FOR SERVICE TRAINING

4JH1-TC ENGINE
Mechanical Specification & Structure

Applicable Model Model Year 2001 2002 2003 Vehicle Model N*R 77 N*R 77 N*R 77 Emission Regulation Euro 3 Euro 3 Euro 3 / EPA 98

ISUZU MOTORS LIMITED

CONTENTS
INTRODUCTION
Page ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----1 ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----3

ENGINE MAIN DATA & SPECIFICATIONS

CYLINDER BLOCK

MAIN CONSTRUCTION PARTS ------------------------------------------------------------------------------------PISTON, PISTON RING & CONNECTING ROD ------------------------------------------------------CRANKSHAFT ------------------------------------------------------------------------------------CYLINDER HEAD ------------------------------------------------------------------------------------VALVE MECHANISM ------------------------------------------------------------------------------------TIMING GEAR TRAIN ------------------------------------------------------------------------------------FLYWHEEL ------------------------------------------------------------------------------------EXHAUST SYSTEM ------------------------------------------------------------------------------------TURBOCHARGER ------------------------------------------------------------------------------------EGR SYSTEM ------------------------------------------------------------------------------------ENGINE LUBRICATION

5 8 14 19 20 27 33 32 33 35

LUBRICATION SYSTEM ------------------------------------------------------------------------------------OIL PUMP ------------------------------------------------------------------------------------OIL FILTER & OIL COOLER --------------------------------------------------------------------------------

37 38 39

ENGINE COOLING
COOLING SYSTEM WATER PUMP

------------------------------------------------------------------------------------------------------------------------------------------------------------------------THERMOSTAT ------------------------------------------------------------------------------------COOLING FAN & FAN CLUTCH --------------------------------------------------------------------------RADIATOR & RADIATOR CAP --------------------------------------------------------------------------RESERVOIR TANK ------------------------------------------------------------------------------------FUEL SYSTEM -------------------------------------------------------------------------------------

41 42 43 44 46 47 48 49 50 51

FUEL INJECTION PUMP ------------------------------------------------------------------------------------FUEL INJECTION NOZZLE -------------------------------------------------------------------------------FUEL FILTER

-------------------------------------------------------------------------------------

ELECTRICAL PARTS
STARTER MOTOR GENERATOR

------------------------------------------------------------------------------------------------------------------------------------------------------------------------PREHEATING SYSTEM ------------------------------------------------------------------------------------SPECIAL TOOLS

----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- ----- -----

53 57 60 62

N*R 4JH1-TC Engine-1

INTRODUCTION

1. Engine Coolant Temperature (ECT) Sensor 2. Injection Pump 3. Check Hole (Scissors Gear) 4. Check Hole (Injection Pump Gear)

5. EGR Valve 6. EGR Cooler 7. Crankshaft Position (CKP) Sensor = Top Dead Center (TDC) Sensor

N*R 4JH1-TC Engine-2

The four cycle direct injection 4JH1-TC engine features two valves per cylinder that are operated via a single camshaft fitted to the engine block. And, the exhaust emission regulations are described in the Euro 3 standards. The 4JH1-TC engine is equipped with a water-cooled turbocharger, intercooler and EGR cooler, a new high-pressure injection pump and an oil filter housing with cooler. The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design provides superior fuel economy over a wide range of driving conditions. Auto-thematic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when the engine is cold. Chrome plated dry type cylinder liners provide the highest durability. The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be reground. The 4JH1-TC engine is equipped with the VP44 injection pump that is fully electrically controlled via the engine management system made by Bosch . The mechanical features are follows; -Flywheel with crankshaft position (CKP) sensor timing slot -Timing gear train -Gear driven camshaft -Idler gear features a scissors gear -Exhaust gas re-circulation (EGR) system with cooler -Gear driven VP44 fuel injection pump

N*R 4JH1-TC Engine-3

ENGINE MAIN DATA & SPECIFICATION

General Engine Model Engine Type Engine Dimension (mm) (Length x Width x Height) Engine Weight (Kg) (With Clutch Housing, Fan Guide) Engine Weight (Kg) (With Engine Oil 7.0L, Coolant 5.8L) Cylinder Layout - Number of Cylinders Fuel Injection Order Bore x Stroke (mm) Total Displacement (cc) Bore Pitch (mm) Compression Ratio Combustion Camber Type Cylinder Liner Idle Speed (rpm) Fast Idle Speed (rpm) Full Load Maximum Engine Speed (rpm) No Load Maximum Engine Speed (rpm) Fuel System Injection Pump Type Injection Nozzle Type Number of Injection Hole Diameter of Injection Hole (mm) Designed Value of Injection Nozzle Operating Pressure (Mpa) Adjustment Value of Injection Nozzle Operating Pressure (Mpa) Fuel Filter Type Valve System Valve Layout Drive Type Intake Valve Open At BTDC (deg) Intake Valve Close At ABDC (deg) Exhaust Valve Open At BBDC (deg) Exhaust Valve Close At ATDC (deg) Intake Valve Clearance At Cold (mm) Exhaust Valve Clearance At Cold (mm) 4JH1-TC Diesel, Four Cycle 767 x 589 x 707 Approximately 255 Approximately 269 Inline-Four Cylinders 1-3-4-2 95.4 x 104.9 2999 106.0 18.3 Direct Injection Dry Type 70025 75025 3600100 4200100 BOSCH VP44 (Electronic Controlled) Two Spring Type (Hole Nozzle) 5 0.21 19.5 (1st) 33.8 (2nd) 20.0 - 21.0 (1st) 34.3 - 35.8 (2nd) Cartridge Paper Element and Water Separator Overhead Valve Gear Drive 24.5 55.5 54.0 26.0 0.4 0.4

N*R 4JH1-TC Engine-4 Cooling System Cooling Method Water Capacity (Litters) (Including Radiator) Water Pump Type Water Pump Pulley Ratio (Crank / Pump) Thermostat Type Thermostat Opening Temperature (deg. C) Lubricating System Lubricating Method Oil Pump Type Oil Capacity (Litter) Oil Filter Type Intake System Turbocharger Intercooler Air Cleaner Type Intake Throttle & Exhaust Throttle Exhaust System EGR System Catalytic Converter Type PCV System Glow System Starting System Starter Motor Output (V-kW) Charge System Alternator Output (V-A) Regulator Type Battery Type Water Cooled 7.3 Centrifugal Impeller Type 1.21 Wax Pellet With Jiggle Valve 822 Pressure Circulation Gear 6.0 - 8.0 Cartridge Paper Element RHF5H Type (IHI) Equipped Dry Paper Element Equipped Water Cooled Assembled in Silencer Closed Type QOS 2 12 - 2.3 12 - 60 / 12 - 80 IC 95D31R

N*R 4JH1-TC Engine-5

MAIN CONSTRUCTION PARTS

CYLINDER BLOCK

Cylinder Block

The cylinder block is a complex structure with cooling water and lubricating oil passages, and crankshaft supports in the lower part. The cylinder block is made of cast iron because it has to be strong enough to resist not only high temperatures, but also the high pressure gasses generated in the cylinders. It also needs to have sufficient corrosion resistance to withstand these gasses. The water cooled cylinder block can be divided into a one-piece cast type and a liner type. In the liner type liners are inserted into the cylinder portion of the block. Furthermore, liners can be divided into a dry type and a wet type according to the cooling method employed. With the dry liner type, thin sleeve is pressed into place inside the cylinder. When worn, the liner can be easily replaced. With dry liner type there is no possibility of cooling water leakage. When replacing liners, it is necessary to measure the liners to make sure that the dimensions meet the requirement, because heat conduction decreases is the liners do not closely fit the cylinder block. With cylinder liners, the wear is greatest near the top of piston ring at top dead center, and the wear decreases towards bottom dead center. This is due to piston slapping, side pressure, and thermal expansion. The sulfur contained in light oil is burnt to form SO2, part of which is oxidized into SO3. When the water vapor in the burnt gas reaches the dew point, sulfuric acid is generated by the reaction (H2O + SO3 = H2SO4). The carbon generated by combustion absorbs the sulfuric acid, and causes serious chemical corrosion.

