engine ISUZU TF SERIES 2004 Owners Manual

6 – 12 TROUBLESHOOTING
10. Abnormal Engine Noise
10–1 Engine knocking
Step Action Value(s) Yes No
1 Was the injection nozzle pressure or injection spray
pattern OK? —
Go to Step 2 Replace the
injection nozzle
2 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm Go to Step 3 Replace the
cylinder head
gasket or
piston ring
3 Are any DTC stored? — Go to indicated
DTC Solved

10–2 Gas leakage noise
Step Action Value(s) Yes No
1 Was the exhaust pipe loose or broken? — Retighten or
replace the
exhaust pipe Go to Step 2
2 Was the exhaust manifold loose? — Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket Go to Step 3
3 Was the injection nozzle loose? — Retighten or
replace the
injection nozzle
fixing bolt Go to Step 4
4 Was the cylinder head gasket broken? — Replace the
cylinder head
gasket Go to Step 5
5 Are any DTC stored? — Go to indicated
DTC Solved

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the
turbocharger? —
Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? — Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged?— Replace the
damaged
gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? — Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? — Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? — Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? — Repair or
replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? — Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/
10W–30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil
feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved

6 – 18 TROUBLESHOOTING
14-5 Charging System Noise
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and
decreasing engine speed? —
Replace the
bearing. Go to Step 3
3 Was there a growling sound and does this sound
stop when the connector was disconnected? — Replace the
stator coil. Go to Step 4
4 Was intermittent sound heard when the generator
was running? — Replace the
brush and/or
slip ring. Go to Step 5
5 Was frictional sound heard when generator was
running? — Clean the slip
ring or replace
the brush. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

TROUBLESHOOTING 6 – 19
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? — Replace the
brush or repair
the
commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty?
—
Clean contact
face Go to Step 4
4 Was the pinion clutch slipped? — Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil.
Was there an open circuit or a short circuit in the
armature field coil? — Repair or
replace the
armature field
coil. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

15-2 Incorrect pinion and ring gear engagement
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken? —
Replace the
wron parts. Go to Step 3
3 Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect? — Adjust or
replace the
movement
parts. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

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