4JA1 and 4JHI ENGINE

WORKSHOP MANUAL
2011MY TF SERIES
ENGINE
4JA1/4JH1 MODELS
SECTION 6
Isuzu Motors Limited
E-Solutions &
Service Marketing Dept.
TROUBLESHOOTING 6 – 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE PAGE
BASIC INSPECTION PROCEDURE....6– 2 11. ROTATING PART WEAR OF
TURBOCHARGER..............................6– 14
1. HARD STARTING............................6– 3
12. OIL LEAKAGE FROM
1-1.Starter Motor Inoperative ..........6– 3
TURBOCHRGER ................................6– 15
1-2. Starter Motor Operates But
13. INSUFFICIENT ACCELERATION
Engine Does Not Turn Over ...........6– 3
AND/OR LACK OF POWER DUE
1-3. Engine Turns Over But Does TO TURBOCHARGER........................6– 15
Not Start Engine..............................6– 4
14. BATTERY CHARGING AND
2. UNSTABLE IDLING.........................6– 5 NOISE PROBLEM ..............................6– 16
3. INSUFFICIENT POWER ..................6– 6 14-1. Battery No Charging...............6– 16
4. EXCESSIVE FUEL 14-2. Battery Overcharging .............6– 16
CONSUMPTION..................................6– 7
14-3. Battery Under Charging .........6– 17
5. EXCESSIVE OIL CONSUMPTION ..6– 8
14-4. Battery Unstable Charging
6. OVERHEATING ...............................6– 9 Current.............................................6– 17
7. WHITE EXHAUST SMOKE..............6– 9 14-5. Charging System Noise .........6– 18
8. DARK EXHAUST SMOKE ...............6– 10 15. STARTER MOTOR PROBLEM .....6– 19
9. OIL PRESSURE DOES NOT RISE..6– 11 15-1. Starter Motor Pinion Engages
10. ABNORMAL ENGINE NOISE........6– 12 to Ring Gear But Engine Does
Not Turn Over..................................6– 19
10-1. Engine Knocking ....................6– 12
15-2. Incorrect Pinion And Ring
10-2. Gas Leakage Noise.................6– 12 Gear Engagement ...........................6– 19
10-3. Continuous Noise ...................6– 13 15-3. Starter Motor Continues To
10-4. Slapping Noise........................6– 13 Run After The Starter Switch Is
Turned Off........................................6– 20
10-5. Excessive Turbocharger
Noise ................................................6– 14 15-4. Excessive Commutator
Sparking ..........................................6– 20
6 – 2 TROUBLESHOOTING
Basic Inspection Procedure

Follow the under inspection procedure, when the problem vehicle comes workshop.
Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn Go to section
ON ? 6E “On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the Was the problem found? Re-charge the
gravity battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil, Was the problem found? Return normal
vacuum and fuel piping) condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E “On Board Was the problem found?
Diagnostic (OBD) System
Check” Verify repair Go to Step 9
9 Go to mechanical Was the problem found?
troubleshooting chart Verify repair —
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1–1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch. — Repair or
Does the starter switch work? replace the
Go to Step 2 starter switch
2 Check the starter relay. — Repair or
Does the starter relay work? replace the
Go to Step 3 starter relay
3 Check the magnetic switch. — Repair or
Does the magnetic switch work? replace the
magnetic
Go to Step 4 switch
4 Check the pinion gear condition on the starter motor. — Replace the
Was the condition normal? Go to Step 5 pinion gear
5 Check the brush wear or brush spring weakness. — Repair or
Was the condition normal? Replace the replace the
starter motor brush or brush
assembly spring
1-2 Starter motor operates but engine does not turn over
1 Check the engine internal seizure. — Check other
Was the engine seized? Repair or DTC by Tech
replace seized 2 and go to
parts indicated DTC
1-3 Engine turn over but does not start engine