Cylinder Liner Grade Identification

N*R 4JH1-TC Engine-6

Production Line Use Liner Outside Grade 1

Measurement in Service Cylinder Body Bore Diam eter Average (mm) 97.001 - 97.010

Service Parts

Liner Outside Diameter (mm) 97.011 - 97.020

Liner Set Grade (Including Piston) 1

Liner Grade (Without Piston) 1-AX (For piston size AX) 1-CX (For piston size CX)

97.011 - 97.020

97.021 - 97.030

2-AX (For piston size AX) 2-CX (For piston size CX)

97.021 - 97.030

97.031 - 97.040

3-AX (For piston size AX) 3-CX (For piston size CX)

97.031 - 97.040

97.041 - 97.050

4-AX (For piston size AX) 4-CX (For piston size CX)

The 4JH1-TC engine employs chrome plated dry type cylinder liner. Marks are made on top of the cylinder block to indicate the cylinder liner diameter. This information is important when cylinder liners need to be replaced. The production line stamped cylinder liner grade on the top of cylinder body, the cylinder liner outside diameter grade 1, 2, 3 and 4. If you find cylinder liner outside diameter grade "1" on the cylinder body and piston outside diameter "B" on the piston top or result of measurement of each parts, you will select service parts grade for cylinder liner "1-AX" grade and for piston "AX" grade.

Inspection Item Cylinder Body Bore Measurement

Required Tool: Cylinder Indicator Measure the point "A" across 1 - 1, 2 - 2, 3 - 3 and 4 - 4. Calculate the average value of the four measurements. Service Standard: 97.001 - 97.040mm

N*R 4JH1-TC Engine-7

Cylinder Liner Bore Measurement

Required Tool: Cylinder Indicator Measure the point "1" (20mm) across 2 - 2 and 3 - 3. Calculate the average value of the two measurements. Service Standard: 95.40mm Service Limit: 95.48mm

Cylinder Body Upper Face Warpage

Required Tool: Straight Edge, Feeler Gauge Service Standard: 0.05mm or less Service Limit: 0.20mm

Cylinder Liner Projection

Required Tool: Straight Edge, Feeler Gauge Service Standard: 0 - 0.1mm Service Limit: Between any two adjacent cylinders must not exceed 0.03mm

N*R 4JH1-TC Engine-8

PISTON, PISTON RING & CONNECTING ROD

1. Connecting Rod Bearing 2. Piston Ring 3. Piston Pin Snap Ring 4. Piston Pin 5. Connecting Rod 6. Piston

The 4JH1-TC engine accommodates the 4 pistons made of aluminum alloy. The pistons are exposed to high temperature and high pressure gas during the explosion stroke. The gas pressure is conveyed to the crankshaft, and most of the heat received is released to the cooling water via the cylinder walls. During operation, the pistons must undergo continuous reciprocating motion at high speed along the cylinder walls under side pressure, and at the same time maintain combustion pressure in the combustion chambers. Thus, various factors, such as piston weight, thermal expansion, shape, and dimensions, must be taken into account in designing the pistons. With the offset piston, the piston pin center is offset a certain amount to the thrust side of the bore to reduce side forces on the piston and this marks for reduced piston slapping noise.

1. Piston Ring Carrier

When the piston temperature rises, piston expansion will increase and this causes piston seizure or ring sticking. Then ring groove wear will increase, and reduce the gas sealing performance. Therefore, particularly, in the case of aluminum alloy pistons, a special cast iron ring carrier is cast into the top ring groove which is exposed to a great heat load and this improves wear resistance of the ring groove.

N*R 4JH1-TC Engine-9

1. Size Mark Identification 2. Front Mark

Size Mark A B C D

Outside Diameter (mm) 95.355 - 95.364 95.365 - 95.374 95.374 - 95.384 95.385 - 95.394

Service Grade AX

Service Piston Diameter (mm) 95.359 - 95.374

CX

95.375 - 95.390

The piston diameter is essential information in case an engine is overhauled. A, B, C and D are the marks used to identify the piston diameter. These marks can be found at the top of the piston. Using the above diagram you can order the correct piston. The tolerance between the piston and the cylinder liner is important to assemble the engine. Note: The cylinder liner installation procedure may result in slight decreases in cylinder liner clearances. Always measure the cylinder liner clearance after installation to be sure that it is correct.

N*R 4JH1-TC Engine-10

1. Oil Ring 2. Second Compression Ring 3. First Compression Ring

The aluminum alloy pistons of 4JH1-TC engine have an integrated toroidal shaped combustion chamber with centrally arranged swirl chambers. Two piston rings guarantee a fast build up of air pressure and one oil ring prevents oil from the sump entering the combustion chamber. The piston rings are fitted into the ring grooves around the pistons to keep the combustion chamber airtight between the piston and cylinder. They also conduct the heat received by the pistons to the cylinder walls. The piston rings scrap off the oil sprayed on the cylinder walls to leave the minimum required oil film to lubricate the pistons and piston rings, and prevent excess oil from entering the combustion chambers. The rings used mainly to maintain combustion pressure are called compression rings, and those used for scraping off excess oil, are known as oil rings. The compression rings alternately hit the top and bottom of the ring grooves as the pistons run up and down. During the explosion stroke the high pressure gas pushes down the rings. This is the only time they move ahead of the pistons. The compression rings also increase combustion pressure as the high pressure gas pushes the rings towards the cylinder walls from behind the rings. Oil rings are tapered or grooved on their sliding surface to increase unit pressure so that a close fit with the cylinder walls can be maintained by their own tension. To meet demands for oil rings with greater unit pressure suitable for high speed engine, oil ring with expander have come into general use.

N*R 4JH1-TC Engine-11

Piston Cooling Jet

Four oil jets are placed under the pistons to cool the piston bottom. The jets are supplied with oil, directly from the oil pump. The piston bottom is special shaped to guide the oil along the entire surface to ensure a sufficient cooling.

1. Piston Front Mark 2. Connecting Rod Front Mark

The connecting rod is a rod which connects a piston to the crankshaft, and transmits explosion forces imposed on the piston, to the crankshaft. The connecting rod is made of forging metal to resist compression, tension and bending forces. One end of the connecting rod is connected to the piston with a piston pin, and is called the "small end". While the other end is called "big end" generally a bushing is press-fitted to the small end, however the big end is divided into two pieces, and they are tightened to the crankshaft with bolts.

N*R 4JH1-TC Engine-12

Inspection Item Piston Diameter & Piston Clearance Measurement

Required Tool: Micrometer Measurement Point: 70mm Service Grade: AX 95.359 - 95.374mm / CX 95.375 - 95.390mm Cylinder Liner & Piston Clearance: 0.057 - 0.075mm

Piston Ring & Ring Groove Clearance

Required Tool: Feeler Gauge Service Standard: 0.09 - 0.13mm (1st) / 0.05 - 0.09 (2nd) 0.03 - 0.07mm (Oil) Service Limit: 0.150mm

Piston Ring Gap

Required Tool: Feeler Gauge Measurement Point: 1- 10mm / 2- 120mm Service Standard: 0.3 - 0.5mm (1st & 2nd) / 0.25 - 0.45mm (Oil) Service Limit: 1.5mm

Piston Pin Diameter

Required Tool: Micrometer Service Standard: 30.995 - 31.000mm Service Limit: 30.97mm

N*R 4JH1-TC Engine-13

Connecting Rod Alignment

Required Tool: Connecting Rod Aligner, Feeler Gauge Service Standard: 0.08mm or Less (Bend) / 0.05mm or Less (Twist) Service Limit: 0.20mm (Bend) / 0.15mm (Twist)

Connecting Rod Thrust Clearance

Required Tool: Feeler Gauge Service Standard: 0.23mm Service Limit: 0.35mm

Piston Pin & Connecting Rod Small End Bushing Clearance

Required Tool: Caliper Calibrator, Dial Indicator Service Standard: 0.008 - 0.020mm Service Limit: 0.050mm

N*R 4JH1-TC Engine-14

CRANKSHAFT

1. Crankshaft 2. Crankshaft Upper Bearing 3. Crankshaft Lower Bearing 4. Crankshaft Thrust Bearing 5. Crankshaft Bearing Cap

The crankshaft is the main shaft of the engine which takes the pressure of burnt gas generated during engine operation at the crankshaft pins via the connecting rods, converts the power into rotary motion, and transmits it to the outside. The crankshaft balance relative to its axial center is maintained by adjusting the balance weights, specially by drilling holes in them. Note: To increase crankshaft strength, tufftriding (nitrizing treatment) has been applied. Because of this, it is not possible to regrind the crankshaft surfaces. Therefore, under size bearing are not available.

