Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, 4JJ1 Models Industrial Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, 4JJ1 Models, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, 4JJ1 Models workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 4,718 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
7-28240_EN - SERVICE MANUAL 4JB1 ISUZU ENGINES.pdf
7-28350_FR - MANUEL DE SERVICE MOTEURS ISUZU 4JB1.pdf
7-28360_DE - WARTUNGSANLEITUNG 4JB1 ISUZU-MOTOREN.pdf
9806-2180 - Isuzu A-4JG1 Industrial Engine Workshop Manual.pdf
9806-3060 - Isuzu Industrial Diesel Engine A1-4JJ1 Workshop Manual.pdf
EDBE-EN-01 - Hitachi_Isuzu 4JJ1 Diesel (Interim Tier 4 compatible) Engine Service Manual.pdf
IDE-2290 - Isuzu 4JG2 Service Manual (Forklift HDF20-30, -2 Series, Engine Base, Reference Only).pdf
IDE-2310 - Isuzu A-4JA1, A-4JB1 Models Industrial Diesel Engine Workshop Manual.pdf
IDE-2320 - Isuzu A-4JG1 Model Industrial Diesel Engine Workshop Manual.pdf
Isuzu 4JB1-TC Engine Mechanical Specification & Structure (Applicable To N_R Series).pdf
Isuzu 4J Series Engine Workshop Manual (applicable to MY94&up NHR55. NKR55. NPR55. NPR69).pdf
KM-4JJ1-E-01 (1_2) - Hitachi 4JJ1 Engine Manual.pdf
KM-4JJ1-E-01 (2_2) - Hitachi 4JJ1 Engine Manual.pdf
KM-4JJ1-E-02 (2_2) - Hitachi 4JJ1 Engine Manual.pdf
W1CDE-00 - Hitachi_Isuzu 4JA1 Engine (A-4JG1 PH-01, AA-4JG1 PH-02) Workshop Manual.pdf
MAIN SECTIONS
7-28240_EN - SERVICE MANUAL 4JB1 ISUZU ENGINES....2
7-28350_FR - MANUEL DE SERVICE MOTEURS ISUZU 4JB1....150
7-28360_DE - WARTUNGSANLEITUNG 4JB1 ISUZU-MOTOREN....298
9806-2180 - Isuzu A-4JG1 Industrial Engine Workshop Manual....446
9806-3060 - Isuzu Industrial Diesel Engine A1-4JJ1 Workshop Manual....669
EDBE-EN-01 - Hitachi_Isuzu 4JJ1 Diesel (Interim Tier 4 compatible) Engine Service Manual....903
IDE-2290 - Isuzu 4JG2 Service Manual (Forklift HDF20-30, -2 Series, Engine Base, Reference Only)....1907
MAIN PAGE....1907
SECTION 1. GENERAL INFORMATION....1910
SECTION 2. MAINTENANCE....1928
SECTION 3. ENGINE ASSEMBLY(1)....1940
SECTION 4. ENGINE ASSEMBLY(2)....1958
SECTION 5. ENGINE ASSEMBLY(3)....1994
SECTION 6. LUBRICATING SYSTEM....2022
SECTION 7. COOLING SYSTEM....2034
SECTION 8. FUEL SYSTEM....2044
SECTION 9. ENGINE ELECTRICALS....2056
SECTION 10. TROUBLESHOOTING....2082
SECTION 11. SPECIAL TOOL LIST....2108
SECTION 12. CONVERSION TABLE....2112
IDE-2310 - Isuzu A-4JA1, A-4JB1 Models Industrial Diesel Engine Workshop Manual....2126
INDUSTRIAL....2126
SECTION 1....2129
GENERAL INFORMATION....2129
GENERAL REPAIR INSTRUCTIONS....2130
NOTES ON THE FORMAT OF THIS MANUAL....2130
MAIN DATA AND SPECIFICATIONS....2134
SECTION 2....2145
MAINTENANCE....2145
MODEL IDENTIFICATION....2146
INJECTION PUMP IDENTIFICATION....2146
LUBRICATING SYSTEM....2146
FUEL SYSTEM....2147
COOLING SYSTEM....2150
VALVE CLEARANCE ADJUSTMENT....2151
INJECTION TIMING....2152
COMPRESSION PRESSURE MEASUREMENT....2154
RECOMMENDED LUBRICANTS....2155
ENGINE REPAIR KIT....2156
SECTION 3....2157
ENGINE ASSEMBLY ( 1 )....2157
GENERAL DESCRIPTION....2158
DISASSEMBLY....2159
SECTION 4....2175
ENGINE ASSEMBLY ( 2 )....2175
INSPECTION AND REPAIR....2176
SECTION 5....2209
ENGINE ASSEMBLY ( 3 )....2209
REASSEMBLY....2210
SECTION 6....2237
LUBRICATING SYSTEM....2237
MAIN DATA AND SPECIFICATIONS....2238
GENERAL DESCRIPTION....2239
OIL PUMP....2242
OIL FILTER WITH BUILT-IN OIL COOLER....2245