Incase of the fuel not being delivered to the injection pump
1 Check clogged, damaged the fuel piping or the —
connector loosen. Repair replace
Was any problem found? problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow
valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved
Incase of the fuel is being delivered to the injection pump

1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 3 Bleed the air
3 Was the injection spray condition complete? —
Replace the
Go to Step 4 injection nozzle
4 Was the injection nozzle injection starting pressure (See below)
OK? Replace the
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
DTC Solved
Injection nozzle opening pressure

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
2. Unstable Idling
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection (See below)
spray condition OK? Replace the
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition. — Repair or
Was the idling port clogged in the throttle valve? replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valves valve clearance Go to Step 10
9 Was the compression pressure OK? 3.0MPa (31.0 Readjust the
2
kg/cm , 441 valve clearance
psi) at or replace the
200rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
Go to Step 11 and valve seat
DTC Solved

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
3. Insufficient Power
1 Was the air cleaner element condition OK? (Clogged — Clean or
or not) replace the air
cleaner
Go to Step 2 element.
2 Was the intake air leakage found from intake — Repair or
system? replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged — Clean or
or not) replace the fuel
Go to Step 4 filter element.
4 Check the fuel injection pipes. — Repair or
Does the injection pipes have obstruction or any replace the fuel
damage? injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern — Readjust the
normal? injection nozzle
pressure or
replace the
Go to Step 7 nozzle.
7 Was the compression pressure OK? 3.0 MPa Readjust the
2
(31.0 kg/cm , valve clearance
441 psi) at or replace the
200 rpm cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust — Repair or
system? replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or — Replace the
cracked? hose. Go to Step 11
11 Was the waste gate working completely? — Replace the
turbocharger
Go to Step 12 assembly.
12 Was turbocharger working completely? — Replace the
turbocharger
DTC Solved
4. Excessive Fuel Consumption

1 Was the air cleaner element clogged? — Clean or
replace the air
cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of — Repair or
the turbocharger? replace the air
intake side of
the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? — Replace the
Go to Step 4 turbocharger
4 Was there the fuel leakage? — Repair or
replace the fuel
leakage part. Go to Step 5
2
gasket or
cylinder liner or
piston or piston
ring or valve
6 Was the injection nozzle pressure or spray pattern —
normal?
Replace the
DTC Solved
5. Excessive Oil Consumption

1 Does the air cleaner element conditon OK? (Clogged — Clean or
or not) replace the air
cleaner
Go to Step 2 element
2 Does PCV (Positive Crankcase Ventilation) Valve — Repair or
has problem? replace the
relation parts. Go to Step 3
3 Was the oil pressure value more than normal value? Less than
588 kPa (6.0 Repair or
2
kg/cm , 85 replace the oil
psi) relief valve Go to Step 4
4 Inspect the front and rear crankshaft oil seal. — Replace the
Was the oil leakage found? failure part. Go to Step 5
5 Was the oil leakage found from any gasket? — Replace the
wrong gasket Go to Step 6
6 Inspect the valve stem seal, the valve stem and the —
valve guide for worn. Replace the
Were any worn found? worn part. Go to Step 7
7 Was the oil leakage found from the turbocharger oil — Replace the oil
seal? seal. Go to Step 8
8 Was the oil drain pipe of the turbocharger restricted? — Repair or
replace the oil
drain pipe. Go to Step 9
9 Was the oil drain passage in the turbocharger center — Clean the
housing restricted? center housing Go to Step 10
10 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 11
DTC Solved
6. Overheating
1 Was the engine coolant level OK? — Replenish the
Go to Step 2 coolant
2 Was the water leakage or the radiator restriction — Repair or
found? (Include radiator cap) replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? — Replace the fan
clutch
5 Was the oil leakage found from fan clutch? — Replace the fan
clutch
assembly Go to Step 6
6 Was the thermostat working normally? — Replace the
Go to Step 7 thermostat.
7 Was the water pump working OK? — Replace the
water pump
8 Was the restriction by the foreign materials in the — Clean or
cooling system found? For example, clog the water replace the
hose between the cylinder body and radiator etc.. clog part. Go to Step 9
9 Was the water leakage found from the sealing cap — Replace the
on the cylinder body? sealing cap or
replace the
cylinder body. Go to Step 10
DTC. Solved
7. White Exhaust Smoke

