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Report this Document Download Now Save Save Manual Motor 4ja1 For Later 91 (22) 91 found this document useful (22 votes) 10K views 704 pages Manual Motor 4ja1 Uploaded by Juan Florez Description: Full description Save Save Manual Motor 4ja1 For Later 91 91 found this document useful, Mark this document as useful 9 9 found this document not useful, Mark this document as not useful Embed Share Print Download Now Jump to Page You are on page 1 of 704 Search inside document Browse Books Site Directory Site Language: English Change Language English Change Language. If you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.If you wish to opt out, please close your SlideShare account. Learn more. You can change your ad preferences anytime. Due to this service you'll save your time and get an essay without plagiarism.Information contained in this Workshop Manual is the latestIsuzu reserves the right to make changes at any time without priorThis Workshop Manual is applicable to 1998 and later models.This will reduce the chance of cable damage and burning due to short circuiting.http://cornerstonedurham.com/images/commercial-manual-floor-sweeper.pdfWhere specified, use the specially designed tool or tools.Discard them as youThis will ensure a smooth reassembly operation. It is especially important to keep fastening parts separate. These parts vary in hardness and design,Oil ports and other openings should be cleaned with compressed air to make sure that they areTo not do so is extremely dangerous.No service operation is complete until you have done this.When more than two engine models are dealt in the manual, such engines have common parts andThe section ENGINE ASSEMBLY is an exception. This parts are divided in three sections to facilitatesMore complex procedures are covered in detail.Inverted EngineParts within a square frame are to beThe number tells you the service oper-Removal of unnumbered parts is unne-The removal or installation of partsThey tell you the type of serviceCommercially available tool useOil Seal Installer: 5-8840-0141-0Letters and numbers contained in aSpecial tools are identified by the. The illustration shows how the spe-Symbols indicate the type of serviceService data and specifications areFront. The cooling fan side of the engine viewed from the flywheel. Right. The right hand side viewed from the same position. Left. The left hand side viewed from the same position. 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 the final cylinder number of the engine. The engine's direction of rotation is counterclockwise viewed from the flywheel.Engine type Water cooled, four-cycle, in-line, overhead valve. Combustion chamber type Direct injection. Cylinder liner type Dry. No. of cylinders - Bore x Stroke mm(in.) 4 - 93.0 x 92.0 4 - 93.0 x 102.0 4 - 93.0 x 102.0Total piston displacement lit(cid) 2.449 (152.4) 2.771 (169.0) 2.771 (169.0). Compression ratio (To 1) 18.4 18.2 18.2. Length x Width x Height (31.7 x 24.6 x 28.7) (29.1 x 24.6 x 29.4) (22.8 x 30.4 x 22.7). Specified fuel Diesel fuel. Injection pump In-line plunger, Bosch A type Bosch distributor. VE type. Governor Variable speed mechanical type. Injection nozzle Multi-hole type. Fuel filter type Cartridge papaer element. Valve clearance (at cold) Intake mm(in.) 0.40 (0.0157). Exhaust mm(in.) 0.40 (0.0157). Lubrication method Pressurized circulation. Oil pump Trochoid type. Main oil filter type Cartridge paper element, full flow. Partial oil filter Not equipped. Oil cooler (if so equipped) Water cooled built in oil filter. Cooling method Pressurized forced circulation. Coolant volume lit.(qts) 5.0 (5.3). Water pump Belt driven impeller type. Thermostat type Wax pellet typeNo mark. Non-RefinedClass. Bolt. Identification. Diameter ?NominalNew bolt. ReusedCrankshaft Damper Pulley, Flywheel, and Oil PanM12 x 1.25 (0.47 x 0.05). M12 x 1.75 (0.47 x 0.07)Maintenance interval such as fuel or oil filter changes should be refered to “INSTRUCTION MANUAL”.The engine number is stamped on the rear left hand sideThe injection pump identification number (A) is stampedNote. Always check the identification number before beginn-Applicable service data will vary according to the ident-Pump No...............Replacement ProcedureFilter WrenchThis will allow the new oil filter to seat properly.Filter WrenchReplacement ProcedureFilter