SECTION 7....2249
COOLING SYSTEM....2249
MAIN DATA AND SPECIFICATIONS....2250
GENERAL DESCRIPTION....2251
WATER PUMP....2253
THERMOSTAT....2259
SECTION 8....2261
FUEL SYSTEM....2261
MAIN DATA AND SPECIFICATIONS....2262
GENERAL DESCRIPTION....2263
INJECTION NOZZLE....2266
INJECTION PUMP DATA....2271
SECTION 9....2275
ENGINE ELECTRICALS....2275
STARTER....2276
ALTERNATOR....2290
SECTION 10....2303
TROUBLESHOOTING....2303
HARD STARTING....2305
UNSTABLE IDLING....2309
INSUFFICIENT POWER....2312
EXCESSIVE FUEL CONSUMPTION....2316
EXCESSIVE OIL CONSUMPTION....2318
OVERHEATING....2319
WHITE EXHAUST SMOKE....2321
DARK EXHAUST SMOKE....2322
OIL PRESSURE DOES NOT RISE....2323
ABNORMAL ENGINE NOISE....2325
SECTION 11....2329
SPECIAL TOOL LIST....2329
SECTION 12....2333
REPAIR STANDARDS....2333
General Rules....2333
Repair standards chart....2334
SECTION 13....2347
CONVERSION TABLES....2347
LENGTH....2348
AREA....2349
VOLUME....2349
MASS....2351
PRESSURE....2352
TORQUE....2353
TEMPERATURE....2354
IDE-2320 - Isuzu A-4JG1 Model Industrial Diesel Engine Workshop Manual....2357
Isuzu 4J Series Engine Workshop Manual (applicable to MY94&up NHR55. NKR55. NPR55. NPR69)....2582
TOP....0
ENGINE 4J SERIES....2582
Sec.00 SERVICE INFORMATION....2586
TROUBLESHOOTING....2587
HARD STARTING....2588
STARTER INOPERATIVE....2588
STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER....2588
ENGINE TURNS OVER BUT DOES NOT START....2589
QUICK-ON START SYSTEM....2590
UNSTABLE IDLING....2591
INSUFFICIENT POWER....2592
EXCESSIVE FUEL CONSUMPTION....2594
EXCESSIVE OIL CONSUMPTION....2594
OVERHEATING....2595
WHITE EXHAUST SMOKE....2595
DARK EXHAUST SMOKE....2596
OIL PRESSURE DOES NOT RISE....2596
ABNORMAL ENGINE NOISE....2597
ENGINE KNOCKING....2597
GAS LEAKAGE NOISE....2597
CONTINUOUS NOISE....2597
SLAPPING NOISE....2598
ENGINE COOLING TROUBLE....2599
ENGINE ELECTRICAL PART TROUBLE....2600
TURBOCHARGER....2605
LUBRICATION CHART....2614
MAIN DATA AND SPECIFICATIONS....2615
SERVICE STANDARD....2619
SERVICING....2623
FIXING TORQUE....2636
SPECIAL TOOLS....2645
Sec.6A GENERAL ENGINE MECHANICAL....2649
CYLINDER HEAD....2650
VALVE SPRING, VALVE GUIDE OIL SEAL, VALVE GUIDE, PUSH ROD....2658
CAMSHAFT, TAPPET....2665
ROCKER ARM ASSEMBLY....2672
OIL PUMP....2675
CRANKSHAFT....2679
PISTON AND CONNECTING ROD....2695
CYLINDER BLOCK....2704
Sec.6A1 4JB1/4JB1T/4JB1TC/4JG2-ENGINE....2717
GENERAL DESCRIPTION....2718
ENGINE MOUNT (RH)....2720
ENGINE MOUNT (LH)....2722
INLET MANIFOLD....2724
EXHAUST MANIFOLD....2726
OIL COOLER ....2728
OIL FILTER CARTRIDGE....2730
CYLINDER HEAD COVER....2731
ROCKER ARM SHAFT ASSEMBLY....2733
VALVESTEM OIL CONTROLLER & VALVE SPRING....2736
TIMING GEAR ....2739
TIMING BELT ....2746
CYLINDER HEAD ASSEMBLY AND GASKET....2753
OIL PAN....2764
OIL PUMP ASSEMBLY....2767
PISTON, PISTON RING AND CONNECTING ROD....2770
CAMSHAFT AND TAPPET....2779
CRANKSHAFT FRONT OIL SEAL (Gear Drive Type)....2787
CRANKSHAFT FRONT OIL SEAL (Belt Drive Type)....2789
CRANKSHAFT REAR OIL SEAL (Gear & Belt Drive Type)....2792
FLYWHEEL AND PILOT BEARING....2799
CRANKSHAFT AND MAIN BEARINGS....2801
ENGINE ASSEMBLY....2812
Sec.6B ENGINE COOLING....2825
GENERAL DESCRIPTION....2825
ON-VEHICLE SERVICE....2830
WATER PUMP....2830
THERMOSTAT....2834
RADIATOR....2836
DRIVE BELT ADJUSTMENT....2839
Sec.6C ENGINE FUEL....2841
GENERAL DESCRIPTION....2842
ON-VEHICLE SERVICE....2847