N*R 4JH1-TC Engine-15

Crankshaft Bearing Grade Mark Identification

Crankshaft Journal Grade Identification

Main Bering Bore Diameter (mm) Grade Main Bearing Bore Diameter (mm) 73.992 - 74.000

Crankshaft Main Journal Diameter (mm) Size Mark 1 or 2 or 3 or Outside Diameter

Crankshaft Bering Size

Oil Clearance (mm)

69.927 - 69.932 69.922 - 69.927 69.917 - 69.922 69.927 - 69.932 69.922 - 69.927 69.917 - 69.922 69.927 - 69.932 69.922 - 69.927 69.917 - 69.922

4 4 5 2 3 4 1 2 2

0.045 - 0.061 0.050 - 0.066 0.052 - 0.068 0.042 - 0.059 0.044 - 0.061 0.046 - 0.063 0.037 - 0.053 0.039 - 0.055 0.044 - 0.060

73.983 73.992

1 or 2 or 3 or

73.975 73.983

1 or 2 or 3 or

N*R 4JH1-TC Engine-16

Inspection Item Crankshaft Run-out

Required Tool: Dial Indicator Service Standard: 0.05mm or Less Service Limit: 0.08mm

Crankshaft & Crank Pin Diameter

Required Tool: Micrometer Measure the point 3, 4 across 1 - 1 and 2 - 2. Service Standard: 69.917 - 69.932mm (Crankshaft Journal) 52.915 - 52.930mm (Crank Pin) 0.05mm or Less (Uneven Wear) Service Limit: 69.91mm (Crankshaft Journal) 52.90mm (Crank Pin) 0.08mm (Uneven Wear)

Crankshaft Journal & Bearing Clearance

Required Tool: Cylinder Indicator Service Standard: 0.037 - 0.068mm Service Limit: 0.110mm

Crankpin & Connecting Rod Bearing Clearance

Required Tool: Cylinder Indicator Service Standard: 0.029 - 0.083mm Service Limit: 0.100mm

N*R 4JH1-TC Engine-17

CYLINDER HEAD

1. Water By-pass Hose 2. Thermostat Housing 3. Cylinder Head Cover 4. Injection Nozzle & Nozzle Holder 5. Rocker Arm Shaft & Rocker Arm 6. Push Rod 7. Cylinder Head 8. Cylinder Head Gasket

The cylinder head is a vital component which forms the combustion chamber together with the cylinder block and piston. It is fitted with a valve mechanism and injection nozzles. The cylinder head is made of cast iron having great heat resistance and strength. It is exposed to burnt gas at high temperatures, and therefore must be airtight against compression and explosion pressures. The exhaust valves and injection nozzles, in particular, have complex water cooling passages to cool them uniformly since they are heated to high temperatures. The cylinder head is mounted on the cylinder block with a gasket between them. Unless the mounting bolts are tightened evenly in the proper order, problems such as burnt gas leakage and gasket damage can result. Because the cylinder head is a casting, it can in some cases become distorted over a long period. It is necessary, therefore, to check the flatness of its seating surface whether it is removed or installed.

N*R 4JH1-TC Engine-18

Loosening Order

Cylinder Head Bolts Torque 1st Step: 49Nm 2nd Step: 60 degree - 75 degree 3rd Step: 60 degree - 75 degree

Tightening Order

Loosen the cylinder head bolts in numerical order a little at a time. They need to be checked for cracks and damages when dismantled. The cylinder head bolts are tightened according to the torque tightening method in numerical order.

Gasket Grade Mark

Piston Projection 0.215 0.265

Gasket Thickness 1.30

0.265 0.315

1.35

0.315 0.365

1.40

A cylinder gasket has to seal the combustion gases, lubricant oil and cooling water at the same time. The cylinder head gasket is of a metal 4 layer type of which the thickness can be identified even when the cylinder head is assembled to the engine. The thickness of the cylinder head gasket can be retrieved from three different marks that are located under the intake manifold. In case of an overhaul of the engine the thickness of the cylinder head gasket can be determined by measuring the piston projection.

N*R 4JH1-TC Engine-19

Inspection Item Cylinder Head Lower Face Warpage

Required Tool: Straight Edge, Feeler Gauge Service Standard: 0.05mm or Less Service Limit: 0.20mm

Cylinder Head Height

Required Tool: Height Gauge Service Standard: 92.00mm Service Limit: 91.55mm

Manifold Fitting Face Warpage

Required Tool: Straight Edge, Feeler Gauge Service Standard: 0.05mm or Less Service Limit: 0.20mm Maximum Grinding Allowance: 0.40mm

Exhaust Manifold Warpage

Required Tool: Straight Edge, Feeler Gauge Service Standard: 0.05mm or Less Service Limit: 0.20mm

N*R 4JH1-TC Engine-20

VALVE MECHANISM

1. Camshaft Timing Gear 2. Camshaft Thrust Plate 3. Camshaft

1. Snap Ring 2. Rocker Arm 3. Rocker Arm Shaft Bracket 4. Rocker Arm 5. Spring 6. Snap Ring 7. Rocker Arm Shaft

The valve mechanism opens and closes the intake and exhaust valves at the correct moment to raise intake and exhaust efficiency and assure satisfactory delivery of engine performance. The crankshaft indirectly of engine performance. The crankshaft indirectly drives the camshaft through a gear. It consists of a crank gear, idler gear, camshaft gear, camshaft, tappets, push rods, rocker arms, valves and valve springs. The camshaft has intake and exhaust cams for every cylinder. Engine performance, involving valve opening and closing timing and firing order, depends particularly on the cams. The rocker arm is a lever moving about the rocker arm shaft, and conveys the motion of the push rod driven by the cam to open and close the valve. The purpose of the camshaft and rocker arms is to open and close the intake and exhaust valves to control the combustion timing. If these parts are worn or damaged, it will seriously affect engine performance.

N*R 4JH1-TC Engine-21

Valve Lift

Ex-Valve

In-Valve

TDC

BDC

TDC

BDC

TDC

54.0 degree

24.5 degree 26.0 degree

55.5degree

Valve timing means the valve opening and closing operation peculiar to an engine, and can be expressed by the crankshaft rotary angle. The valves do not open and close exactly at top dead center and bottom dead center because the intake air would not flow in immediately upon the opening of the intake valve. There is some delay due to the fact that the intake air has a moment of inertia and that the intake air passage area does not instantaneously increase. It follows, therefore, more air can be drawn into the cylinder by opening the valve slightly before top dead center. Air keeps flowing into the cylinder as long as there is a negative pressure, so the intake valve is closed after the piston begins to rise from bottom dead center. The exhaust valve is opened before bottom dead center to assure smooth discharge of exhaust gas, and closed after top dead center, as the combustion chamber pressure is high. It is known from the above description that there is a overlap period where both the intake and exhaust valves are open near top dead center. This is to discharge the remaining burnt gas by the intake of a fresh charge of air. This condition is known as valve overlap. The timing is controlled by the camshaft.

Tappet

Tappets operate to convey the cam action to the valves through push rod and rocker arms. Tappets have to withstand large forces these are the pressure of burnt gas, the tensile force of valve springs and inertia force of moving parts. Therefore, tappets are made of special cast iron, and the surface in contact with the cam is hardened by a suitable heat treatment. Furthermore, the bottom surfaces of the tappet is machined to a spherical surface to prevent the cam and tappet from deviating wear. To put is other way, each cam and tappet are offset to turn the tappet during operation and this makes for even contact with each other, and to improve the contact condition.