2
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
Go to Step 2 parts.
2 Was the PCV (Positive Crankcase Ventilation) valve — Repair or
working completely? replace the
Go to Step 3 PCV valve.
3 Was the turbocharger working completely? — Replace the
Go to Step 4 turbocharger.
DTC Solved
8. Dark Exhaust Smoke

1 Was the air cleaner element normal condition? — Clean or
replace the air
cleaner
Go to Step 2 element
2 Was the EGR valve sticking? — Replace the
EGR valve Go to Step 3
3 Was the injection nozzle pressure or the injection —
spray pattern OK?
Replace the
4 Was the oil leakage found from the turbocharger oil — Replace the oil
seal? seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted? — Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the — Clean the
turbocharger center housing restricted? center housing Go to Step 7
7 Does turbine wheel has any impact damage? — Replace the
8 Does PCV (Positive Crankcase Ventilation) Valve — Repair or
has problem? replace the
relation parts Go to Step 9
DTC Solved
9. Oil Pressure Does Not Rise

1 Was the oil pressure warning lamp working OK? — Replace the oil
pressure
Go to Step 2 warning lamp
2 Does the oil filter element clog? — Replace the oil
filter element Go to Step 3
3 Does the relief valve open? — Repair or
replace the
relief valve Go to Step 4
4 Does the oil strainer clog? — Clean or
replace the oil
strainer Go to Step 5
5 Was the oil pump working OK? (The pump related — Repair or
parts worn etc.) replace the oil
Go to Step 6 pump.
6 Was the rocker arm and/or relation parts worn? — Replace the
rocker arm
and/or relation
parts Go to Step 7
7 Was the camshaft and/or relation parts worn? — Replace the
camshaft
and/or relation
parts Go to Step 8
8 Was the crankshaft and/or relation parts worn? — Replace the
crankshaft
and/or relation
parts Go to Step 9
DTC Solved
Table of pressure unit

2
Pressure kPa (kg/cm ) 100 980
(1.0) (10.0)
Resistance ohm 81 30
Electric current A 63.5 106.7
10. Abnormal Engine Noise

10–1 Engine knocking
1 Was the injection nozzle pressure or injection spray —
pattern OK?
Replace the
2 Was the compression pressure OK? 3.0 MPa Replace the
2
(31.0 kg/cm , cylinder head
441 psi) at gasket or
200 rpm Go to Step 3 piston ring
DTC Solved
10–2 Gas leakage noise

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
DTC Solved
10–3 Continuous noise

1 Was the fan belt tension OK? 9 – 13 mm
(0.35 – 0.51
in)
Adjust the fan

Go to Step 2 belt tension.
2 Was the cooling fan loose? — Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? — Repair or
replace the
generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? — Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? — Readjust the
valve
clearance. Go to Step 6
DTC Solved
10-4 Slapping noise

1 Was noise coming from the cylinder head cover? — Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in) Adjust the
both intake valve
and exhaust clearances Go to Step 3
3 Were the rocker arms damaged? — Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? — Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? — Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft. — Replace the
Was the crankshaft bearing and/or crankshaft worn? worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin. —
Was the connecting rod bearing and/or crankpin Replace the
worn? worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or —
piston pin.
Was the connecting rod small end bushing and/or Replace the
piston pin worn? worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner. — Replace the
Was the piston and/or cylinder liner worn or worn or
damaged? damaged parts Go to Step 10
DTC Solved
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.
1 Was the excessive noise coming from the —
turbocharger? Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands. — Tighten the
Was any problem found? 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. — Replace the
Was the turbine wheel rotation rough? turbocharger. Go to Step 5
5 Inspect the turbine wheel. — Replace the
Was the turbine wheel rubbing against housing? turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
7 Were there carbon deposits in the turbine or — Clean or
compressor housing? replace the
8 Inspect the oil supply condition. — Repair or
Was the oil feed pipe clogged? replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
DTC Solved
11. Rotating Part Wear of Turbocharger