FUEL FILTER ASSEMBLY....2847
FUEL FILTER CARTRIDGE....2848
INJECTION NOZZLE....2849
INJECTION PUMP ASM (4JB1/4JB1T, 4JG2 Gear Drive Type)....2866
INJECTION PUMP ASSEMBLY (4JG2 Belt Drive Type)....2871
INJECTION TIMING ADJUSTMENT....2881
Adjustment of Idling Speed....2882
INJECTION PUMP DATA....2883
INJECTION VOLUME AND GOVERNOR PERFORMANCE DIAGRAM....2885
FUEL TANK....2895
FUEL GAUGE UNIT....2897
ACCELERATOR CONTROL....2898
ACCELERATOR CONTROL CABLE....2898
ACCELERATOR PEDAL....2900
IDLING CONTROL CABLE....2902
AIR CLEANER ELEMENT....2904
Sec.6D ENGINE ELECTRICAL....2907
6D1 BATTERY....2907
GENERAL DESCRIPTION....2908
DIAGNOSIS....2908
ON-VEHICLE SERVICE....2910
BATTERY CHARGING....2910
JUMP STARTING....2911
REMOVAL AND INSTALLATION OF THE BATTERY....2913
MAIN DATA AND SPECIFICATIONS....2913
6D2 STARTING SYSTEM....2915
GENERAL DESCRIPTION....2915
ON-VEHICLE SERVICE....2917
UNIT REPAIR....2919
6D3 CHARGING SYSTEM....2927
GENERAL DESCRIPTION....2927
DIAGNOSIS....2930
ON-VEHICLE SERVICE....2931
UNIT REPAIR....2935
6D6 QOSII PREHEATING SYSTEM....2949
GENERAL DESCRIPTION....2949
SYSTEM DIAGRAM....2950
Inspection on QOSII System Operation....2951
QOSII SYSTEM TROUBLESHOOTING....2952
6D7 QOSIII PREHEATING SYSTEM....2955
GENERAL DESCRIPTION....2955
SYSTEM DIAGRAM....2956
Inspection on QOSIII System Operation....2959
Sec.6E EXHAUST GAS RECIRCULATION (EGR) SYSTEM....2963
GENERAL DESCRIPTION....2964
EGR SYSTEM WIRING DIAGRAM....2965
EGR SYSTEM OPERATION....2965
Exhaust Gas Recirculation (EGR) System Check....2966
INSPECTION....2967
Sec.6F ENGINE EXHAUST....2969
GENERAL DESCRIPTION....2970
THREE WAY CATALYTIC CONVERTER....2971
ON-VEHICLE SERVICE....2972
FRONT EXHAUST PIPE....2972
Exhaust Brake Unit....2973
INSPECTION....2973
Sec.6G TURBOCHARGER....2975
TURBOCHARGER....2976
MAIN DATA AND SPECIFICATIONS....2976
GENERAL DESCRIPTION....2977
IDENTIFICATION OF UNIT....2978
TURBOCHARGER SERVICING....2978
PRECAUTIONS....2978
DISASSEMBLY....2979
INSPECTION AND REPAIR....2981
REASSEMBLY....2983
IHI SERVICE NETWORK....2985
Isuzu 4JB1-TC Engine Mechanical Specification & Structure (Applicable To N_R Series)....2988
KM-4JJ1-E-01 (1_2) - Hitachi 4JJ1 Engine Manual....3050
COVER....3050
Introduction....3052
General Contents....3054
Control System....3056
4JJ1 Electronic Control Fuel Injection System (Common Rail Type)....3056
How to Use This Manual....3058
How to use this manual....3058
Table of abbreviation....3059
Conversion formula....3060
About colors of wirings....3061
About wiring diagrams....3062
How to read trouble diagnosis section....3063
Precautions on Service Work....3065
Electrical system....3065
Fuel injection system....3065
Procedure of Trouble Diagnosis....3067
About trouble diagnosis....3067
Trouble diagnostic procedure....3068
Interview....3069
Pre-inspection....3071
Trouble diagnosis....3071
How to read DTC....3072
Confirmation after repair....3074
List of final check items....3074
How to clear DTC....3075
Trouble diagnosis with scan tool....3076
Data reference value....3083
How to Inspect Injector....3087
Injector balance test (Tech2, EMPSIII)....3087
How to Use Breaker Box....3088
Breaker box inspection procedure....3088
Engine Control System....3091
Description of function and operation for engine control (common rail) system....3091
Engine control module (ECM)....3107
Engine component location diagram....3109