N*R 4JH1-TC Engine-22

Valve & Valve Spring

The purpose of the intake and exhaust valves is to assist passage of as much air and discharge gas as possible in the very short time of a single cycle of this piston. In addition the valves prevent high pressure gas leaking while in the are the closed position being able to open and close correctly despite exposure to high temperature burnt gas. Further, they have to withstand operation over an extended period. The valves supported by valve guides, operate only in the vertical plane. The valve face is machined to angle of 45 degree to seal the gas and convey heat to the valve seat when the valve is closed. The valves are made of heat resistant steel because the intake valves have to withstand temperatures up to about 400 degree centigrade and the exhaust valves operate in a temperature from 500 degree centigrade to 800 degree centigrade. The valve spring holds the valve to the valve seat while it is closed to keep the combustion chamber airtight. Valve springs hold the working parts of the intake and exhaust valve mechanism to the cams by spring tension while the valves are in motion, thereby correctly opening and closing the valve according to the cam profile.

Inspection Item Rocker Arm Shaft Run-out

Required Tool: Dial Indicator, V-Block Service Limit: 0.2mm

Rocker Arm Shaft Outside Diameter

Required Tool: Micrometer Service Standard: 18.98 - 19.00mm Service Limit: 18.90mm

N*R 4JH1-TC Engine-23

Rocker Arm Inside Diameter

Required Tool: Caliper Calibrator, Dial Indicator Service Standard: 19.010 - 19.030mm 0.06 - 0.08mm (Clearance) Service Limit: 19.100mm 0.10mm (Clearance)

Camshaft Thrust Clearance

Required Tool: Dial Indicator Service Standard: 0.08mm Service Limit: 0.20mm

Camshaft Run-out

Required Tool: Dial Indicator, V-Block Service Standard: 0.02mm or Less Service Limit: 0.10mm

Camshaft Journal Diameter

Required Tool: Micrometer Measure the point across 1 - 1 & 2 - 2 Service Standard: 49.945 - 49.975mm Service Limit: 49.60mm

Cam Height

Required Tool: Micrometer Service Standard: 42.02mm Service Limit: 41.65mm

N*R 4JH1-TC Engine-24

Camshaft Bearing Inside Diameter

Required Tool: Cylinder Indicator Service Standard: 50.00 - 50.03mm 0.025 - 0.085mm (Camshaft Bearing Clearance) Service Limit: 50.08mm 0.12mm (Camshaft Bearing Clearance)

Tappet Outside Diameter

Required Tool: Micrometer Service Standard: 12.97 - 12.99mm Service Limit: 12.95mm

Tappet & Cylinder Body Clearance

Required Tool: Cylinder Indicator Service Standard: 0.03mm Service Limit: 0.10mm

Push Rod Curvature

Required Tool: Feeler Gauge Service Limit: 0.4mm or Less

Valve Clearance

Required Tool: Feeler Gauge Service Standard: 0.4mm (In & Ex)

N*R 4JH1-TC Engine-25

Valve Stem & Valve Guide Clearance

Required Tool: Dial Indicator with Stand Service Standard: 0.039 - 0.069mm (In) / 0.064 - 0.093mm (Ex) Service Limit: 0.200mm (In) / 0.250mm (Ex)

Valve Stem Outside Diameter

Required Tool: Micrometer Service Standard: 7.946 - 7.961mm (In) / 7.921 - 7.936mm (Ex) Service Limit: 7.880mm (In) / 7.850mm (Ex)

Valve Thickness

Required Tool: Vernier Caliper Service Standard: 1.41mm (In) / 1.38mm (Ex) Service Limit: 1.1mm

Valve Depression

Required Tool: Straight Edge, Depth Gauge Service Standard: 1.1mm (In & Ex) Service Limit: 1.6mm (In & Ex)

Valve Contact Width

Required Tool: Vernier Caliper Service Standard: 1.7mm (In) / 2.0mm (Ex) Service Limit: 2.2mm (In) / 2.5mm (Ex)

N*R 4JH1-TC Engine-26

Valve Spring Free Height

Required Tool: Vernier Caliper Service Standard: 48.0mm Service Limit: 47.1mm

Valve Spring Squareness

Required Tool: Steel Square Service Limit: 1.7mm

Valve Spring Tension

Required Tool: Spring Tester Compressed Height: 38.9mm Service Standard: 296.2N Service Limit: 257.9N

N*R 4JH1-TC Engine-27

TIMING GEAR TRAIN

1. Crankshaft Gear 2. Idle Gear A 3. Idle Gear B (Scissors Gear) 4. Fuel Pump Gear 5. Camshaft Gear

The 4JH1-TC engine used a gear type timing system. Benefits of a gear type timing system are; -Stiff and compact construction -Maintenance free -Direct power drive The gear train consists of five gears, where one idler gear is equipped with "scissors gear". This special gear, eliminates play in the gear train and reduces engine noise.

1. Timing Mark Crankshaft Gear "." & Idle Gear A "." 2. Timing Mark Camshaft Gear ":" & Idle Gear A ":" 3. Timing Mark Idle Gear B ". :" & Idle Gear A ". :" 4. Timing Mark Idle Gear B ". ." & Fuel Pump Gear". ."

N*R 4JH1-TC Engine-28

Crankshaft Gear

1. Crankshaft Gear Timing Mark

The crankshaft gear (30 teeth) has a timing mark "." that corresponds with a timing mark on the idler gear A.

Idler Gear A The idler gear A is a gear that transfers the rotating force to the idler gear B and camshaft gear. The bearing is supplied with oil via the hollow shaft. It has timing mark ":" which correspond to timing mark on the camshaft gear, and ". :" which corresponded to timing mark on the idler gear B, and "." which corresponded to timing mark on the crankshaft gear. The number of teeth of the idler gear A is 42 teeth.

Idler Gear B

1. Pin (Main Gear Side) 2. Locking Bolt 3. Pin (Sub Gear Side) 4. Align Mark for Idle Gear 5. Align Mark for Pump Gear 6. Spring 7. Pin 8. Front 9. Sub Gear 10. Bushing 11. Main Gear

The idler gear B is a scissors gear type, installed onto a shaft. It has timing marks ". :" which corresponded to timing marks on the idler gear A, and ". ." which corresponded to the fuel pump gear. The number of teeth of the idler gear B is 52 teeth. Special about this idler gear B is that it is equipped with two scissors gears. The one at the back eliminates that backlash of idle gear A and the pump gear.

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Structure & Action of Scissors Gear

1. Drive Gear 2. Main Gear 3. Sub Gear 4. Spring Force 5. Rotation Direction 6. Spring

1. Snap Ring 2. Spring 3. Spring 4. Snap Ring 5. Rear Gear 6. Main Gear 7. Bearing 8. Front Gear 9. Lock Bolt

The scissors gear comprises a main gear, sub gear, pins and an elliptical spring. The pins are fixed on the main gear and the sub gear, and the elliptical spring is set between those pins. When installing the scissors gear, the main gear and sub gear must be fixed with the spring compressed. The idler gear A and idler gear B must be fixed with a bolt. The cam gear must be fixed with a bolt and is positioned by a key. After installing the scissors gear, the bolt is removed to release the spring. Under this condition, the main gear and sub gear are opened by the tensile force of the spring between the mate gears to reduce the backlash to zero.

N*R 4JH1-TC Engine-30

Fuel Pump Gear The fuel pump gear is fixed to the fuel pump with a center bolt and positioned by a key to the fuel pump shaft. The fuel pump pulley has a timing mark ". ." which corresponds to timing marks on idler gear B. The fuel pump gear has 60 teeth.

In case the gear case is removed, two or three different timing marks are visible on the gears. To inspect or set the aligning of the timing gear, inspection holes are available in the timing case. Under normal circumstances, a cover seals these inspection holes. When the covers are removed, the second mark of the gear becomes visible. These marks are used for aligning timing related parts that do not require disassembling of the timing case. Please take in account that when timing gears are aligned using the timing gear marks shown in the picture above, that you have to rotate the crankshaft to top dead center to check the timing through the inspection holes. Top dead center can be identified by the marks on the crankshaft pulley and the timing gear case.

