replace Check uneven fuel injection Uneven Adjust Check valve clearance adjustment Poor adjus...

Page 106: ...r cleaner stained Clean or replace Check valve clearance and cam lift Abnormal Adjust or replace Check compression pressure Cooling system Check cooling water level Insufficient Check for leakage Leak to internal Replenish Leak to external Repair or replace Repair Check fan belt for slip Slipping Adjust Check thermostat Malfunction Replace Check cooling system for stain and radiator for clogging S...

Page 107: ...lty shop for repair 1 Disordered valve timing 2 Broken piston ring or misassembly 3 Worn camshaft 4 Worn valve or insert Overhaul Air cleaner clogged Replace air cleaner element Check air hose for crash OK OK OK OK OK OK OK OK Over discharge of battery Battery Check electrolyte level Low Check specific gravity Low Recharge Recharging impossible Bring it to a battery specialty shop Battery case cra...

Page 108: ... Wear of sliding part 4 Oil pump clogged 5 Defective valve stem seal Overhaul Worn bore and worn or broken ring Measure compression pressure and check entrance of dust Low Replenish Check cooling water temperature Check oil in crankcase Water or fuel mixed Check fuel system and cooling system High See Overheat Improper viscosity Check relief valve Defective Repair or replace 1 Oil pump malfunction...

Page 109: ...MEMO ...

Page 110: ...ssion gauge adapter 23 5 8840 9016 0 3 Nozzle tester 24 J 28829 5 8840 9015 0 4 Oil filter wrench JKM 9004 5 5 8840 9030 0 Valve spring compressor 57 6 1 85221 029 0 Piston ring pliers 41 5 8840 9018 0 7 Piston ring compressor J 8037 8 5 8840 9031 0 Front oil seal installer 9 5 8840 9032 0 Rear oil seal installer 10 5 8840 9034 0 Camshaft bearing installer 11 5 8840 9035 0 Valve guide installer 12...

Page 111: ...MEMO ...

Page 112: ...8 3 8583 24 0 9449 49 1 9291 74 2 9134 99 3 8976 25 0 9843 50 1 9685 75 2 9528 100 3 9370 in mm in mm 1 64 0 3969 33 64 13 0969 1 32 0 7938 17 32 13 4938 3 64 1 1906 35 64 13 8906 1 16 1 5875 9 16 14 2875 5 64 1 9844 37 64 14 6844 3 32 2 3813 19 32 15 0813 7 64 2 7781 39 64 15 4781 1 8 3 1750 5 8 15 8750 9 64 3 5719 41 64 16 2719 5 32 3 9688 21 32 16 6688 11 64 4 3656 43 64 17 0656 3 16 4 7625 11 ...

Page 113: ...08 3990 311 6798 314 9606 318 2415 321 5223 324 8032 90 100 328 0840 331 3648 334 6457 337 9265 341 2074 344 4882 347 7690 351 0499 354 3307 357 6116 100 MILES TO KILOMETERS miles 0 1 2 3 4 5 6 7 8 9 km km km km km km km km km km 00 1 609 3 219 4 828 6 437 8 047 9 656 11 265 12 875 14 484 10 16 093 17 703 19 312 20 921 22 531 24 140 25 749 27 359 28 968 30 577 10 20 32 187 33 796 35 405 37 015 38 ...

Page 114: ...5 16 430 16 585 16 740 16 895 100 CUBIC INCHES TO CUBIC CENTIMETERS in3 0 1 2 3 4 5 6 7 8 9 in3 cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc cm3 cc 00 16 387 32 774 49 161 65 548 81 935 98 322 114 709 131 097 147 484 10 163 871 180 258 196 645 213 032 229 419 245 806 262 193 278 580 294 967 311 354 10 20 327 741 344 128 360 515 376 902 393 290 409 677 426 064 442 451 458 838 475 ...

Page 115: ...5 25 6247 25 8889 26 1530 90 100 26 4172 26 6814 26 9455 27 2097 27 4739 27 7381 28 0022 28 2664 28 5306 28 7947 100 GALLONS IMP TO LITERS Imp gal 0 1 2 3 4 5 6 7 8 9 Imp gal liters liters liters liters liters liters liters liters liters liters 00 4 5459 9 0918 13 6377 18 1836 22 7295 27 2754 31 8213 36 3672 40 9131 10 45 4590 50 0049 54 5508 59 0967 63 6426 68 1885 72 7344 77 2803 81 8262 86 3721...

Page 116: ...209 439 211 644 213 848 216 053 218 257 90 100 220 462 222 667 224 871 227 076 229 280 231 485 233 690 235 894 238 099 240 304 100 KILOGRAMS TO NEWTON kg 0 1 2 3 4 5 6 7 8 9 kg N N N N N N N N N N 0 9 81 19 61 29 42 39 23 49 03 58 84 68 65 78 45 88 26 10 98 07 107 87 117 68 127 49 137 29 147 10 156 91 166 71 176 52 186 33 10 20 196 13 205 94 215 75 225 55 235 36 245 17 254 97 264 78 274 59 284 39 ...

Page 117: ... 1308 52 1322 74 1336 96 1351 19 1365 41 1379 63 1393 85 1408 08 90 100 1422 30 1436 52 1450 75 1464 97 1479 19 1493 42 1507 64 1521 86 1536 08 1550 31 100 KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL kg cm2 0 1 2 3 4 5 6 7 8 9 kg cm2 KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa 00 98 1 196 1 294 2 392 3 490 3 588 4 686 5 784 5 882 6 10 980 7 1078 7 1176 8 1274 9 1372 9 1471 0 1569 1 1667 1 1765 2 1...

Page 118: ...723 30 730 53 737 77 745 00 752 23 759 47 766 70 773 93 781 16 788 40 100 KILOGRAMMETERS TO NEWTONMETERS kg m 0 1 2 3 4 5 6 7 8 9 kg m N m N m N m N m N m N m N m N m N m N m 00 9 81 19 61 29 42 39 23 49 03 58 84 68 65 78 45 88 26 10 98 07 107 87 117 68 127 49 137 29 147 10 156 91 166 71 176 52 186 33 10 20 196 13 205 94 215 75 225 55 235 36 245 17 254 97 264 78 274 59 284 39 20 30 294 20 304 01 3...

Page 119: ... 440 226 7 CENTIGRADE TO FAHRENHEIT C F C F C F C F C F C F C F C F 50 58 0 18 0 4 14 57 2 46 114 8 78 172 4 110 230 0 142 287 6 174 345 2 49 56 2 17 1 4 15 59 0 47 116 6 79 174 2 111 231 8 143 289 4 175 347 0 48 54 4 16 3 2 16 60 8 48 118 4 80 176 0 112 233 6 144 291 2 176 348 8 47 52 6 15 5 0 17 62 6 49 120 2 81 177 8 113 235 4 145 293 0 177 350 6 46 50 8 14 6 8 18 64 4 50 122 0 82 179 6 114 237...

Page 120: ...r in part without the written consent of ISUZU MOTORS LIMITED WORKSHOP MANUAL INDUSTRIAL 4LE2 IDE 2330 Issued by ISUZU MOTORS LIMITED Powertrain Service Parts Powertrain Operations 6 26 1 Minami oi Shinagawa ku Tokyo 140 8722 Japan TEL 03 5471 1111 First edition Sep 1999 107 02K ...

Page 121: ...PRINTED IN JAPAN IDE 2330 ...