Wiring diagram of engine control module (ECM)....3122
Pin arrangement of engine control module (ECM)....3123
Circuit diagram....3127
Engine harness location....3141
Connector list....3145
List of Function Checks....3148
List of function checks....3148
OBD system check....3149
Diagnosis lamp illumination circuit system check....3151
Diagnosis lamp blinking circuit system check....3153
Scan tool power supply circuit system check (Tech2)....3156
Scan tool power supply circuit system check (EMPSIII)....3158
Scan tool communication circuit system check....3160
Starting circuit system check....3163
Starting system check....3168
Fuel system check....3171
Intake system check....3175
Exhaust system check....3175
EGR control system check....3176
QOS system check....3179
List of Diagnostic Trouble Codes....3184
List of diagnostic trouble codes....3184
DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump)....3197
DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)....3207
DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump)....3213
DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short....3218
DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short)....3224
DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)....3230
DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit)....3236
DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)....3242
DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)....3249
DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)....3255
DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)....3263
DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)....3269
DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)....3277
DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)....3283
DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system....3289
DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system....3294
DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system....3299
DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system....3304
DTC: P0219 (Flash code 543) Overrun....3309
DTC: P0237 (Flash code 32) Boost pressure sensor fault (low voltage fault, open circuit)....3311
DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit)....3318
DTC: P0335 (Flash code 15) Crank sensor fault (no signal)....3325
DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)....3333
DTC: P0340 (Flash code 14) Cam sensor fault (no signal)....3339
DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)....3346
DTC: P0380 (Flash code 66) Glow relay circuit fault....3352
DTC: P0381 (Flash code 67) Glow plug lamp circuit fault....3357
DTC: P0487 (Flash code 44) EGR position sensor fault....3362
DTC: P0488 (Flash code 45) EGR valve control fault....3368
DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)....3374
DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)....3380
DTC: P0601 (Flash code 53) ROM fault....3387
DTC: P0603 (Flash code 54) EEPROM fault....3389
DTC: P0606 (Flash code 51) CPU fault....3391
DTC: P0606 (Flash code 52) CPU monitoring IC fault....3393
DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)....3395
DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)....3398
DTC: P0615 (Flash code 19) Starter cut relay circuit fault....3401
DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault....3406
DTC: P1093 (Flash code 227) No pump pressure feed....3411
