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2. Isuzu Repair Manual online, free

• 2

  Table of Contents
• 3

  General Information
• 4

  General Repair Instructions
• 6

  Symbols Used in the Manual
• 8

  Main Data and Specifications
• 11

  Design Features and General Outline
• 11

  Main Engine Parts and Their Function
• 11

  Cylinder Head
• 12

  Cylinder Body
• 12

  Crankshaft
• 13

  Pistons
• 13

  Valve Mechanism
• 14

  Tightening Torque Specifications
• 15

  Angular Nut and Bolt Tightening Method
• 17

  Major Part Fixing Nuts and Bolts
• 17

  Cylinder Head and Cover
• 18

  Cylinder Body Diagram
• 19

  Oil Pan and Dipstick Diagram
• 20

  Camshaft and Rocker Arm Diagram
• 21

  Crankshaft, Piston and Flywheel Diagram
• 22

  Thermostat and Thermostat Housing Diagram
• 23

  Intake and Exhaust Manifold Diagram
• 24

  Timing Gear Case and Flywheel Housing Diagram
• 25

  Oil Cooler, Oil Filter, and Oil Pump Diagram
• 26

  Fuel System Diagram
• 27

  Turbocharger Diagram
• 28

  Identifications
• 28

  Engine Serial Number
• 28

  Injection Pump Number
• 29

  Maintenance
• 30

  Lubricating System Maintenance
• 30

  Main Oil Filter Replacement
• 30

  Center Bolt Type Removal/Installation
• 30

  Cartridge (Spin-on) Type Removal/Installation
• 31

  Fuel System Maintenance
• 31

  Fuel Filter Replacement
• 32

  Injection Nozzle Maintenance
• 33

  Spray Condition Check (During Injection Nozzle Tester Operation)
• 34

  Water Separator (Water Sedimentor) Check
• 34

  Air Bleeding Check
• 35

  Cooling System Maintenance
• 35

  Valve Clearance and Adjustment
• 35

  Cooling Fan Drive Belt Adjustment
• 35

  Thermostat Inspection
• 37

  Injection Timing
• 37

  Flange Mounted Injection Pump Injection Timing Checking and Adjustment
• 38

  Injection Timing Checking Procedure
• 41

  Coupling Driven Injection Pump Timing Adjustment
• 43

  Compression Pressure Measurement
• 44

  Turbocharger Inspection
• 45

  Engine Repair-kit (For Non-turbocharged Engines) Diagram
• 46

  Engine Repair Kit (For Turbocharged Engines) Diagram
• 47

  Recommended Lubricants
• 47

  Engine Oil Viscosity Chart
• 49

  Engine Assembly I (Disassembly)
• 50

  External Parts Disassembly Steps
• 50

  Model 6BD1T Right Side View/Disassembly Steps
• 51

  Model 4BD1T View/Disassembly Steps
• 52

  Injection Pump With Injection Pump Gear
• 52

  Flange Mounted Injection Pump Removal
• 52

  Coupling Mounted Injection Pump Removal
• 52

  Remove of the Air Compressor (If Equipped)
• 53

  Model 6BD1T Left Side View/Disassembly Steps
• 54

  Model 4BD1T Left Side View/Disassembly Steps
• 55

  Major Components/Disassembly Steps
• 56

  Rocker Arm Shaft
• 56

  Cylinder Head Bolts
• 56

  Crankshaft Pulley Nut
• 57

  Taper Bushing (6B Series Only)
• 57

  Flywheel
• 58

  Major Components II/Disassembly Steps
• 59

  Idler Gear
• 59

  Cam Shaft
• 59

  Crankshaft Bearing Cap
• 60

  Rocker Arm and Rocker Arm Shaft View/disassembly Steps
• 61

  Cylinder Head View/Disassembly Steps
• 61

  Split Collar Removal
• 62

  Piston and Connecting Rod View/Disassembly Steps
• 63

  Piston Rings Removal
• 63

  Snap Ring and Piston Pin Removal
• 65

  Engine Assembly II (Inspection and Repair)
• 66

  Cylinder Head Lower Face Warpage Check
• 66

  Water Jacket Water Pressure Test
• 67

  Valve Stem and Valve Guide Clearance
• 67

  Valve Guide Replacement/Removal
• 68

  Valve Depression
• 68

  Valve Contact Width
• 68

  Valve Seat Insert Replacement/Removal
• 69

  Valve Seat Installation
• 69

  Valve Seat Insert Correction
• 70

  Valve Spring Free Length Measurement
• 71

  Valve Spring Inclination
• 71

  Valve Spring Tension
• 71

  Tappet (Cam Follower or Valve Lifter) Inspection
• 72

  Push Rod Inspection
• 72

  Rocker Arm Correction
• 72

  Rocker Arm Shaft and Rocker Arm Inspection
• 72

  Rocker Arm Shaft Outside Diameter Measurement
• 73

  Idler Gear and Idler Gear Shaft Inspection
• 73

  Rocker Arm Shaft and Rocker Arm Clearance Check
• 74

  Camshaft Inspection
