Isuzu N-Series. Manual — part 496
Engine Mechanical (4HK1-TC) 6A-89
Legend
1. Spring Pitch
2. Paint Mark
8. Install the spring upper sheet.
9. Install the split collar.
• Use the replacer to compress the valve spring
and install the split collar.
Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)
10. Install the idle gear C.
• Apply engine oil on the idle gear C shaft and
the inner diameter of the idle gear, install the
idle gear C so that the side with gear groove is
on the side of the rear surface of the engine.
• Tighten the idle gear C with the designated
torque.
• Do not use impact wrench and like.
Tighten:
Bolt to 95 N
⋅m (9.7 kg⋅m/70 lb⋅ft)
Legend
1. Idle Gear C
2. Shaft
11. Install the idle gear C cover.
• Apply liquid gasket (Loctite 262) on the outer
diameter of the idle gear C cover, use the
sealing cup setting tool to hammer it in so that
the measurements follow the drawing.
Special tool
Sealing cup installer: 5-8840-2222-0
(EN-47690)
12. Install the thermostat.
N6A6119E
N6A6113E
N6A6134E
N6A6165E
6A-90 Engine Mechanical (4HK1-TC)
• Install the thermostat on the position shown in
the drawing.
Legend
1. Thermostat
13. Install the water outlet pipe.
• Tighten the water outlet pipe with the
designated torque.
Tighten:
Bolts to 24 N
⋅m (2.4 kg⋅m/17 lb⋅ft)
14. Install the exhaust gasket.
15. Install the exhaust manifold.
• Install the distance tube conical spring and the
nut on the stud of the cylinder head in this
order.
Legend
1. Distance Tube
2. Conical Spring
3. Nut
• Tighten the exhaust manifold in the order
described in the drawing.
Tighten:
Bolt (1),(2),(3),(4),(5),(6) and Nut (7), (8) to 34 N
⋅m (3.5
kg
⋅m/25 lb⋅ft)
Caution:
Do not tighten it too much so that it hinders extraction
and contraction of the manifold due to heat.
• Install the heat protector.
Tighten:
Bolts to 10 N
⋅m (1.0 kg⋅m/87 lb⋅ft)
N6A6166E
N6A6167E
N6A6168E
N6A6046E
Engine Mechanical (4HK1-TC) 6A-91
16. A/C compressor bracket.
Install the bracket, tighten the bolt with the
designated torque.
Tighten:
Bolts to 48 N
⋅m (4.9 kg⋅m/35 lb⋅ft)
17. Install the inlet cover.
• Apply liquid gasket (ThreeBond1207C or
equivalent) in accordance with the groove of
the inlet cover, with the bead diameter of
φ2.5 –
5.5 mm (0.0984 – 0.2165 in).
• Tighten in the order described in the drawing.
• Tighten the stud bolts (6) and (9) jointly with the
fuel rail.
Tighten:
Stud bolts to 22 N
⋅m (2.2 kg⋅m/16 lb⋅ft)
18. Install the throttle assembly.
• Coat the liquid gasket and mount within 7
minutes.
Tighten:
Bolt and nut to 24 N
⋅m (2.4 kg⋅m/17 lb⋅ft)
• Install the intake throttle valve connector.
Installation
1. Install the cylinder head gasket.
• Select the cylinder head gasket.
• Clean the head of the piston and the upper
surface of the cylinder block.
• Use a dial gauge to measure the extrusion of
the piston. Measure at two points of each
cylinder.
N6A6051E
N6A6169E
N6A6170E
N6A6035E
6A-92 Engine Mechanical (4HK1-TC)
• The following drawing shows the measurement
points and the standard point of the cylinder
block.
Caution:
Note that there are three options for the head gasket
according to the amount of extrusion of piston shown in
the following table.
• Calculate the average piston extrusion amount
of each cylinder.
• Calculate the maximum amount of the average
amount of each cylinder.
• Select a gasket of an appropriate grade based
on Timax.
Legend
1. Grade Recognition Hole
• Apply liquid gasket
• Apply liquid gasket (ThreeBond 1207C or
equivalent) on the joint (1) of the cylinder block
and the flywheel housing with the bead
diameter of 3 mm (0.118 in).
• Install the cylinder head within seven minutes
after applying liquid gasket.
Measurement
points:
Head of the piston
(2) and (3)
Standard point: Upper surface of the
cylinder block
(1)
N6A6171E
N6A6172E
Gasket
Grade
Recognized
by
Piston extrusion
amount mm (in)
A
(no hole)
0.439 (0.01728) –
0.519 (0.02043)
B
(1 hole)
0.519 (0.02043) –
0.589 (0.02319)
C
(2 holes)
0.589 (0.02319) –
0.669 (0.02633)
N6A6173E
N6A6174E
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