N*R 4JH1-TC Engine-31

FLYWHEEL

1 2 3
1. Crankshaft Position (CKP) Sensor 2. Flywheel with Sensor Slot 3. Clutch Cover

The flywheel is added crankshaft position (CKP) sensor pulsar function. The sensor reads the four slots that are incorporated in the flywheel. The CKP sensor located at the flywheel housing uses these slots to generate an inductive signal. This signal is required by the ECM to identify the crankshaft position and the engine speed.

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EXHAUST SYSTEM

1. Exhaust Brake Unit 2. Exhaust Silencer With Catalytic Converter

The oxidation catalytic converter is housed inside the silencer just after the engine brake valve. This oxidation catalytic converter is capable of decreasing Hydro Carbon (HC) and Carbon monoxide (CO) by utilizing excess air present in the exhaust gasses of a diesel engine. The catalytic converter exists of a ceramic carrier that has a thin active layer that consists of small quantities of noble metals. The following metals can be used Barium (Ba), Platinum (Pt), Rhodium (Rh) or Palladium (Pd). The conversion rate is very dependent on the temperature of the ceramic material. The normal operating temperature of an oxidation catalytic converter is 600-800 degree centigrade. Please note that the ceramic material can be damaged if subject to excessive shocking.

Inspection Item Exhaust Brake Unit

Required Tool: Vacuum Gauge Check to see if the exhaust valve opens and closes smoothly when the power chamber is applied with a negative pressure (400 mmHg 700mmHg) by the vacuum pump.

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TURBOCHARGER

Turbo Spec.

1 2 3

1. Turbocharger Specification Number 2. Production Serial Number 3. Isuzu Parts Number

Serial No. RHF5H Parts No.

A water-cooled turbocharger, with floating bearings, made by Ishikawajima-Harima Heavy Ind. Co., Ltd. (IHI RHF5) is used. The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings. These parts are supported by the bearing housing. The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing air exhaust port. The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption, and minimal engine noise. The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and machined to extremely high precision. Turbocharger servicing requires great care and expertise. If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or wear, trouble with the turbocharger is indicated.

N*R 4JH1-TC Engine-34

1. Turbocharger Assembly 2. Oil Feed Pipe 3. Exhaust Manifold

1. Turbocharger Assembly 2. Adapter 3. Water Pipe

Inspection Item Waste Gate Operating Pressure

Required Tool: Pressure Gauge Service Standard: 115.2 - 124.8KPa (862 - 934mmHg) when the rod is moved to 2mm

Wheel Shaft End Play

Required Tool: Dial Indicator Service Standard: 0.02 - 0.08mm Service Limit: 0.09mm

N*R 4JH1-TC Engine-35

Wheel Shaft & Bearing Clearance

Required Tool: Dial Indicator Service Standard: 0.07 - 0.12mm Service Limit: 0.16mm

EGR SYSTEM

1. EGR Valve 2. EGR Cooler 3. Intercooler 4. Intake Manifold 5. Exhaust Manifold 6. Waste Gate 7. Fresh Air 8. Exhaust Gas 9. Turbocharger

The 4JH1-TC engine is equipped with the EGR cooler. The EGR cooler reduces the temperature of the air being drawn into the engine and the combustion temperature. This results in reducing nitrogen oxide (Nox) emissions. The amount of EGR is controlled by EVRV (electrical vacuum regulating valve) via the engine control module (ECM) command signal depends on the engine speed, operating of the accelerator pedal and engine coolant temperature. The EVRV is shaped to control vacuum applied to the diaphragm chamber of the EGR valve based on control signal sent from the ECM.

N*R 4JH1-TC Engine-36

1. EGR Cooler 2. EGR Valve 3. Intake Manifold 4. Exhaust Manifold 5. Turbocharger Assembly

Inspection Item EGR Valve Operating Pressure Test

Required Tool: Vacuum Gauge With negative pressure applied to the diaphragm chamber, make sure that the valve is smoothly actuated. Service Standard: -15.99 - -21.32KPa (-120 - -160mmHg) when the shaft is moved

EVRV Resistance

Required Tool: Circuit Tester Service Standard: Approximately 14 ohms at 20 degree centigrade

N*R 4JH1-TC Engine-37

ENGINE LUBRICATION
LUBRICATION SYSTEM
5: Oil Press. SW Warning Lamp

Cylinder Body Oil Gallery

Oil Filter & Cooler Assembly 6: Regulating Valve Oil Filter 4: Relief Valve Idler Gear Shaft Oil Cooler Piston Cooling Jet 3: Relief Valve 2: Regulating Valve Timing Gear 1: Relief Valve Oil Pump Rocker Arm Oil Strainer Rocker Arm Shaft Connecting Rod Bearing Camshaft Bearing Vacuum Pump Crankshaft Bearing Turbocharger

Oil Pan

1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa) 2. Regulating Valve Operating Pressure: 5.8 - 6.4kg/cm 2 (570 - 630Kpa) 3. Oil Cooler Relief Valve Opening Pressure: 3.2 - 3.7kg/cm 2 (310 - 370Kpa) 4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (80 - 120Kpa) 5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa) 6. Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and oil filter. It is then delivered to the vital parts of the engine from the cylinder body oil gallery. The engine has many sliding and rotating parts. These parts constantly generate friction, which acts a frictional resistance. The process of forming an oil film to prevent direct contact of these friction-causing parts, converting their friction into fluid friction, and thus minimizing frictional resistance is called lubrication. The entire oil supply route is called a lubricating system. Oil not only reduces friction between moving parts but cools, cleans, seals, prevents rusting, and keeps dust out. A forced circulation system which pressure-feeds oil from an oil pump is generally used. The forced circulation lubrication system consists of an oil pan, oil pump, oil filter, oil cooler, and oil gallery in the cylinder block.

N*R 4JH1-TC Engine-38

OIL PUMP

1. Oil Pipe 2. Oil Strainer 3. Pump Cover 4. Driven Gear 5. Drive Gear 6. Relief Valve Assembly 7. Pinion Gear 6. Oil Pump Body

The oil pump is installed on the cylinder body by means of two bolts, and it is driven by the gear on the camshaft to conduct oil in the oil pan to the parts to be lubricated.
A

1. Drive Gear (driven by the camshaft) 2. Driven Gear

The gear type oil pump is adopted to the 4JH1-TC engine. The geared pump is structured as shown in the picture. The oil pump driven gear turns along the inner surface of the housing together with the pump gear which is driven by the camshaft. As a result, a negative pressure is created between the gears and the housing which draws the oil out of the oil pan through a strainer (from A). The drawn oil is discharged along the housing (to B), and pressure-fed to the oil gallery. The efficiency of the geared pump varies with the clearance between the gears and housing, oil pipe resistance, oil feed pressure, rpm and oil viscosity.

N*R 4JH1-TC Engine-39

Inspection Item Gear Teeth & Body Inner Wall Clearance

Required Tool: Feeler Gauge Service Standard: 0.14mm Service Limit: 0.20mm

Gear & Body Clearance

Required Tool: Feeler Gauge, Steel Square Service Standard: 0.06mm Service Limit: 0.15mm

OIL FILTER & OIL COOLER

1. Oil Cooler 2. Oil Filter 3. Oil Cooler & Filter Body 4. Oil Cooler Relief Valve 5. Regulating Valve

Engine oil will slowly become contaminated by metal fragments produced by the friction of the working and sliding parts of the engine, and by carbon and sludge generated by fuel combustion. Heavy sediment will settle to the bottom of the oil pan, while particles in suspension will be fed with the oil to engine parts, possibly causing accelerated wear and seizure. It is for these reason that an oil filter is installed in the oil passage to remove such foreign particles. The filter is either a full-flow type, which allows all the oil to pass through it, or a partial-flow type, which allows only part of the oil to pass through. The full-flow type is used for 4JH1-TC engine. A bypass valve is built into the oil filter. In case of filter element become clogged, the oil can be directly fed to the oil gallery without going through the element. Thus safe lubrication of the system is assumed.