1 Inspect engine oil. — Replace the
Was it contaminated with foreign materials? engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity API CD or
being used? ISUZU
genuine/
10W–30 Replace the
Go to Step 3 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
6 Was there oil sludge and/or coking on the turbine — Replace the
shaft? turbocharger Go to Step 7
DTC Solved
12. Oil Leakage from Turbocharger

1 Inspect the oil leakage area. — Tighten the eye
Was the oil feed pipe eye bolt loose or the gasket bolt or replace
broken? the gasket. Go to Step 2
2 Were the V band fixing faces tight? — Tighten band or
replace the
3 Was there oil leakage from the flange of the turbine — Replace the
housing? turbocharger Go to Step 4
4 Was there oil leakage from the flange of compressor — Tighten the bolt
housing? and/or hose
clamp. Go to Step 5
DTC Solved
13. Insufficient Acceleration and/or Lack of Power due to turbocharger

1 Inspect the air or exhaust route. — Tighten flange
Was the air and/or exhaust gas piping loose? bolts or hose
clamp. Go to Step 2
2 Inspect the work of waste gate valve control. —
Was there rust on the linkage rod or pin of the waste Replace the
gate valve? turbocharger Go to Step 3
3 Was air leakage found from the actuator piping? — Repair or
replace the
actuator pipe or
hose/ Go to Step 4
4 Inspect the inside of the turbocharger. — Replace the
Was the turbine shaft end nut loose? turbocharger Go to Step 5
5 Were the turbine blades bent? — Replace the
6 Was the turbine wheel rubbing against housing? — Replace the
DTC Solved
14. Battery Charging and Noise Problem

Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
1 Was “Visual/Physical Check" performed. — Go to
visual/physical
Go to Step 2 check
2 Inspect the brush contact condition on the generator. — Repair or
Was there poor contact between the brush and the replace the
slip ring? brush and/or
the slip ring. Go to Step 3
3 Inspect the stator coil on the generator. —
Was there an open circuit or the scorching on the Replace the
stator coil? stator coil. Go to Step 4
4 Inspect the rotor coil on the generator. —
Was there an open circuit or the scorching on the Replace the
rotor coil? rotor coil. Go to Step 5
5 Inspect the rectifier on the generator. — Replace the
Was the rectifier defective? rectifier Go to Step 6
6 Inspect the IC regulator. — Replace the IC
Was the IC regulator defective? regulator. Go to Step 7
DTC. Solved
14-2 Battery Overcharging

visual/physical
Go to Step 2 check
2 Inspect the terminal circuit. — Repair the
Were the B and F terminals shorted? short circuit. Go to Step 3
3 Check the regulating voltage. — Replace the IC
Was the IC regulator voltage excessive? regulator. Go to Step 4
DTC. Solved
14-3 Battery Under Charging

visual/physical
Go to Step 2 check
Was there intermittent contact between the brush replace the
and the slip ring? brush holder
assembly. Go to Step 3
3 Inspect the rotor coil on the generator. — Repair or
Was there a short circuit in the rotor coil? replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator. — Repair or
Was there an open circuit or the short circuit on the replace the
5 Inspect the rectifier on the generator. — Replace the
Was the rectifier defective? rectifier Go to Step 6
6 Inspect the IC regulator on the generator. — Replace the IC
7 Was the electrical load excessive? — Replace more
higher capacity
generator. Go to Step 8
DTC. Solved
14-4 Battery Unstable Charging Current