WrenchThis will allow the new fuel filter to seat properly.Be very careful to avoid fuel spillage.Check the water separator float 1 level. If the float 1 has reached level 2, loosen the drain plugInjection Nozzle Inspection. Use a nozzle tester to check the injection nozzle openingIf the opening pressure is above or below the specifiedIf the spray condition is bad, the injection nozzle must beSpray ConditionIf the injection nozzle does not open at the specifiedAdjusting Shim Availability mm(in.). Increment 0.025 (0.001). Total No. of Shims 40Removing or installing one shim will increase orFan belt tension is adjusted by moving the alternator. A Crankshaft damper pulley. B Alternator pulley. C Cooling fan drive pulley. D Depress the drive belt mid-portion with a 10 kgf (22. Drive Belt Deflection mm(in.)Operating TestStir the water constantly to avoid direct heat beingRocker Arm Shaft Bracket BoltNo. 4 cylinder to TDC on the compression stroke byIf the No. 1 cylinder intake and exhaust valve pushIf the No. 1 cylinder intake and exhaust valve pushAdjust the No. 1 or the No. 4 cylinder valve clearancesValve Clearance mm(in.)Insert a feeler gauge of the appropriate thicknessAdjust the clearances for the remaining valves as shownThe No. 1 cylinder will now be at the point whereInjection Timing (Static BTDC)The No. 1 cylinder will now be at the point whereMeasuring device: 5-8840-0145-0Starting Timing mm(in.)Tighten the pump fixing nut, adjust bolt and pumpInjection PumpStandard LimitCompression Gauge:5-8840-2675-0. Adapter:5-8840-9029-0Without turbocharger. CC or CD grade. Diesel engine oil. With turbocharger. CD gradeTemperatureAuto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engineChrome plated dry type cylinder liners provide the highest durability. The laminated steel sheet cylinder head gasket is very durable. This type of gasket eliminates cylinder head bolt retightening. The tufftrided crankshaft has a long service life. Because it is tufftrided, it cannot be reground. The crankshaft main bearings and the connecting rod bearings are aluminum plated. These bearings areIt is very important that the oil ports andDo not apply excessive force to the injection pipes.Note. Plug the injection pump delivery holder ports with theLoosen the exhaust manifold bolts a little at a timeInverted EngineDisassembly Steps - 3Nozzle Holder Remover: 5-8840-2034-0. Sliding Humme: 5-8840-0019-0Loosen the rocker arm shaft bracket bolts in numer-Note. Failure to loosen the rocker arm shaft bracket bolts inLoosen the cylinder head bolts in numerical order aNote. Failure to loosen the cylinder head bolts in numericalDamper Pulley RemoverMeasure the camshaft timing gear backlash, theTiming Gear Backlash MeasurementHold both the gear to be checked and the adjoiningTake the dial indicator reading. If the measured value exceeds the specified limit,Timing Gear Backlash mm(in.). Standard Limit. Idler Gear “A” End Play Measurement. Insert a feeler gauge between the idler gear and theIf the measured value exceeds the specified limit, theIdler Gear End Play mm(in.). Standard LimitPlateNote. Be careful not to damage the camshaft journal, the cam,If the connecting rod lower bearings are to be rein-Do this before removing the crankshaft bearingIf the measured value exceeds the specifiedCrankshaft End Play mm(in.). Standard LimitIf the crankshaft bearings are to be reinstalled,If the crankshaft upper bearings are to be reinstalled,If the tappets are to be reinstalled, mark their fittingRemove the flywheel housing. With the oil seal pushed in deep, install the specialOil Seal Remover: 5-8840-2360-0If the rocker arms and rocker arm shaft bracketsDo not allow the valve to fall from the cylinderSpring Compressor: 9-8523-1423-0If the intake and exhaust valves are to be reinstalled,If there is excessive valve wear or damage, the valveRefer to Page 50 of “Inspection and Repair” for theNote. If there is excessive valve guide wear or damage, theRefer to Page 49 of “Inspection and Repair” for the valveThe valve and the valve guides must be replaced as aIf the connecting rod bearings are to be reinstalled,Take care not to damage the connecting rod.Piston Ring Replacer. Do not attempt to use some other tool toPiston ring stretchingUse a pair of snap ring pliers to remove the pistonTap the piston pin out with a hammer and a brassIf the pistons are to be reinstalled, mark their