• 75

  Cylinder Liner Bore Measurement
• 76

  Cylinder Liner Projection Inspection
• 76

  Cylinder Liner Replacement
• 77

  Cylinder Bore Measurement
• 77

  Cylinder Liner Grade Selection
• 77

  Cylinder Body Inside Diameter Measurement
• 78

  Cylinder Liner Outside Diameter Measurement
• 78

  Cylinder Bore and Cylinder Liner Outside Diameter Combinations
• 79

  Cylinder Liner Installation
• 79

  Piston Grade Selection
• 80

  Cylinder Liner Bore Measurement/Piston Outside Diameter
• 81

  Cylinder Liner Bore and Piston Clearance
• 82

  Piston Ring and Piston Ring Groove Clearance
• 82

  Piston Ring and Piston Groove Clearance
• 82

  Piston Ring Gap
• 83

  Piston Pin Outside Diameter
• 83

  Piston Pin and Piston Clearance
• 83

  Piston Pin and Piston Pin Hole Clearance
• 84

  Connecting Rod Alignment
• 84

  Piston Pin and Connecting Rod Small End Bushing Clearance
• 84

  Connecting Rod Bushing Replacement
• 85

  Connecting Rod Bearing Inspection
• 86

  Crankshaft and Bearing Inspection
• 86

  Crankshaft Journal and Crankpin Outside Diameter
• 87

  Crankshaft Journal and Bearing Clearances
• 88

  Crankshaft Journal Bearing Inside Diameter
• 88

  Connecting Rod Bearing Inside Diameter
• 89

  Crankshaft Run-Out
• 89

  Main Bearing and Connecting Rod Bearing Tension
• 89

  Crankshaft Regrinding
• 90

  Crankshaft Regrinding Procedure
• 90

  Crankshaft Grinding Limit
• 91

  Plastigage Clearance Measurement
• 91

  Crankshaft Journal Bearing Clearance
• 92

  Crankshaft Pin Bearing Clearance
• 92

  Crankshaft Tufftriding Inspection
• 93

  Oil Seal Wear Ring Replacement (6BD1T, 6BG1, 6BG1T)
• 93

  Crankshaft Gear Inspection
• 94

  Crankshaft Gear Replacement
• 94

  Flywheel and Flywheel Housing (Rear Oil Seal) Inspection
• 94

  Rear Gear Inspection/Replacement/Installation
• 94

  Flywheel Housing Oil Seal Replacement
• 95

  Timing Gear Case Cover Inspection
• 95

  Crankshaft Front Oil Seal Replacement
• 97

  Engine Assembly III (Reassembly)
• 98

  Piston and Connecting Rod Reassembly Steps - Minor Component
• 99

  Pistons Heating/ Connecting Rod Installation
• 99

  Piston Pin Snap Ring Installation
• 99

  Piston Ring Installation
• 99

  Connecting Rod Bearing Installation
• 100

  Cylinder Head Reassembly Steps
• 101

  Valve Stem Oil Seal Installation
• 101

  Intake and Exhaust Valves Installation
• 101

  Intake and Exhaust Valve Springs Installation
• 101

  Spring Seat Split Collar Installation
• 102

  Intake Manifold and Gasket Installation
• 102

  Exhaust Manifold and Gasket Installation
• 104

  Rocker Arm and Rocker Arm Shaft Reassembly Steps
• 105

  Major Component Reassembly Steps I
• 106

  Oil Jet Installation
• 106

  Crankshaft Bearing Configuration
• 106

  Crankshaft Installation
• 106

  Thrust Bearing Installation
• 107

  Crankshaft Bearing Cap Installation
• 107

  Timing Gear Case Installation
• 107

  Camshaft/Thrust Plate Bolts Tightening
• 107

  Idler Gear Shaft Installation
• 108

  Idler Gear Installation
• 108

  Piston and Connecting Rod Installation
• 109

  Oil Pump and Coupling Installation
• 109

  Flywheel Housing Installation
• 110

  Oil Pan Installation
• 110

  Oil Cooler Installation
• 111

  Major Component Reassembly Steps II
• 112

  Flywheel Installation
• 112

  Injection Pump and Injection Pump Gear Assembly
• 112

  Air Compressor Installation
• 113

  Tappet Chamber Cover Installation
• 113

  Water Pump Installation
• 113

  Cylinder Head Gasket/Bolt Installation
• 115

  Rocker Arm and Rocker Arm Shaft Installation
• 116

  External Parts Reassembly Steps (Left-hand Side)
• 117

  Cylinder Head Cover Installation
• 117

  Fan Belt Adjustment
• 117

  Starter Motor Installation
• 118

  Turbocharger Mounting Flange Gasket Positioning
• 118

  Turbocharger Nuts Tightening
• 118

  Oil Drain Pipe Installation
• 119

  Oil Feed Pipe Installation
• 119

  Turbo Adaptor Tightening
• 120

  External Parts Reassembly Steps (Right-hand Side) - Model 6BD1T
• 121