visual/physical
Go to Step 2 check
Was there poor contact between the brush and the replace the
slip ring? brush and/or
the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator. — Repair or
Was there the short circuit or an open circuit in the replace the
rotor coil? rotor coil. Go to Step 4
4 Inspect the stator coil on the generator. — Repair or
Was there an open circuit or the short circuit in the replace the
5 Inspect the connection between the rectifier and —
stator coil on the generator. Repair the
Was there a loose connection between the rectifier loose
and stator coil ? connection. Go to Step 6
6 Inspect the IC regulator on the generator. — Replace the IC
DTC. Solved
14-5 Charging System Noise

visual/physical
Go to Step 2 check
2 Was there intermittent noise or continuous noise and —
that could be identified clearly by increasing and Replace the
decreasing engine speed? bearing. Go to Step 3
3 Was there a growling sound and does this sound — Replace the
stop when the connector was disconnected? stator coil. Go to Step 4
4 Was intermittent sound heard when the generator — Replace the
was running? brush and/or
slip ring. Go to Step 5
5 Was frictional sound heard when generator was — Clean the slip
running? ring or replace
the brush. Go to Step 6
DTC. Solved
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
visual/physical
Go to Step 2 check
2 Check the contact condition between the brush and — Replace the
the commutator. brush or repair
Was the brush and the commutator contact the
intermittent? 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. — Repair or
Was there an open circuit or a short circuit in the replace the
armature field coil? armature field
coil. Go to Step 6
DTC. Solved
15-2 Incorrect pinion and ring gear engagement

visual/physical
Go to Step 2 check
2 Inspect the pinion and the ring gear teeth. —
Were the pinion and/or the ring gear teeth worn or Replace the
broken? wron parts. Go to Step 3
3 Inspect the pinion gear return movement. — Adjust or
Was the pinion gear return movement incorrect? replace the
movement
parts. Go to Step 4
DTC. Solved
15-3 Starter motor continues to run after the starter switch is turned off
visual/physical
Go to Step 2 check
2 Inspect the magnetic switch contact point. — Repair or
Was the contact point seized? replace the
magnetic
switch. Go to Step 3
3 Inspect the starter switch. — Replace the
Was the starter switch defective? starter switch. Go to Step 4
DTC. Solved
15-4 Excessive commutator sparking

visual/physical
Go to Step 2 check
2 Inspect the contact condition between the brush and — Replace the
the commutator. brush or repair
Was the brush and the commutator contact the
intermittent? commutator. Go to Step 3
3 Was there the slag accumulation on the contact — Clean the
face? contact face or
replace the
brush. Go to Step 4
4 Was the brush holder loose? — Repair the
brush holder Go to Step 5
5 Inspect the commutator. — Repair or
Was there excessive wear or pitting? replace the
commutator. Go to Step 6
6 Was there loose the solder on the commutator? — Clean and
repair Go to Step 7
7 Inspect the armature shaft. —
Was the run-out of armature shaft outside the Replace the
standard value due to worn bearing ? bearing Go to Step 8
DTC. Solved
ENGINE MECHANICAL 6A – 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications....................................................................................... 6A - 4
Torque Specification ..................................................................................................... 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
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
MAIN DATA AND SPECIFICATIONS

Engine model
4JA1T (L) 4JA1TC
Item
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type Dry type, chrome plated
Timing gear train system 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
3 3
Total piston displacement cm (in ) 2,499 (152.4)
Compression ratio (to 1) 18.5
2
Compression pressure MPa (kg/cm /psi) 3.0 (31.0/441) – 200 rpm
SEngine weight (dry) kg (lb) Approximately 239 (527)
Fuel injection order 1–3–4-2
Fuel injection timing BTDC deg 8 -
Specified fuel type JIS No. 2, DIN/EN590, GB252-1944 Diesel fue
Idling speed rpm 730 ± 25 (A/C OFF) 730 ± 25 (A/C OFF)
850 ± 25 (A/C ON) 780 ± 25 (A/C ON)
Valve clearances (At cold): Intake mm (in)
0.4 (0.016)
Exhaust mm (in)
0.4 (0.016)
Intake valves Open at (BTDC) deg
24.5
Close at (ABDC) deg
55.5
Exhaust valves Open at (BBDC) deg
54.0
Close at (ATDC) deg
26.0
Fuel system
Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed Electronically controled
type)
Injection nozzle type Hole with 5 orifices
2
MPa (kg/cm /psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2nd (Reference) 2nd (Reference)
25.5∼27.0 34.0∼35.5
(260∼275 / 3,702∼3,920) (347∼362 / 4,936∼5,154)
Main fuel filter type Cartridge paper element and water separator
Lubricating system
Lubricating method Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Engine model
4JA1T (L) 4JA1TC
Item
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 *IHI RHF 4H
Turbine type Mixed flow type
Compressor type Backward & rake
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.