instal-Take care not to damage the camshaft.Universal Puller: 5-8840-0086-0If the measured values exceed the maximum grind-Cylinder Head Lower Face Warpage mm(in). Maximum Grinding. AllwanceCylinder Head Height (Reference) mm(in). Note. If the cylinder head lower face is reground, valveUse a straight edge and a feeler gauge to measure theRegrind the manifold cylinder head fitting faces if theIf the measured values exceed the maximum grindingMeasuring Method - IRead the dial indicator. Note the highest dial indication. If the measured values exceed the specified limit,Valve Stem Clearance mm(in). Intake Valve. Exhaust Valve. Manifold Fitting Face Warpage mm (in). AllwanceMeasuring Method - IIRefer to the Item “Valve Stem Outside Diameter”.Valve Guide Replacement. Valve Guide Removal. Use a hammer and the valve guide replacer to drive outValve Guide Replacer: 9-8523-1212-0Valve Guide Replacer: 9-8523-1212-0Valve Guide Upper End Height (H)If the valve guide has been removed, both the valve andMeasure the valve stem diameter at three points. If the measured value is less than the specified limit, theValve Stem Outside Diameter mm(in). Valve Thickness. Measure the valve thickness. If the measured value is less than the specified limit, theIntake and Exhaust Valve Thickness mm(in). Standard LimitMake smooth the valve contact surfaces.If the measured value exceeds the specified limit,Valve Contact Width mm(in). Intake 1.7 (0.067) 2.2 (0.087). Exhaust 2.0 (0.079) 2.5 (0.098). Valve DepressionIf the measured value exceeds the specified limit,Valve Depression mm(in). Intake 0.73 (0.029) 1.28 (0.050). Exhaust 0.70 (0.028) 1.20 (0.047)Valve Seat Insert RemovalThis will invite contraction and make removal of theTake care not to damage the cylinder head 4.Note. The smooth side of the attachment must contact theNote. Do not apply an excessive amount of pressure with theRemove only the scratches and rough areas. Do notNote. Use an adjustable valve cutter pilot. Do not allow the valve cutter pilot to wobble inside theUse a spring tester to measure the valve spring tension. If the measured value is less than the specified limit, theCompressed Height Standard LimitUse a vernier caliper to measure the valve spring freeIf the measured value is less than the specified limit, theValve Spring Free Height mm(in). Standard LimitUse a surface plate and a square to measure the valveIf the measured value exceeds the specified limit, theValve Spring Inclination mm(in). Standard LimitUse a micrometer to measure the rocker arm fittingIf the measured value is less than the specified limit, theRocker Arm Shaft Outside Diameter mm(in). Standard LimitIf the run-out is very slight, correct the rocker armThe rocker armIf the measured rocker arm shaft run-out exceedsRocker Arm Shaft Run-Out mm(in). Standard LimitRocker Arm Bushing Inside Diameter mm(in). Standard LimitIf the measured value exceeds the specified limit,Rocker Arm and Rocker Arm Shaft Clearance mm(in). Standard LimitIf necessary, use compressed air to clean the rockerInspect the rocker arm valve stem contact surfaces forIf the contact surfaces have light step wear or scoring,If the step wear or scoring is severe, the rocker arm mustRefer to “Cylinder Liner Replacement”.Standard LimitIf the measured value is more than the limit, theStandardRefer to “Cylinder Body Bore Measurement”.Use a cylinder indicator to measure the cylinder bore atMeasuring Point 1: Maximum wear portion. If the measured value exceeds the specified limit, theCylinder Liner Bore mm(in). The inside of the dry type cylinder liner is chromeIf the inside of the cylinder liner is scored or scorched,Cylinder Liner Projection mm(in). Standard. The difference in the cylinder liner projection heightCylinder Liner RemovalCylinder Liner Remover: 5-8840-2039-0Note. Take care not to damage the cylinder body upper faceRefer to “Cylinder Body Upper Face Warapage”.Measure the cylinder body inside diameter and selectStandard Fitting Interference (Reference) mm(in). If the cylinder liner fitting interference is too small,If the cylinder liner fitting interference is too large, it willCylinder Body Bore MeasurementMeasuring Point 1: 98 mm (3.86 in)Nominal Cylinder Body. Liner Grade. Dimension Bore DiameterNote. All foreign material must be carefully removed from theCylinder Liner Installer: 5-8840-2040-0Note. Check that the cylinder liner is set perpendicular