DTC: P1095 (Flash code 225) Pressure limiter open....3422
DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)....3433
DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)....3440
DTC: P1173 (Flash code 542) Overheat....3447
DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault....3453
DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault....3457
DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault....3464
DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault....3471
DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault)....3477
DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)....3482
DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault)....3487
DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)....3492
DTC: P1345 (Flash code 16) Cam sensor out of phase....3497
DTC: P1625 (Flash code 416) Main relay fault....3502
DTC: P1630 (Flash code 36) A/D conversion fault....3508
DTC: P1631 (Flash code 55) Voltage fault in 5V power supply 1....3510
DTC: P1632 (Flash code 55) Voltage fault in 5 V power supply 2....3514
DTC: P1633 (Flash code 55) Voltage fault in 5V power supply 3....3518
DTC: P1634 (Flash code 55) Voltage fault in 5V power supply 4....3522
DTC: P1635 (Flash code 55) Voltage fault in 5V power supply 5....3526
DTC: U2104 (Flash code 84) CAN Bus fault....3530
DTC: U2106 (Flash code 85) CAN timeout fault....3535
List of Trouble Symptom....3540
List of trouble symptom....3540
Engine start failure....3541
Engine stall....3548
Engine hunting, rough idling....3553
Engine output shortage....3558
Exhaust gas contains a lot of white smoke.....3562
Exhaust gas contains a lot of black smoke.....3565
Noise....3567
Fuel consumption deteriorates.....3569
Oil consumption deteriorates.....3572
Special Tool....3574
List of special tool....3574
KM-4JJ1-E-01 (2_2) - Hitachi 4JJ1 Engine Manual....3576
COVER....3576
Introduction....3578
General Contents....3580
General Information....3582
General Information....3582
General Information....3585
Service Precautions....3585
Reading the Model....3589
General Information....3589
Engine....3596
Engine Mechanical (4JJ1)....3596
Diesel Engine (4JJ1)....3598
Precautions on Service Work....3598
Main Data and Specifications....3603
Special tool....3604
Engine Foot....3605
Components....3605
Removal....3605
Installation....3606
Cylinder Head Cover....3608
Components....3608
Removal....3609
Installation....3610
Torque Specifications....3611
Intake Manifold....3612
Components....3612
Removal....3612
Installation....3613
Torque Specifications....3615
Exhaust Manifold....3616
Components....3616
Removal....3616
Inspection....3617
Installation....3618
Torque Specifications....3620
Timing Gear Train....3621
Components....3621
Removal....3621
Disassembly....3624
Reassembly....3624
Inspection....3625
Installation....3626
Torque Specifications....3630
Special Tool....3630
Camshaft ASM....3631
Components....3631
Removal....3632
Disassembly....3633
Reassembly....3635
Installation....3636
Torque Specifications....3638
Special Tool....3638
Rocker Arm Shaft ASM....3639
Components....3639
Removal....3639
Disassembly....3640
Reassembly....3642
Installation....3642
Torque Specifications....3643
Valve Stem Seal, Valve Spring....3644
Components....3644
Removal....3644
Inspection....3645
Installation....3646
Special Tool....3647
Cylinder Head....3648
Components....3648
Removal....3648