MAIN DATA AND SPECIFICATIONS

Engine model
4JH1TC
Item
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type Dry type, chrome plated
Timing gear train system 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
3 3
Total piston displacement cm (in ) 2,999 (183.0)
Compression ratio (to 1) 18.3
2
Compression pressure MPa (kg/cm /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) 0.4 (0.016)
Exhaust mm (in) 0.4 (0.016)
Intake valves Open at (BTDC) deg 24.5
Close at (ABDC) deg 55.5
Exhaust valves Open at (BBDC) deg 54.0
Close at (ATDC) deg 26.0
Fuel system
Injection pump type BOSCH distributor VP44 type
Injection nozzle type Hole with 5 orifices
2
MPa (kg/cm /psi) 1st 19.5 (199/2,828)
2nd (Reference) 34.3∼35.8 (350∼365/4,980∼5,197)
Main fuel filter type Cartridge paper element and water separator
Lubricating system
Lubricating method Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Oil pump type Gear
Oil filter type 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 model
4JH1TC
Item
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
80D26L × 1
Battery type/voltage × No. of units
95D31L × 1 (OPT)
75D26R × 2 (OPT for EC, MT)
80D26R × 2 (OPT for EC, AT)
12 – 60/12 – 80
Generator capacity V-A
12 – 2.3
Starter motor output V-kW
*IHI RHF5
Turbocharger model
Mixed flow type Radial-inflow
Turbine type
Backward & rake type Radial-outflow
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
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)
Strength 8.8
Class 4.8 (4T) (7T) 9.8 (9T)
Refined Non-Refined
Bolt
Identification
Bolt
Diameter ×
Pitch (mm)
M 6 × 1.0 5.88 ± 1.96 7.35 ± 2.45 -
(0.60 ± 0.20/4.33 ± 1.44) (0.75 ± 0.25/5.43 ± 1.80)
M 8 × 1.25 12.74 ± 4.90 17.15 ± 5.39 23.52 ± 6.86
(1.30 ± 0.50/9.40 ± 3.62) (1.75 ± 0.55/12.66 ± 4.00) (2.40 ± 0.70/17.36 ± 5.06)
M 10 × 1.25 27.44 ± 6.86 36.75 ± 9.31 49.98 ± 12.74
(2.80 ± 0.70/20.25 ± 5.06) (3.75 ± 0.95/27.12 ± 6.87) (5.10 ± 1.30/36.89 ± 9.40)
M 12 × 1.25 61.25 ± 12.25 75.95 ± 15.19 94.57 ± 19.11
(6.25 ± 1.25/45.21 ± 9.04) (7.75 ± 1.55/56.06 ± 11.21) (9.65 ± 1.95/69.80 ± 14.10)
M 14 × 1.5 95.55 ± 19.11 116.13 ± 23.03 142.10 ± 28.42
(9.75 ±1.95/70.52 ± 14.10) (11.85 ± 2.35/85.71 ± 17.00) (14.50 ± 2.90/104.88 ± 21.00)
M 16 × 1.5 130.34 ± 26.46 169.54 ± 34.30 199.92 ± 40.18
(13.30 ± 2.70/96.20 ± 19.53) (17.30 ± 3.50/125.13 ± 25.32) (20.40 ± 4.10/147.55 ± 29.66)
M 18 × 1.5 188.16 ± 37.24 244.02 ± 49.00 287.14 ± 57.82
(19.20 ± 3.80/138.87 ± 27.49) (24.90 ± 5.00/180.10 ± 36.17) (29.30 ± 5.90/211.93 ± 42.67)
M 20 × 1.5 257.74 ± 51.94 337.12 ± 67.62 395.92 ± 79.38
(26.30 ± 5.30/190.23 ± 38.33) (34.40 ± 6.90/248.82 ± 49.41) (40.40 ± 8.10/292.21 ± 58.59)
M 22 × 1.5 332.22 ± 81.34 453.25 ± 90.65 530.18 ± 105.84
(33.90 ± 8.30/245.20 ± 60.03) (46.25 ± 9.25/334.53 ± 66.91) (54.10 ± 10.80/391.30 ± 78.12)
M 24 × 2.0 448.84 ± 90.16 570.36 ± 140.14 691.88 ± 138.18
(45.80 ± 9.20/331.27 ± 66.54) (58.20 ± 14.30/420.96 ± 103.43) (70.60 ± 14.10/510.65 ± 101.99)
* M 10 × 1.5 26.46 ± 6.86 36.26 ± 8.82 48.02 ± 11.76
(2.70 ± 0.70/19.53 ± 5.06) (3.70 ± 0.90/26.76 ± 6.50) (4.90 ± 1.20/35.44 ±8.68)
* M 12 × 1.5 56.84 ± 11.76 70.56 ± 13.72 89.18 ± 17.64
(5.80 ± 1.20/41.95 ± 8.68) (7.20 ± 1.40/52.08 ± 10.13) (9.10 ± 1.80/65.82 ± 13.02)
* M 14 × 2.0 89.18 ± 17.64 109.76 ± 21.56 133.28 ± 26.46
(9.10 ± 1.80/65.82 ± 13.02) (11.20 ± 2.20/81.01 ± 15.91) (13.60 ± 2.70/98.37 ± 19.53)
* M 16 × 2.0 124.46 ± 24.50 161.70 ± 32.34 191.10 ± 38.22
(12.70 ± 2.50/91.86 ± 18.08) (16.50 ± 3.30/119.34 ± 23.87) (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 Pipe diameter mm