to theRefer to “Cylinder Liner Projection Inspection”.If the cylinder liner is a chrome plated dry type, it isCooling the cylinder liner with dry ice will cause theNote. It is important that the cylinder liner be inserted to theSelect the same grade number as the one for theGrade of cylinder. Grade of piston CombinationMeasure the cylinder liner bore. Then select theThere are two measuring points ( 1 and 2 ). Measure the cylinder liner bore in four differentCalculate the average value of the eight measure-Measuring Points 1: 20 mm (0.79 in) for all A-4J modelsCylinder Liner Bore mm(in). It is most important that the correct piston grade bePiston Measuring Point 1: 70 mm (2.76 in). Piston Grade mm(in). Grade. Piston Outside DiameterNote:However, theAlways measureRefer to the illustration at the left.Note. The tappet surfaces are spherical. Do not attempt toMeasure the tappet outside diameter with a micrometer. If the measured value is less than the specified limit, theTappet Outside Diameter mm(in). Standard LimitStandard LimitIf the measured value exceeds the specified limit,Push Rod Curvature mm(in). LimitThe push rod must beCamshaft Journal Diameter. Use a micrometer to measure each camshaft journalCamshaft Journal Diameter mm(in). Standard LimitMeasure the cam height (H) with a micrometer. If theCam Height H mm(in). Standard LimitIf the measured value exceeds the specified limit,Camshaft Run-Out mm(in). Standard LimitUse an inside dial indicator to measure the camshaftCamshaft Bearing Inside Diameter mm(in). If the clearance between the camshaft bearing insideCamshaft Bearing Clearance mm(in). Standard LimitCamshaft Bearing RemovalBearing Replacer: 5-8840-2038-0Bearing Replacer: 5-8840-2038-0If the measured value exceeds the specified limit,Camshaft End Play mm(in). Standard LimitThrust Plate RemovalUniversal Puller: 5-8840-0086-0Inspect the oil seal fitting surfaces for excessive wearInspect the oil ports for obstructions. To increase crankshaft strength, tufftriding (Nitrizing. Treatment) has been applied. Because of this, it is notHold the surface to be inspected perfectly horizontalNote. Do not allow the solution to come in contact with the oilThe portion to be testedThe sliding surfaceTest liquid shouldApproximatelyJudgmentIf there is no discoloration after thirty or forty sec-If discoloration appears (the surface being testedRead the dial indicator as you turn the crankshaft. If the measured value exceeds the specified limit,Crankshaft Run-Out mm(in). Standard LimitThe ammonium cuprous chloride solution is highly cor-Check to see if the bearing has enough tension, so that aCrankshaft Journal and Crankpin DiameterIf the measured values are less than the limit, theStandard LimitStandard Limit. Crankshaft Journal and Crankpin. Uneven Wear mm(in). Standard LimitIf the clearance between the measured bearing insideCrankshaft Bearing Cap Bolt. Crankshaft brg’ cap Bolt Torque. Crankshaft Journal and. Bearing Clearance mm(in). Connecting Rod Bearing Inside DiameterConnecting Rod Bearing Cap BoltIf the clearance between the measured bearing insideCrankpin and Bearing Clearance mm(in). Standard LimitCrankshaft Journal and Bearing ClearanceCrankshaft Bearing Cap Bolt. Do not allow the crankshaft to turn during bearingIf the measured value exceeds the limit, perform theIf the crankshaft journal and bearing clearanceCrankshaft Journal and Bearing Clearance mm(in). Standard LimitDo not allow the crankshaft to move when installingApply engine oil to the Plastigage to keep it fromDo not allow the connecting rod to move whenConnecting Rod Bearing Cap BoltIf the measured value exceeds the specified limit,If the crankpin and bearing clearance exceedsCrankpin and Bearing Clearance mm(in). Standard LimitCrankshaft Timing Gear RemovalCrankshaft Timing Gear Remover: 9-8840-2057-0Crankshaft Gear Installer: 9-8522-0020-0Crankshaft Pilot Bearing Removal. Use the pilot bearing remover to remove the pilot bear-Pilot Bearing Remover: 5-8840-2000-0. Sliding Hammer: 5-8840-0019-0. Crankshaft Pilot Bearing InstallationPilot Bearing Installer: 5-8522-0024-0. Strike only the crankshaft pilot bearing outer races withBearing damage and reduced bearing service life willThe flywheel friction surface area actually makingThere will be a ridge on the flywheel surface area. Be sure to measure the surface wear in the areaIf the measured value is between the standard