Disassembly....3653
Inspection....3654
Reassembly....3659
Installation....3662
Torque Specifications....3670
Special Tool....3670
Piston, Connecting Rod....3672
Components....3672
Removal....3672
Disassembly....3673
Reassembly....3679
Installation....3680
Torque Specifications....3682
Special Tool....3682
Flywheel....3683
Components....3683
Removal....3683
Inspection....3684
Installation....3684
Torque Specifications....3686
Special Tool....3686
Gear Case ASM....3687
Components....3687
Removal....3687
Installation....3688
Torque Specifications....3689
Crankshaft Front Oil Seal....3690
Components....3690
Removal....3690
Installation....3691
Torque Specifications....3693
Special Tool....3693
Crankshaft Rear Oil Seal....3694
Components....3694
Removal....3695
Installation....3695
Torque Specifications....3697
Special Tool....3697
Crankshaft....3698
Components....3698
Removal....3698
Disassembly....3699
Reassembly....3700
Inspection....3700
Installation....3704
Torque Specifications....3707
Cylinder Block....3708
Components....3708
Removal....3708
Inspection....3709
Installation....3711
Lubrication System....3712
Precautions on Service Work....3712
Functional Check....3713
Special Tool....3714
Oil Filter ASM....3715
Components....3715
Removal....3715
Installation....3716
Oil Port Cover ASM....3717
Components....3717
Removal....3717
Installation....3717
Oil Cooler....3718
Components....3718
Removal....3718
Disassembly....3719
Reassembly....3720
Installation....3720
Oil Relief Valve....3722
Components....3722
Removal....3722
Installation....3723
Crankcase, Oil Pan....3725
Components....3725
Removal....3725
Disassembly....3726
Reassembly....3727
Installation....3727
Torque Specifications....3729
Oil Pump....3730
Components....3730
Removal....3730
Disassembly....3732
Reassembly....3732
Inspection....3732
Installation....3734
Oil Pressure Switch....3737
Components....3737
Removal....3737
Inspection....3737
Installation....3738
Engine....3740
Cooling System....3740
Cooling System....3743
Precautions on Service Work....3743
A List of Defective Phenomena....3749
Main Data and Specifications....3749
Water Pump....3750
Components....3750
Removal....3750
Inspection....3751
Installation....3752
Torque Specifications....3754
Thermostat....3755
Components....3755
Removal....3755
Inspection....3756
Installation....3756
Drive Belt....3757
Components....3757
Inspection....3757
Torque Specifications....3758
Fan Clutch, Cooling Fan....3759
Inspection....3759
Engine....3760
Fuel System....3760
Fuel System....3763
Precautions on Service Work....3763
Special Tool....3771
Fuel Filter ASM....3772
Components....3772
Removal....3772
Installation....3772
Fuel Filter Element....3773
Removal....3773
Installation....3773
Special Tool....3773
Fuel Injector....3774
Components....3774
Removal....3775
Installation....3775
Torque Specifications....3778
Common Rail....3779
Components....3779
Removal....3779
Installation....3780
Torque Specifications....3782
Fuel Supply Pump....3783
Components....3783
Removal....3784
Installation....3787
Torque Specifications....3792
Gauze filter....3793
Removal....3793
Installation....3793
Electromagnetic Pump Filter....3794
Removal....3794
Installation....3794
Engine....3796
Engine Electrical....3796
Service Precautions....3799
General Procedure....3799
Charging System....3800
General Description....3800
Inspection....3801
