ISUZU TF SERIES 2004 Workshop Manual

ENGINE MECHANICAL 6A – 1


SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit ........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43

6A – 2 ENGINE MECHANICAL
Disassembly ............................................................................................................... 6A- 47
Internal Parts........................................................................................................... 6A- 47
Major Components.............................................................................................. 6A- 47
Minor Components ............................................................................................. 6A- 56
Rocker Arm Shaft and Rocker Arm................................................................ 6A- 56
Cylinder Head .................................................................................................. 6A- 57
Piston and Connecting Rod ........................................................................... 6A- 59
Inspection and Repair................................................................................................ 6A- 61
Cylinder Head ......................................................................................................... 6A- 61
Rocker Arm Shaft and Rocker Arm ....................................................................... 6A- 68
Cylinder Body ......................................................................................................... 6A- 69
Camshaft ................................................................................................................. 6A- 77
Crankshaft and Bearing ......................................................................................... 6A- 79
Crankshaft Bearing Selection................................................................................ 6A- 83
Crankshaft Pilot Bearing........................................................................................ 6A- 85
Flywheel and Ring Gear ......................................................................................... 6A- 85
Piston....................................................................................................................... 6A- 86
Cylinder Head Gasket Selection............................................................................ 6A- 88
Connecting Rod ...................................................................................................... 6A- 90
Idler Gear Shaft and Idler Gear.............................................................................. 6A- 91
Timing Gear Case Cover ........................................................................................ 6A- 91
Reassembly ................................................................................................................ 6A- 93
Internal Parts........................................................................................................... 6A- 93
Minor Component ............................................................................................... 6A- 93
Rocker Arm Shaft and Rocker Arm................................................................ 6A- 93
Cylinder Head .................................................................................................. 6A- 94
Piston and Connecting Rod ........................................................................... 6A- 96
Positive Crankcase Ventilation (PCV) Valve ................................................. 6A- 99
Major Component................................................................................................ 6A- 101
Installation .................................................................................................................. 6A- 118
External Parts ......................................................................................................... 6A- 118
Lubrication System........................................................................................................ 6A- 126

ENGINE MECHANICAL 6A – 3
Lubricating Flow ........................................................................................................ 6A- 126
Oil Pump and Oil Filter .............................................................................................. 6A- 127
Oil Pump ..................................................................................................................... 6A- 128
Disassembly............................................................................................................ 6A- 128
Inspection and Repair ............................................................................................ 6A- 129
Reassembly............................................................................................................. 6A- 130
Oil Filter and Oil Cooler ............................................................................................. 6A- 131
Disassembly............................................................................................................ 6A- 131
Inspection and Repair ............................................................................................ 6A- 132
Reassembly............................................................................................................. 6A- 133
Inter Cooler .................................................................................................................... 6A- 135
Removal .................................................................................................................. 6A- 136
Installation .............................................................................................................. 6A- 136
Special Tools.................................................................................................................. 6A- 137

6A – 4 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JA1T (L) 4JA1TC
Engine type
Combustion chamber type
Cylinder liner type
Timing gear train system Four-cycle, overhead valve, water cooled
Direct injection
Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 93
92 (3.66
3.62)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement cm3 (in3)
Compression ratio (to 1) 2,499(152.4)
18.5
Compression pressure Mpa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) Approximately 239 (527)
Fuel injection order 1 – 3 – 4 - 2
Fuel injection timing BTDC deg 8 -
Specified fuel type
Idling speed rpm

Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
730  25 (A/C Off)
850  25 (A/C ON)
0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed
type) Electronically controled
Injection nozzle type
Injection nozzle opening pressure Hole with 5 orifices

Mpa(kg/cm2/psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2nd (Reference)
25.527.0
(260275 / 3,7023,920) 2nd (Reference)
34.035.5
(347362 / 4,9365,154)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)

ENGINE MECHANICAL 6A – 5
Engine model
Item 4JA1T (L) 4JA1TC
Oil pump type
Oil filter type
Oil capacity lit (US/UK gal)
Oil cooler type Gear
Cartridge paper element
6.2 (1.64/1.36)
Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage
No. of units 80D26L
1

95D31L
1 (OPT)
Generator capacity V-A 12 – 60
12 – 80
Starter motor output V-Kw 12 – 2.3
Turbocharger model
Turbine type
Compressor type *IHI RHF 4H
Mixed flow type
Backward & rake

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

6A – 6 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JH1TC
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type
Timing gear train system Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 95.4
104.9 (3.76
4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter
Compression ratio (to 1) 2,999
18.3
Compression pressure MPa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) MT : Approximately 249 (549)
AT : Approximately 236 (520)
Fuel injection order 1 – 3 – 4 - 2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm
700
25 (A/C OFF)
800
25 (A/C ON)
Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system
Injection pump type 0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

BOSCH distributor VP44 type
Injection nozzle type
Injection nozzle opening pressure
MPa(kg/cm
2/psi)Hole with 5 orifices

1st 19.5 (199/2,828)
2nd (Reference) 34.335.8 (350365/4,9805,197)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Oil pump type
Oil filter type Gear
Cartridge paper element
Oil capacity lit (US/UK gal)
6.2 (1.64/1.36) (For 4
2)
7.0 (1.85/1.54) (For 4
4)
Oil cooler type Water cooled

ENGINE MECHANICAL 6A – 7

Engine model
Item 4JH1TC
Cooling system
Water pump type
Thermostat type
Air cleaner type

Battery type/voltage
No. of units



Generator capacity V-A
Starter motor output V-Kw
Turbocharger model
Turbine type
Compressor type
Centrifugal
Wax pellet with jiggle valve
Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
80D26L
1
95D31L
1 (OPT)
75D26R
2 (OPT for EC, MT)
80D26R
2 (OPT for EC, AT)
12 – 60/12 – 80
12 – 2.3
*IHI RHF5
Mixed flow type Radial-inflow
Backward & rake type Radial-outflow
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.

