Isuzu engine 4j series. Manual — part 27

6A – 44

GENERAL ENGINE MECHANICAL

10) Crankshaft Timing Gear

!

Install the camshaft timing gear to the camshaft.
The timing gear mark (“Y – Y”) must be facing
outward.

"

Tighten the timing gear to the specified torque.

N∙m (kg∙m/lb∙ft)

64 (6.5/47)

9) Idle Gear

!

Apply engine oil to the idle gear and the idler gear
shaft.
The idler shaft oil hole must be facing up.

"

Position the idler gear setting marks “X” and “Y” so
that they are facing the front of the engine.

#

Align the idler gear “X” setting mark with the
crankshaft timing gear

!

“X – X” setting mark.

$

Align the idler gear “Y” setting mark with the camshaft
timing gear

!

“Y – Y” setting mark.

%

Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.

&

Tighten the idler gear bolt to the specified torque.

N∙m (kg∙m/lb∙ft)

19 (1.9/14)

8) Idler Gear “B” and Shaft

!

Apply engine oil to the idler gear and the idler gear
shaft.

"

Align the idler gear “B”

#

“Z” setting mark with the

idler gear “A”

$

“Z-Z” setting mark.

#

Tighten the idler gear bolt to the specified torque.

N∙m (kg∙m/lb∙ft)

76 (7.7/56)

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GENERAL ENGINE MECHANICAL 6A – 45

7) Injection Pump

!

Install the O-ring

!

to the injection pump flange

"

.

"

Install the injection pump to the timing gear case.
Align the idler gear “B”

#

“V-V” mark.

#

Temporarily tighten the six injection pump nuts

%

.

The injection pump nuts will be finally tightened after
the injection pump rear bracket bolts.

$

Install the injection pump rear bracket

&

and the rear

bracket bolts

'

to the cylinder body.

%

Install the rear bracket bolts

(

to the injection pump

bracket

)

.

Do not tighten the bolts.
The rear bracket bolts

'

and

(

will be finally

tightened to the specified torque.

N∙m (kg∙m/lb∙ft)

19 (1.9/14)

6) Timing Gear Oil Pipe

!

Install the oil pipe to the timing gear case and idler
gear “A”.

"

Tighten the oil pipe eye bolt

!

and bolt

"

to the

specified torque.

N∙m (kg∙m/lb∙ft)

13 (1.3/9)

5) Timing Gear Case Cover

!

Align the gear case with the timing gear case knock
pin and then install the timing gear case cover.

"

Tighten the gear case cover bolts to the specified
torque.

N∙m (kg∙m/lb∙in)

8 (0.8/69)

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6A – 46

GENERAL ENGINE MECHANICAL

4) Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the
specified torque.

NOTE:

Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley.

N∙m (kg∙m/lb∙ft)

206 (21/152)

3) Cooling Fan Assembly
•

Mount fan pulley, distance piece, and cooling fan asm
(in this order) on the water pump, and tighten to the
specified torque.

N∙m (kg∙m/lb∙in)

8 (0.8/69)

2) AC Generator, Power Steering Pump Drive Belt
•

Install AC Generator, Power Steering pump drive belt
and adjust belt tension.

•

Depress the drive belt mid-portion with a 98 N (10
kg/22 lb) force.

Drive Belt Deflection

mm (in)

8 (0.31) - 12 (0.47)

•

Tighten the idler lock nut to the specified torque.

N∙m (kg∙m/lb∙ft)

27 (2.8/20)

1) Fan Shroud
•

Install the fan shroud and reservoir tank hose.

•

Pour coolant

•

Start the engine and check coolant leakage.

2. Oil Pan Assembly

Above works refer to “OIL PUMP” Section in this manual.

1. Cylinder Head Assembly and Gasket

•

Piston Head Projection Measurement Point

•

Cylinder Head Assembly

•

Push Rod

•

Rocker Arm Shaft Assembly

Valve clearance adjustment.
Above works refer to “CYLINDER BLOCK” Section in this
manual.

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GENERAL ENGINE MECHANICAL 6A – 47

PISTON AND CONNECTING ROD

DISASSEMBLY

1. Cylinder Head Assembly

2. Oil Pan Assembly

3. Oil Pump Assembly

4. Piston Cooling Oil Pipe

5. Connecting Rod Bearing Cap

6. Piston and Connecting Rod

•

Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.

6A-47-1.tif

Disassembly steps

1. Cylinder head Assembly
2. Oil pan Assembly
3. Oil pump Assembly
4. Piston cooling oil pipe
5. Connecting rod bearing cap
6. Piston and connecting rod
7. Piston ring
8. Piston pin snap ring
9. Piston pin
10. Piston
11. Connecting rod

Reassembly steps
To reassemble, follow the
disassembly steps in the reverse
order.