N*R 4JH1-TC Engine-40

Lubricating oil for the most part often acts as a coolant for surfaces that are subject to severe friction. When the temperature of lubricating oil exceeds 125 - 130 degree centigrade, its lubricating performance, stable up to this temperature, suddenly drops, and it becomes difficult to maintain the oil film. As a result, rotating and sliding parts may begin to stick. Therefore, vehicles operated under severe conditions, that is, under extreme load at high speed for extended periods, are equipped with an oil cooler to prevent the lubricating oil from overheating. The plate tube type oil cooler allows lubricating oil to pass through the tube whose outer surfaces are cooled by engine coolant. Inspection to determine if any clogging up of the oil cooler elements has occurred, when the oil cooler unit is detached from the engine, pour oil or light oil into the oil cooler element through the inlet port, and check to see that it flows away from the outlet port. However if the oil cooler unit is attached to the engine, the following procedure is recommended; 1) Check oil gallery pressure at idling speed If the oil cooler element is clogged up, the oil gallery pressure reading will be increased 1 to 2 kg/cm2 (100 - 200 Kpa) over the normal figure. This increased pressure is due to an oil pressure loss in the oil cooler element. 2) Check the oil temperature in the oil gallery If the oil cooler element is clogged up, the oil temperature in the oil gallery will be higher than normal. If the engine operates at high speed, or is heavily loaded, the oil temperature will increase rapidly. 3) Check the operation of the oil cooler by-pass valve If the oil cooler element is clogged up, the by-pass valve should be fully open. The by-pass valve opens when the pressure difference between the element inlet and outlet port exceeds a certain figure. A visual check of by-pass valve movement is too difficult and it can only be confirmed by a slap sound which occurred when the valve opens and close. Inspection Item Water Leakage

1. Submerge the oil cooler water passage. 2. Apply compressed air (200Kpa /2kg/cm 2 ) If air bubbles rise to the surface, there is water leakage.

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ENGINE COOLING
COOLING SYSTEM

1. Radiator 2. Radiator Cap 3. Reservoir Tank 4. Thermostat 5. Cylinder Head 6. Oil Cooler 7. EGR Cooler 8. Car Heater 9. Water Pump 10. Turbocharger 11. Cooling Fan

The cooling system is a pressurized coolant forced circulation type, which consists of a coolant pump, a thermostat, thermostat assembly, a cooling fan, a radiator and an EGR cooler. The circulating coolant cools the lubricating oil in the heat exchanger and the turbocharger. The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat. The heat generated by fuel combustion in the cylinder heats the component parts around the combustion chambers of the engine. If these parts are not properly cooled, the inside engine temperature rises sharply and overheats, thus reducing output power. It also adversely affects the lubricating oil supplied to the moving parts of the engine, possibly reducing lubrication performance, altering oil properties, or causing abnormal wear and seizure. To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the water pump and through the by-pass hose and back to the cylinder body. The coolant does not circulate through the radiator. Overcooling, on the other hand, can lower thermal efficiency and deteriorate combustion. It can also accelerate cylinder liner wear as the sulfur dioxide generated in the combustion stroke is combined with the water in the gas to form a corrosive substance. The cooling system is designed to prevent engine overheating and overcooling, and maintain engine operation at an appropriate temperature. When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing amount of coolant will circulate through the radiator. The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now circulating through the radiator for effective engine cooling.

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WATER PUMP

Water Pump Assembly

The water pump is a centrifugal impeller type and is driven by V type drive belt. The water pump draws the coolant from the radiator, feeds it through the oil cooler into the cylinder block to cool the outer surfaces of the cylinders, and then into the cylinder head. The water in the cylinder head is directed by a water jacket to cool the outer surfaces of the nozzle holders and around the valve seats. After cooling the cylinder head, the water runs through the water outlet pipe to the radiator. The water outlet pipe has a thermostat to regulate the engine cooling water temperature. If the cooling water temperature is below the valve operating temperature, the cooling water is fed back through the water pump by-pass into the engine without returning to the radiator.

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THERMOSTAT

1. Jiggle Valve

The thermostat is a wax pellet type with a jiggle valve and has an opening temperature of 82 - 95 degree centigrade. The full opening valve lift is more than 9.5 mm. The thermostat opens and closes the water outlet pipe and radiator water passage according to the cooling water temperature to control it and prevent the engine from overheating or overcooling. When the cooling water is cold immediately after starting the engine, the water passage is closed by the valve, and the cooling water keeps circulating through the by-pass circuit without going through the radiator, thus permitting speedy engine warm up. As the water temperature rises, the valve opens to connect the water passage to the radiator and the by-pass circuit is closed so that the engine temperature may be kept at an appropriate level. If the engine becomes overcooled during operation, the water passage valve is automatically closed. This thermostat has wax sealed inside its casing, and the valve opens or closes when the wax expands or contracts, moving a spring. When the cooling water temperature is low, the wax is solid and contracted so that the valve is closed under the pressure of the spring. When the water temperature rises, the wax liquefies and expands to push the spring and valve down, to open the valve. A complete cut off of the cooling water to the radiator when the thermostat is fully closed will shorten engine warm up time, but the system cannot be filled with cooling water because air will remain trapped inside the engine. Therefore, the thermostat is generally fitted with a small air vent. The jiggle valve releases the air while cooling water is being added, and closes when even the slightest water pressure is applied as the engine start running, thereby preventing the cooling water from flowing out. Inspection Item Thermostat Operating Temperature

Required Tool: Thermometer, Agitating Rod Initial Opening Temperature: 82 degree centigrade Full Opening Temperature: 95 degree centigrade Valve Lift: 9.5mm

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COOLING FAN & FAN CLUTCH

1. Fluid Coupling 2. Bimetal

The cooling fan consists of seven plastic blades and is fitted with a fan clutch of the fluid coupling type filled with silicon oil. The engine cooling capacity is designed to prevent engine overheating even at a high ambient temperature. Thus, it is un-necessary for the fan to run fast when the engine is running fast at a low ambient temperature. High speed operation of the fan increases noise and causes a marked power loss. The fan clutch senses and drop in the ambient temperature and controls the fan speed.

N*R 4JH1-TC Engine-45

Inspection Item Thermostat Operating Temperature

Required Tool: Thermistor, Heat Gun Warm up the bimetal up to 80 degree centigrade. If the fan clutch rotates more readily, silicone grease is leaking internally.

Cooling Fan Drive Belt Deflection

Required Tool: Ruler Apply a force of 98Nm (10kg) to the drive belt mid-portion. Service Standard: 8 - 10mm

N*R 4JH1-TC Engine-46

RADIATOR & RADIATOR CAP

1. Radiator 2. Radiator Cap 3. Intercooler

The radiator is a device for a large volume of water in close contact with a large volume of air so that heat will transfer from the water to the air. The radiator core is divided into two separate and intricate compartments; water passes through one, and air passes through the other. The radiator is a tube type with corrugated fins. The corrugated fin type also consists of a series of long tubes extending from the top to bottom of the radiator. While fins are placed between the tubes and have a corrugation shape. Radiation efficiency is great in sprite of the same volume of the radiator, because of the corrugated fin has a great radiation area. Furthermore the louver on the corrugated fin increases air speed and this makes for increased radiation efficiency. The radiator cap has a pressure valve, which is used to maintain the pressure in the radiator at required level, and thus increases the capacity and cooling efficiency of the water pump. There is also a vacuum valve to take fresh air from the out side if the radiator pressure is reduced when the engine cools off, thereby protecting the radiator from collapse.

N*R 4JH1-TC Engine-47

Inspection Item Radiator Pressure Proof

Required Tool: Radiator Cap Tester Testing Pressure: 147KPa (1.5kg/cm 2 )

Radiator Cap Pressure Proof

Required Tool: Radiator Cap Tester Testing Pressure: 93.0 - 123KPa (0.95 - 1.25kg/cm 2 )

RESERVOIR TANK

Reservoir Tank

The reservoir tank is employed to prevent coolant loss, and to control the internal pressure of the radiator tank, namely to ensure cooling efficiency. Generally, the coolant volume expands by about 5% when the temperature exceeds 90 degree centigrade, and expanded volume of coolant overflows from the radiator. Therefore, the radiator has a suitable sized upper tank which corresponds to the increase in the volume of coolant. This prevents coolant loss to a large degree. Vapor, on the other hand, is forced out of the radiator. When the coolant temperature in the radiator falls, for example when the engine is stopped, the internal pressure in the radiator becomes negative which causes the coolant to be drawn back into the radiator. Thus coolant loss is prevented, and the period between topping up the radiator is greatly increased.