6A – 8 ENGINE MECHANICAL

TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
N ·m (kg ·m/lb ·ft)
8.8
4.8 (4T) (7T) Refined Non-Refined 9.8 (9T) Strength
Class
Bolt
Identification


Bolt
Diameter

Pitch (mm)
M 6






1.0

M 8






1.25

M 10






1.25

M 12






1.25

M 14






1.5

M 16






1.5

M 18






1.5

M 20






1.5

M 22






1.5

M 24






2.0

* M 10






1.5

* M 12






1.5

* M 14






2.0

* M 16






2.0
5.88 ± 1.96
(0.60 ± 0.20/4.33 ± 1.44)
12.74
4.90
(1.30 ± 0.50/9.40 ± 3.62)
27.44 ± 6.86
(2.80 ± 0.70/20.25 ± 5.06)
61.25 ± 12.25
(6.25 ± 1.25/45.21 ± 9.04)
95.55 ± 19.11
(9.75 ±1.95/70.52 ± 14.10)
130.34 ± 26.46
(13.30 ± 2.70/96.20 ± 19.53)
188.16 ± 37.24
(19.20 ± 3.80/138.87 ± 27.49)
257.74 ± 51.94
(26.30 ± 5.30/190.23 ± 38.33)
332.22 ± 81.34
(33.90 ± 8.30/245.20 ± 60.03)
448.84 ± 90.16
(45.80 ± 9.20/331.27 ± 66.54)
26.46 ± 6.86
(2.70 ± 0.70/19.53 ± 5.06)
56.84 ± 11.76
(5.80 ± 1.20/41.95 ± 8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
124.46 ± 24.50
(12.70 ± 2.50/91.86 ± 18.08) 7.35 ± 2.45
(0.75 ± 0.25/5.43 ± 1.80)
17.15 ± 5.39
(1.75
0.55/12.66
4.00)
36.75 ± 9.31
(3.75 ± 0.95/27.12 ± 6.87)
75.95 ± 15.19
(7.75 ± 1.55/56.06 ± 11.21)
116.13
23.03
(11.85 ± 2.35/85.71 ± 17.00)
169.54 ± 34.30
(17.30 ± 3.50/125.13 ± 25.32)
244.02 ± 49.00
(24.90 ± 5.00/180.10 ± 36.17)
337.12 ± 67.62
(34.40 ± 6.90/248.82 ± 49.41)
453.25 ± 90.65
(46.25 ± 9.25/334.53 ± 66.91)
570.36 ± 140.14
(58.20 ± 14.30/420.96 ± 103.43)
36.26 ± 8.82
(3.70 ± 0.90/26.76 ± 6.50)
70.56 ± 13.72
(7.20 ± 1.40/52.08 ± 10.13)
109.76 ± 21.56
(11.20 ± 2.20/81.01 ± 15.91)
161.70 ± 32.34
(16.50 ± 3.30/119.34 ± 23.87) -

23.52 ± 6.86
(2.40 ± 0.70/17.36 ± 5.06)
49.98 ± 12.74
(5.10 ± 1.30/36.89 ± 9.40)
94.57 ± 19.11
(9.65 ± 1.95/69.80 ± 14.10)
142.10 ± 28.42
(14.50 ± 2.90/104.88 ± 21.00)
199.92 ± 40.18
(20.40 ± 4.10/147.55 ± 29.66)
287.14 ± 57.82
(29.30 ± 5.90/211.93 ± 42.67)
395.92 ± 79.38
(40.40 ± 8.10/292.21 ± 58.59)
530.18 ± 105.84
(54.10 ± 10.80/391.30 ± 78.12)
691.88 ± 138.18
(70.60 ± 14.10/510.65 ± 101.99)
48.02 ± 11.76
(4.90 ± 1.20/35.44 ±8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
133.28 ± 26.46
(13.60 ± 2.70/98.37 ± 19.53)
191.10 ± 38.22
(19.50 ± 3.90/141.04 ± 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS N ·m (kg ·m/lb ·ft)
Pipe diameter mm
(in) Torque Pipe diameter mm
(in) Torque
4.76 (0.187)
6.35 (0.250)
8.00 (0.315) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8)
26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1)
44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 10.00 (0.394)
12.00 (0.472)
15.00 (0.591) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

ENGINE MECHANICAL 6A – 9

SPECIAL PARTS FIXING NUTS AND BOLTS
Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
N·m (kg·m/lb·ft)



RTW46AXF000501

6A – 10 ENGINE MECHANICAL
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
N·m (kg·m/lb·ft)





RTW36AXF000101