andIf the measured value exceeds the specified limit,Flywheel Friction Surface Depth 1 mm(in). LimitNote. Because a ridge is produced at the flywheel friction sur-Ring Gear Removal. Strike around the edges of the ring gear with a hammerRing Gear. Inspect the ring gear. If the ring gear teeth are broken or excessively worn, theDo not allow the temperature of the gas burner toThe ring gear must be installed with the chamferNote. Another method of heating the ring gear to invite ther-Cylinder liner diameter is the smallest at these twoDo not allow the piston ring to slant to one side orMeasuring Point 1: 10 mm (0.39 in)Measuring Point 2: 120 mm (4.72 in). If the piston ring gap exceeds the specified limit, theMeasurement. Refer to the Section “CYLINDER BODY”, Item “Cylinder. Liner Bore Measurement” for details on piston gradeStandard Limit. Oil Ring. Piston Ring and Piston Ring Groove Clearance. Use a feeler gauge to measure the clearance betweenIf the clearance between the piston ring and the pistonPiston Ring and Piston Ring Groove. Clearance mm(in). Standard LimitOil Ring. Visually inspect the piston. If a piston ring groove isUse a micrometer to measure the piston pin outsideIf the measured value is less than the specified limit, thePiston Pin Diameter mm(in). Standard LimitUse an inside dial indicator to measure the piston pinPiston Pin Hole mm(in). Piston Pin and Piston Pin Hole. Piston Pin and Connecting Rod Small End Bushing. Clearance. Use a caliper calibrator and a dial indicator to measureIf the clearance between the piston pin and the connect-Piston Pin and Connecting Rod Small. End Bushing Clearance mm(in). Standard LimitConnecting Rod Bushing RemovalConnecting Rod Bushing ReplacerUse a connecting rod aligner to measure the distortionIf either the measured distortion or parallelism exceedConnecting Rod Alignment. Per Length of 100 mm (3.94 in) mm(in). DistortionConnecting Rod Bushing Replacer:If the measured value exceeds the specified limit,Connecting Rod and Crankpin Side Face. Standard LimitUse a micrometer to measure the idler gear shaft out-If the measured value is less than the specified limit, theIdler Gear Shaft Outside Diameter mm(in). Standard LimitIdler Gear Inside Diameter mm(in). If the clearance between the idler gear shaft outsideIdler Gear Shaft and Idler Gear. Idler Gear “B”. Bearing replacement. Use a suitable bar and a bench press or hammer. Bearing projection amount should be within the spec-Oil Seal Removal. Use a plastic hammer and a screwdriver to tap aroundTake care not to damage the oil seal fitting surfaces.Oil Seal Installer: 5-8840-2061-0Oil Seal Installer: 5-8840-2033-0Take care not to allow the installed valves to fallTake care not to allow the installed valves to fallSpring Compressor: 9-8523-1423-0Take care not to damage the connecting rod.The piston head front mark 1 and the con-Piston Ring Replacer. Install the piston rings in the order shown in theNote. Install the compression rings with the stamped sideInsert the expander coil into the oil ring groove so thatCarefully wipe any oil or other foreign material fromInverted EngineUse compressed air to thoroughly clean the insideNote. The tappet must be installed before the camshaft.The crankshaft upper bearings have an oil hole andApply an ample coat of engine oil to the crankshaftNote. Do not apply engine oil to the bearing back faces and theThe crankshaft thrust bearing oil groove mustNote. Be sure that the bearing cap fitting surface is completelyDo not allow the silicon adhesive to obstruct the cylinderThe bearing cap arrow marks must be facing theThe arrow mark journal number must corre-Note. The No. 4 journal bearing cap does not have a numberPlateTake care not to damage the camshaft bearings.This will facilitate smooth break-in when theNote. Do not apply engine oil to the bearing back faces and thePiston Ring CompressorAt the same time, rotate the crankshaft until theThe bearing cap front marks must be facing theThe bearing cap number (at the side of theNote. It is absolutely essential that the bearing caps beReversing the bearingInstall the oil pump with the oil pipe and tighten theNote. Take care not to damage the O-rings when tighteningOil Seal Installer: 5-8840-0141-0Oil Seal Installer: 5-8840-9057-0Be absolutely sure that the lipped portion isThe idler gear shaft oil hole must be facing up.M 8x1.25 (0.31x0.05). M12x1.25 (0.47x0.05).