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FUEL SYSTEM

1. VP44 Fuel Injection Pump 2. Injection Pump Control Unit (PSG) *PSG=Pumpen Steuer Great (German) 3. Engine Control Unit (ECM) 4. Injection Nozzle 5. Fuel Filter With Water Separator 6. Fuel Tank

The fuel system consists of the fuel tank, the fuel filter with water separator, the injection pump, and the injection nozzle. The fuel in the fuel tank of a diesel engine is pumped up into a fuel filter by a feed pump, where water and dust are removed from the fuel before fed to the injection pump. After being pressurized by the VP44 fuel injection pump, diesel fuel is supplied at pressures of up to 100 Mpa to the injection nozzle, and injects it into the combustion chambers of the engine through injection nozzles. The feed pump increase the fuel feed rate in direct proportion to the engine speed, but the amount of fuel required to be injected into the cylinders varies with vehicle running conditions, and not in direct proportion to engine speed. Thus, there is always an excess of fuel from the feed pump. Therefore, the fuel return pipes run from the nozzles and injection pump to the fuel tank via fuel filter to return the excess fuel to the fuel tank.

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FUEL INJECTION PUMP

1. Injection Pump Gear Check Hole Cover 2. Scissors Gear Check Hole Cover 3. Injection Pump Bracket 4. VP44 Fuel Injection Pump

The biggest and most significant changes on the 4JH1-TC engine in comparison to the previous 4J series engine can be found on the engine management system. The Bosch engine management features a fully electronic controlled VP44 fuel injection pump. The VP44 fuel injection pump has a pump control unit (PSG) fitted on top it, that exchanges information with the engine control module (ECM) via a CAN-bus. The ECM calculates the desired fuel quantity and fuel injection timing and sends this information to the pump control unit (PSG). This pump control unit (PSG) then actuates the internal actuators accordingly. Note: This VP44 fuel injection pump is not allowed to disassembly repair even though any pump failures, because the pump is specially calibrated by special pump tester in the manufacturing process. Depending on the characteristic of each pumps such as manufacturing dispersion, the pump control unit (PSG) memorizes a peculiar data for the specified engine performance which is differed from pump to pump. The pump is only allowed to replace some gaskets of external parts such as feed pipe gaskets in case of the fuel leaks.

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FUEL INJECTION NOZZLE

1. 1st Opening Pressure Adjustment Shim 2. 2nd Opening Pressure Adjustment Shim 3. Push Rod 4. Speacer 5. Injection Cavity 6. 1st Spring 7. 2nd Spring 8. Nozzle Needle Valve 9. Nozzle Body

The fuel is injected inside the combustion chamber by means of two stage injectors with five holes. These holes have a diameter of 0.21 mm. The two stage injectors feature two springs that each can be adjusted separately in order to achieve the following injector opening pressures. -Designed Operating Pressure: 19.5MPa (1st Stage) / 33.8MPa (2nd Stage) -Adjusting Operating Pressure: 20.0 - 21.0MPa (1st Stage) / 34.3 - 35.8MPa (2nd Stage)

1. Gasket Nozzle Holder 2. Gasket Injection Nozzle 3. Clamp Nozzle Holder 4. Leak-off Pipe 5. Injection Nozzle Assembly 6. Injection Pipes 7. Copper Gaskets

N*R 4JH1-TC Engine-51

The injection nozzles are attached to the cylinder head by means of a clamp and seal off in the cylinder head by means of a gasket nozzle holder and gasket injection nozzle. Copper gaskets provide a seal between the nozzle leak-off pipe and the injection nozzles. Note: This injection nozzle is not allowed to disassembly repair even though any nozzle failures, because the nozzle is specially tightened in the manufacturing process. The nozzle is only allowed to check the 1st operating pressure, fuel leaks and splay conditions. If the operating pressure is incorrect, fuel leaks from the nozzle or bad splay conditions, the nozzle must be replaced to new one.

FUEL FILTER

1. Priming Pump 2. Body Assembly 3. Air Bleeder Plug 4. Filter Cartridge 5. Filter Element 6. Float 7. Drain Plug 8. Level Sensor Assembly

The fuel filter assembly equipped with a water separator is adopted for the 4JH1-TC engine. On top of it, air bleeding plug is provided. As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The fuel filter and the water separator removes water particles and other foreign material from the fuel before it reaches the injection pump. The water separator has an internal float. When the float reaches the specified level, a warning light comes on to inform the driver to drain the water from the water separator. A diaphragm type priming pump is installed at the top of the water separator. It is used during the water draining and air bleeding procedure.

N*R 4JH1-TC Engine-52

Note: The air bleeding procedure for fuel system has been modified for the 4JH1-TC engine. If the fuel injection pump has been replaced, the fuel has been exhausted or the fuel filter has been replaced, the following air bleeding procedure will require. 1. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 15 cycles). 2. Stop pumping and tighten the air bleeder plug. And, wait 1 minute. 3. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 10 cycles). 4. Stop pumping and tighten the air bleeder plug. And, wait 1 minute. 5. Loosen the air bleeder plug and operate the priming pump until strong resistance is felt (about 5 cycles). 6. Stop pumping and tighten the air bleeder plug. 7. Depress the accelerator pedal and clutch pedal to the floor and hold them down. Turn the ignition switch to the "ON" position. Wait until the glow indicator lamp turns off. And then, turn the ignition switch to the "START" position and crank the engine until it starts. 8. If the engine does not start, repeat Step 5 - 7. 9. Allow the engine to idle for 5 minuets.

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ELECTRICAL PARTS
STARTER MOTOR

Starter Assembly

Connecting Diagram

The starting system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with ring gear. Then, the ring gear runs to start the engine. On the 4JH1-TC engine has an output of 2.3 kW made by Hitach.

N*R 4JH1-TC Engine-54

1. Magnetic Switch Assembly 2. Magnetic Switch 3. Adjusting Shims 4. Plunger 5. Torsion Spring 6. Shift Lever 7. Gear Case 8. Dust Cover 9. Bolt 10. Pinion Assembly 11. Clutch 12. Pinion Shaft 13. Return Spring 14. Pinion Stopper 15. Pinion Stopper Clip 16. Bearing Retainer 17. Screw 18. Motor Assembly 19. Armature 20. Yoke 21. Brush Holder 22. Rear Cover 23. Screw 24. Through Bolt 25. Lead Wire

N*R 4JH1-TC Engine-55

Inspection Item Commutator Run-out

Required Tool: Dial Indicator, V-Block Service Standard: 0.02mm Service Limit: 0.05mm

Commutator Mica Segments Wear

Required Tool: Vernier Caliper Service Standard: 0.7 - 0.9mm Service Limit: 0.2mm

Commutator Outside Diameter

Required Tool: Vernier Caliper Service Standard: 35mm Service Limit: 34mm

Armature Grounding Test

Required Tool: Circuit Tester Hold one probe of the circuit tester against the commutator segment. And, hold the other circuit tester probe against the armature core. If the circuit tester indicates continuity, the armature is grounded.

Armature Continuity Test

Required Tool: Circuit Tester 1 Hold the circuit tester probes against two armature core segments. 2 Repeat Step 1 at different segments of the armature core. There should be continuity between all segments of the armature core.

N*R 4JH1-TC Engine-56

Yoke Field Winding Ground Test

Required Tool: Circuit Tester Hold one circuit tester probe against the field winding end or brush. Hold the other circuit tester probe against the bare surface of the yoke body. If there is continuity, the field coil is grounded.

Yoke Field Winding Continuity Test

Required Tool: Circuit Tester Hold one circuit tester probe against the C terminal lead wire. Hold the other circuit tester probe against the field winding brush. There should be continuity.