  Injection Nozzle Installation
• 121

  Fuel Injection Pipe and Fuel Leak Off Pipe Installation
• 121

  Oil Filter Installation
• 122

  Fuel Pipe, Fuel Return Pipe, Intake Pipe Installation
• 122

  Injection Timing Adjustment
• 123

  Engine Tuning Operation
• 125

  Engine Sectional View
• 127

  Lubricating System
• 128

  Lubricating System - General Description
• 129

  Oil Pump Disassembly
• 130

  Oil Pump Drive Gear Inspection
• 130

  Oil Pump Driven Gear Inspection
• 131

  Main Oil Filter Disassembly/Inspection and Repair
• 132

  Lubricating System Reassembly
• 132

  Center Bolt and Drain Plug Installation
• 133

  Oil Cooler Disassembly, Inspection and Repair
• 134

  Lubricating System Reassembly Steps
• 134

  Oil Cooler Element Installation
• 135

  Cooling System
• 136

  Cooling System - General Description
• 137

  Water Pump Disassembly Steps
• 138

  Impeller/Pulley Center/Snap Ring Removal
• 138

  Spindle, Bearing, Spacer/Seal Unit, Washer and Seal Removal
• 139

  Bearing Replacement
• 140

  Cooling System Reassembly Steps
• 141

  Spindle, Bearing, and Spacer Installation
• 141

  Snap Ring/Pulley Center Installation
• 141

  Seal Unit, Washer and Seal Installation
• 142

  Impeller/Pulley Installaton
• 142

  Thermostat Inspection and Repair
• 143

  Fuel System
• 144

  Fuel System - General Description
• 145

  Fuel Filter Disassembly/Inspection and Repair
• 147

  Injection Nozzle Disassembly
• 148

  Push Rod Spring Check
• 148

  Nozzle Holder Push Rod Check
• 148

  Injection Nozzle Check
• 149

  Fuel Filter Reassembly Steps
• 150

  Injection Pipe Connector/Injection Nozzle/Retaining Nut Check
• 150

  Injection Starting Pressure Adjustment
• 151

  Nozzle Holder Cap Nut Check
• 152

  Injection Pump Calibration Data
• 152

  Identification Plate and Product Serial Number
• 152

  Test Conditions Required for the Fuel Injection Amount Adjustment
• 153

  Inj. Pump Calibration Data
• 154

  Governor Adjustment
• 155

  Turbocharger
• 156

  Turbocharger - General Description
• 157

  Turbocharger Identification
• 158

  Rotor Shaft Play Inspection
• 158

  Rotor Shaft Axial Play Measurement
• 159

  Air Compressor
• 160

  Air Compressor Sectional View/Main Data
• 161

  Air Compressor Disassembly Steps
• 162

  Air Compressor Inspection and Repair
• 164

  Air Compressor Reassembly Steps
• 165

  Connecting Rod/Bearing Cover Installation
• 165

  Cylinder Body/Cylinder Head Installation
• 167

  Engine Electricals
• 168

  Starter Motor Identification
• 168

  Nikko Identification Plate
• 168

  Hitachi Identification Plate
• 169

  Starter Motor Main Data and Specifications
• 171

  Starter Motor Sectional View
• 172

  Starter Motor Exploded View
• 173

  Alternator Identification
• 174

  Alternator Main Data and Specifications
• 176

  Regulator Main Data and Specifications
• 177

  Alternator Sectional View
• 178

  Alternator Exploded View
• 179

  Troubleshooting
• 180

  Hard Starting
• 180

  Starter Inoperative
• 181

  Starter Motor Operates but Engine Does Not Turn Over
• 182

  Engine Turns Over but Does Not Start, Fuel Is Being Delivered to the Injection Pump
• 183

  Engine Turns Over but Does Not Start
• 184

  Unstable Low Idling
• 187

  Unsufficient Power
• 190

  Excessive Fuel Consumption
• 193

  Overheating
• 195

  White Exhaust Smoke
• 196

  Dark Exhaust Smoke
• 197

  Oil Pressure Does Not Rise
• 199

  Abnormal Engine Noise
• 199

  Engine Knocking
• 199

  Gas Leakage Noise
• 200

  Continuous Noise
• 201

  Slapping Noise
• 203

  Special Tool List
• 207

  Conversion Table
• 207

  Length Conversion Table
• 209

  Area Conversion Table
• 209

  Volume Conversion Table
• 211

  Mass Conversion Table
• 212

  Pressure Conversion Table
• 213

  Torque Conversion Table
• 214

  Temperature Conversion Table

Workshop Manual Free

Isuzu Repair Manual online, free

Manuals for Isuzu Diesel Engines Owner and Workshop Manuals are important documents that should be. Workshop Manual 4H Serie s. Workshop Manual 4JA1-NA.