Torque Torque
(in) (in)
4.76 (0.187) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8) 10.00 (0.394) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
6.35 (0.250) 26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1) 12.00 (0.472) 88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
8.00 (0.315) 44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 15.00 (0.591) 105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

4JA1 and 4JHI ENGINE

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4JA1 and 4JHI ENGINE

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WORKSHOP MANUAL

Isuzu Motors Limited

Basic Inspection Procedure

1-3 Engine turn over but does not start engine

Incase of the fuel is being delivered to the injection pump

Injection nozzle opening pressure

Injection nozzle opening pressure

4. Excessive Fuel Consumption

5. Excessive Oil Consumption

7. White Exhaust Smoke

8. Dark Exhaust Smoke

9. Oil Pressure Does Not Rise

Table of pressure unit

10. Abnormal Engine Noise

10–2 Gas leakage noise

10–3 Continuous noise

Adjust the fan

10-4 Slapping noise

10-5 Excessive turbocharger noise

11. Rotating Part Wear of Turbocharger

12. Oil Leakage from Turbocharger

13. Insufficient Acceleration and/or Lack of Power due to turbocharger

14. Battery Charging and Noise Problem

14-2 Battery Overcharging

14-3 Battery Under Charging

14-4 Battery Unstable Charging Current

14-5 Charging System Noise

15. Starter Motor Problem

15-2 Incorrect pinion and ring gear engagement

15-4 Excessive commutator sparking

Lubricating Flow ........................................................................................................ 6A- 126

MAIN DATA AND SPECIFICATIONS

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

MAIN DATA AND SPECIFICATIONS

Pipe diameter mm Pipe diameter mm

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