Brush Length

Required Tool: Vernier Caliper Service Standard: 14.5mm Service Limit: 9.5mm

Brush Holder Insulation Test

Required Tool: Circuit Tester Touch one probe to the holder plate and the other probe to the positive brush holder. There should be no continuity.

Overrunning Clutch

Inspect the overrunning clutch gear teeth for excessive wear and damage. Rotate the pinion clockwise. It should turn smoothly. Try to rotate the pinion in the opposite direction. The pinion should lock.

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GENERATOR

Generator Assembly

Connecting Diagram

The basic charging system is the IC integral regulator charging system. The internal components are connected electrically as shown in connecting diagram. The generator features a solid state regulator that is mounted inside the generator. All regulator components are enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame. On the 4JH1-TC engine, two type of outputs (60A or 80A) can be used depends on vehicle specification.

N*R 4JH1-TC Engine-58

1. Vacuum Pump 2. Cover 3. Brush 4. Through Bolt 5. Pulley Assembly 6. Pulley Nut 7. Pulley 8. Fan 9. Rotor Assembly 10. Speacer 11. Ball Bearing 12 Rotor 13. Front Cover Assembly 14. Front Cover 15. Ball Bearing 16. Bearing Retainer 17. Screw 18. Terminal Bolt & Nut 19. Condenser 20. Rear Cover 21. Stator 22. Diode 23. Holder Plate 24. Brush Holder 25. IC Regulator Assembly 26. Lead Wire 27. Mold Terminal 28. IC Regulator

Inspection Item Rotor Slip Ring Wear

Required Tool: Vernier Caliper Check the rotor slip ring surfaces for contamination and roughness. If rough, polish with #500-600 sandpaper. Service Standard: 34.6mm Service Limit: 33.6mm

Rotor Slip Ring Continuity Test

Required Tool: Circuit Tester Check for continuity between slip rings. There should be continuity.

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Rotor Slip Ring Insulation Test

Required Tool: Circuit Tester Check for continuity between the slip rings and the rotor core or shaft. There should be no continuity.

Stator Coil Continuity Test

Required Tool: Circuit Tester Check for continuity across the stator coils. There should be continuity.

Stator Coil Insulation Test

Required Tool: Circuit Tester Check for continuity between each stator coils and the stator core. There should be no continuity.

Brush Length

Required Tool: Vernier Caliper Service Standard: 20mm Service Limit: 6mm

Diode Insulation Test

Required Tool: Circuit Tester Check for continuity between the battery and each of the three stator coil lead terminals. If there is continuity, the diode is normal. Reverse the polarity of the test probes. If there is no continuity, the diode is normal.

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Vacuum Pump Check Valve Test

Apply a light pressure onto the "B" side of valve with a screw driver and check that valve operates smoothly. Apply compressed air 1 - 5 kg/cm 2 onto "A" side of valve and check if there is air leak.

PREHEATING SYSTEM

1. ECM Main Relay 2. Battery Voltage 3. Ignition Switch 4. Glow Fuse 50A 5. Gauge Back Fuse 10A 6. Glow Relay 7. Glow Indicator Lamp 8. Glow Plug 9. Engine Control Unit (ECM)

The 4JH1-TC engine is adopted with the quick on system 2 (QOS 2) preheating system which is controlled by engine control module (ECM). The voltage on the coil of the relay glow plug is supplied by the relay engine control module (ECM) main. The ECM switches glow relay to operate glow plug depends on the coolant temperature. The function of the glow time indicator lamp is to inform the driver whether the glow system is activated. When the lamp extinguishes the engine can be started. This does not imply that the glow plugs are no longer activated. In the after glow phase the lamp is not illuminated but the glow plugs remain active for a certain period depending on engine coolant temperature.

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Pre Glow Setting Curve 8 7 6 Time (Sec.) 5 4 3 2 1 0 -30 -20 -10 0 10 20 Coolant Temperature (degree centigrade) 30 40 50

After Glow Setting Curve 35 30 Time (Sec.) 25 20 15 10 5 0 -30 -20 -10 0 10 20 Coolant Temperature (degree centigrade) 30 40 50

Inspection Item Glow Plug Continuity

Required Tool: Circuit Tester Service Standard: 0.9 ohm

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SPECIAL TOOLS

5-8840-0200-0 Oil Filter Wrench (89.0mm / 3.5 in)

9-8523-1423-0 Valve Spring Compressor

5-8840-2033-0 Oil Seal Installer

5-8840-9018-0 Piston Ring Compressor

5-8840-2093-0 Tacho Meter

9-8523-1212-0 Valve Guide Replacer

5-8840-2036-0 Front Oil Seal Installer

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5-8840-2675-0 Compression Gauge

5-8531-7001-0 Gauge Adapter

5-8531-7002-0 Gauge Adapter

5-8840-0266-0 Angle Gauge

5-8840-2038-0 Camshaft Bering Replacer

5-8673-9149-0 Base 5-8673-9150-0 Lever Scissors Gear Setting Tool

5-8840-2360-0 Rear Oil Seal Remover

N*R 4JH1-TC Engine-64

5-8840-2359-0 Rear Oil Seal Installer

5-8840-2313-0 Cylinder Liner Installer

5-8840-2304-0 Cylinder Liner Remover

5-8840-2000-0 Pilot Bearing Remover

5-8840-0019-0 Sliding Hammer

5-8522-0024-0 Pilot Bearing Installer

5-8521-0002-0 Universal Puller

N*R 4JH1-TC Engine-65

5-8840-0075-0 Pressure Gauge

5-8840-0279-0 Vacuum Pump With Gauge

VP44 CHECK SHEET Issuer:

OEM Distributor name: VIN Number:

Date of issue: Customers name:

Vehicle retail date: Vehicle trouble Mileage: (mm.dd.yy) Mile date: (mm.dd.yy)

Km or

Pump part number:

Pump serial number:

Diagnostic Trouble Code (DTC) Set :( ) DTC Present or Not Present :( ) Engine warning light: Lit ( ) Flashing ( ), No warning light ( )

Customers complaint: Please enter x between brackets (

) & Please enter phenomenon between underlined bracket ( ).

1.Engine stall ( ): After stalling, engine would restart ( ) or would not restart ( ). 2.After starting the engine, are there any abnormal conditions? ( ) 3.Engine hard to start ( ): After some time, engine would start ( ) or would not start ( ). 4.Hunting ( ): Engine speed is ( rpm) ( rpm). 5.Lack of engine power ( ). 6.Excessive black smoke ( ). 7. Excessive white smoke ( ) 8.Other trouble ( ). When the trouble occurred: 1) 2) 3) From when the vehicle was purchased ( ) Km, miles) From ( or Other (

).

Where the trouble occurs: 1) On the highway ( ) 4) Driving downhill ( ) 2) On city roads ( ) 5) In traffic jam ( ) 3) Driving uphill ( ) 6) Other (

Vehicle condition when the trouble occurs: 1) During acceleration ( ) 2) Slowing down ( ) 3) Stopping ( ) or range) 4) Constant speed ( ) ( Km/hr, gear position 5) During engine starting after warm-up ( ) or engine still cold ( ) 6) From stationary acceleration ( ) 7) During braking ( ) 8) Other ( ) Condition of additional devices when the trouble occurs: 1) Air-conditioning is ON ( ) 2) Power steering operating ( ) 3) Position of A/T gear selector (

range)

Additional parts replaced other than the injection pump: Injector Nozzle 1) Spray Pattern 2) Injection Pressure # 1 Cylinder Good or Bad Mpa # 2 Cylinder Good or Bad Mpa # 3 Cylinder Good or Bad Mpa # 4 Cylinder Good or Bad Mpa

THE RIGHT IS RESERVED TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE. THIS MANUAL MAY NOT BE REPRODUCED OR COPIED, IN WHOLE OR IN PART WITHOUT THE WRITTEN PERMISSION OF ISUZU MOTORS.

Issued by

ISUZU MOTORS LIMITED

SERVICE MARKETING DEPARTMENT Tokyo, Japan COPYRIGHT-ISUZU MOTORS LIMITED SBT-TM-4JHM-2-03 (version 1)
February 2003