Isuzu Engine 4HK1 6HK1 Workshop Service Repair Manual
Description:
Isuzu Engine 4HK1 6HK1 Workshop Service Repair Manual
To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in maintaining the engine: When taking down the engine on the ground, do not make the bearing surface of the oil pan touch directly the ground. Use a wood frame, for example, to support the engine with the engine foot and the flywheel housing.
Because there is only a small clearance between the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer.
• When the air duct or air cleaner is removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If it gets into it, it can considerably damage the cylinder and others while the engine is operating.
• When maintaining the engine, never fail to remove the battery ground cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others.
• Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started.
• When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them.
• When installing them, put them back to the same location as they were removed.
• Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled.
• As for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust may be clung to them. Then, apply the designated liquid gasket to each place anew before assembly.
• Surfaces covered with liquid gasket must be assembled within 7 minutes of gasket application. If more than 7 minutes have elapsed, remove the existing liquid gasket and apply new liquid gasket.
• When assembling or installing parts, fasten them with the specified tightening torque so that they may be installed properly.
Table Of Contents:
Isuzu Engine 4HK1 6HK1 Workshop Service Repair Manual
ISUZU DIESEL ENGINE (4HK1 6HK1) 1A-3
Precautions on Service Work 1A-3
Main Data and Specifications 1A-11
Cylinder Head Cover1A-14
Components 1A-14
Removal1A-15
Installation 1A-16
Torque Specifications 1A-18
Inlet Cover 1A-20
Components 1A-20
Removal1A-21
Installation 1A-22
Torque Specifications 1A-24
Turbocharger and Exhaust Manifold 1A-25
Components 1A-25
Removal1A-26
Inspection 1A-27
Installation 1A-28
Torque Specifications 1A-32
Timing Gear Train1A-35
Components 1A-35
Removal1A-36
Inspection 1A-38
Installation 1A-40
Torque Specifications 1A-51
Special Tool1A-52
Rocker Arm Shaft ASM 1A-53
Components 1A-53
Removal1A-53
Disassembly 1A-54
Reassembly1A-56
Installation 1A-57
Torque Specifications 1A-58
Camshaft ASM 1A-59
Components 1A-59
Removal1A-60
Disassembly 1A-61
Reassembly1A-63
Fixing torque 1A-65
Special Tool1A-65
Installation 1A-66
Torque Specifications 1A-68
Valve Stem Seal Valve Spring 1A-69
Components 1A-69
Removal1A-69
Inspection 1A-70
Installation 1A-71
Special Tool1A-73
Cylinder Head1A-74
Components 1A-74
Removal1A-74
Disassembly 1A-78
Inspection 1A-81
Reassembly1A-87
Installation 1A-93
Torque Specifications 1A-100
Special Tool 1A-100
Piston Connecting Rod1A-102
Components 1A-102
Removal 1A-102
Disassembly 1A-103
Reassembly 1A-109
Installation 1A-111
Torque Specifications 1A-113
Special Tool1A-113
Flywheel 1A-114
Components 1A-114
Removal1A-114
Inspection 1A-116
Installation 1A-116
Torque Specifications 1A-118
Special Tool1A-118
Front Cover 1A-119
Components 1A-119
Removal 1A-120
Installation1A-121
Torque Specifications 1A-123
Crankshaft Front Oil Seal 1A-125
Components 1A-125
Removal 1A-125
Installation1A-127
Torque Specifications 1A-132
Special Tool 1A-132
Crankshaft Rear Oil Seal 1A-133
Components 1A-133
Removal 1A-133
Installation1A-134
Special Tool 1A-137
Crankshaft 1A-138
Components 1A-138
Removal 1A-138
Disassembly 1A-140
Reassembly 1A-140
Inspection1A-140
Installation1A-145
Torque Specifications 1A-149
Special Tool 1A-149
Cylinder Block 1A-151
Components 1A-151
Removal 1A-151
Inspection1A-152
Installation1A-153
Lubrication System 1A-156
Precautions on Service Work 1A-156
1A-2 ENGINE MECHANICAL (4HK1 6HK1)
Function Check 1A-157
Special Tool 1A-158
Oil Port Cover ASM1A-159
Components 1A-159
Removal 1A-159
Installation1A-159
Oil Cooler 1A-161
Components 1A-161
Removal 1A-162
Disassembly 1A-163
Reassembly 1A-163
Installation1A-164
Oil Pan 1A-167
Components 1A-167
Removal 1A-167
Installation1A-167
Oil Pump1A-170
Components 1A-170
Removal 1A-170
Disassembly 1A-171
Reassembly 1A-171
Inspection1A-172
Installation1A-173
Oil Pressure Switch1A-177
Inspection1A-177
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Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Ahmir Zyaire –
Zaid Alistair –