Inspection....3801
Generator....3802
Removal....3802
Installation....3803
Torque Specifications....3803
Specifications....3804
Connector terminal....3804
Internal connections....3804
Disassembly of generator....3805
Inspection and repair of generator....3806
Performance test....3808
Handling of generator....3809
Trouble and action....3810
Starting System....3811
General Description....3811
Service on the Machine: Starting System....3812
Starter....3813
Removal....3813
Installation....3814
Torque Specifications....3814
Main Data and Specifications....3815
Connections (Hitachi, Ltd.)....3816
Inspection and repair of starter....3817
Handling of starter....3817
Trouble countermeasure....3818
Preheating System....3819
Glow Plug Replacement....3819
Precautions on Service Work....3819
A List of Defective Phenomena....3819
Main Data and Specifications....3820
Engine....3822
Exhaust System and Turbocharger....3822
EGR System....3825
Precautions on Service Work....3825
EGR Cooler....3826
Components....3826
Removal....3827
Inspection....3827
Installation....3827
Torque Specifications....3829
Exhaust System....3830
A List of Defective Phenomena....3830
Troubleshooting....3830
Turbocharger....3831
Turbocharger inspection....3831
Inspection....3831
Measurement Tool....3832
Other Material....3832
KM-4JJ1-E-02 (2_2) - Hitachi 4JJ1 Engine Manual....3833
W1CDE-00 - Hitachi_Isuzu 4JA1 Engine (A-4JG1 PH-01, AA-4JG1 PH-02) Workshop Manual....4111
ENGINE.pdf....0
SECTION 1 GENERAL INFORMATION ....4493
General Repair Instructions ....4494
Notes On The Format Of This Manual ....4494
Main Data And Specifications ....4498
Tightening Torque Specifications ....4503
SECTION 2 MAINTENANCE....4513
Model Indentification ....4514
Injection Pump Identification ....4514
Lubricating System....4514
Fuel System....4515
Cooling System....4517
Valve Clearance Adjustment....4518
Injection Timing....4520
Compression Pressure Measurement....4521
Recommended Lubricants....4522
Engine Repair Kit....4523
SECTION 3 ENGINE ASSEMBLY(1) ....4525
General Description....4526
Disassembly....4527
SECTION 4 ENGINE ASSEMBLY(2) ....4543
Inspection And Repair ....4544
SECTION 5 ENGINE ASSEMBLY(3) ....4575
Reassembly....4576
SECTION 6 LUBRICATING SYSTEM....4603
Maine Data And Specifications ....4604
General Description....4605
Oil Pump....4608
SECTION 7 COOLING SYSTEM....4613
Maine Data And Specifications ....4614
General Description....4615
Thermostat....4617
SECTION 8 FUEL SYSTEM....4619
Maine Data And Specifications ....4620
General Description....4621
Injection Nozzle....4622
Injection Pump Calibration Data....4624
SECTION 9 ENGINE ELECTRICALS....4635
Starter....4636
Alternator....4651
SECTION 10 TROUBLESHOOTING....4664
Hard Starting....4666
Unstable Idling....4670
Insufficient Power....4673
Excessive Fuel Consumption....4677
Excessive Oil Consumption....4679
Overheating....4680
White Exhaust Smoke....4682
Dark Exhaust Smoke....4683
Oil Pressure Does Not Rise....4684
Abnormal Engine Noise....4686
SECTION 11 SPECIAL TOOL LIST....4689
SECTION 12 REPAIR STANDARDS....4693
General Rules....4693
Repair Standards Chart....4694
SECTION 13 CONVERSION TABLE....4707
Length....4707
Area....4709
Volume....4709
Mass....4711
Pressure....4712
Torque....4713
Temperature....4714
Isuzu A-4JG1, A-4JB1, 4JB1, 4JB1-TC, A-4JG1, 4JG2, A1-4JJ1, 4JJ1 Models Industrial Engines Repair Service Manual
