Isuzu Hitachi 6HK1 Tier 2 Engine Workshop Manual EDDE-EN-00 PDF

Description

Isuzu Hitachi 6HK1 Tier 2 Engine Workshop Manual EDDE-EN-00 – PDF DOWNLOAD 

FILE DETAILS:

Isuzu Hitachi 6HK1 Tier 2 Engine Workshop Manual EDDE-EN-00 – PDF DOWNLOAD 

Language : English
Pages : 238
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Isuzu Hitachi 6HK1 Tier 2 Engine Workshop Manual EDDE-EN-00 – PDF DOWNLOAD 

ESS-185A 1
GENERAL INFORMATION 3
General Information 3
General Repair Instruction 3
Illustration Arrows 4
Abbreviations 5
Nut and Bolt Angular Tightening Method 6
Standard Bolt Torque Specifications 8
Recommended Thread Locking Agents 10
Main Data and Specifications 11
Performance Curve 13
External View Drawing 14
Service Standard 15
Torque Specifications 19
Special Tools 27
Troubleshooting 28
Lubricant Application 38
Sealant Application 38
Service Information 39
Identification 39
Lubrication System 40
Fuel System 40
Cooling System 44
Valve Clearance Adjustment 44
Compression Pressure Measurement 46
Recommended Lubricants 47
Engine Oil Viscosity Chart 47
ENGINE 49
Engine Mechanical 49
Service Precautions 50
General Description 50
Engine Cleanliness and Care 50
Engine Service 50
Engine Components 50
Turbocharger 52
Removal 52
Installation 52
Exhaust Manifold 53
Removal 53
Installation 53
Intake Cover 55
Removal 55
Installation 55
Water Pump 57
Removal 57
Installation 59
Alternator 61
Removal 61
Installation 61
Injection Pump 62
Removal 62
Installation 64
Bearing Case 66
Removal 66
Installation 66
Oil Cooler 68
Removal 68
Installation 68
Rocker Arm and Shaft Assembly 71
Removal 71
Installation 72
Disassembly 75
Inspection and Repair 76
Reassembly 79
Camshaft 80
Removal 80
Installation 81
Disassembly 84
Inspection and Repair 85
Reassembly 86
Cylinder Head 87
Removal 87
Installation 89
Disassembly 93
Inspection and Repair 96
Reassembly 102
Crank Pulley and Flywheel 110
Removal 110
Installation 111
Disassembly 112
Inspection and Repair 112
Reassembly 112
Timing Gears 114
Removal 114
Inspection and Repair 115
Installation 116
Flywheel Housing 119
Removal 119
Installation 120
Oil Pan 124
Removal 124
Installation 125
Front Cover 126
Removal 126
Installation 127
Piston 130
Removal 130
Installation 131
Disassembly 133
Inspection and Repair 134
Reassembly 139
Crankshaf 142
Removal 142
Installation 144
Disassembly 148
Inspection and Repair 149
Reassembly 152
Cylinder Block 154
Removal 154
Installation 155
Disassembly 156
Inspection and Repair 157
Reassembly 160
Engine Cooling 163
Service Precautions 163
General Description 164
Thermostat 165
Disassembly 166
Inspection and Repair 166
Reassembly 167
Water Pump 168
Disassembly 168
Inspection and Repair 169
Reassembly 170
Engine Fuel 173
Service Precautions 173
General Description 174
Fuel Filter 177
Disassembly 177
Inspection and Repair 178
Reassembly 178
Injection Nozzle Holder 179
Nozzle and Holder Specification 179
Disassembly 180
Reassembly 181
Injection Pump 190
Identification 190
Calibration Data 191
Starting and Charging 195
Service Precautions 195
Alternator 196
General Description 196
Disassembly 199
Inspection and Repair 201
Reassembly 202
Starter motor 205
General Description 205
Disassembly 208
Inspection and Repair 210
Reassembly 212
Engine Lubrication 217
Service Precautions 217
General Description 218
Oil Pump 220
Disassembly 221
Inspection and Repair 221
Reassembly 223
Oil Cooler 224
Disassembly 224
Inspection and Repair 225
Reassembly 225
Oil Port Cover 227
Removal 228
Inspection and Repair 228
Installation 228
Engine Induction 229
Service Precaution 229
Turbocharger 230
General Description 230
Troubleshooting 232
Inspection and Repair 234

DESCRIPTION:

Isuzu Hitachi 6HK1 Tier 2 Engine Workshop Manual EDDE-EN-00 – PDF DOWNLOAD 

General Repair Instruction:

1. Before performing service operations, disconnect the ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting.
2. Use a cover on body, seats and floor to protect them against damage and contamination.
3. Brake fluid and anti-freeze solution must be handled with care because they can cause paint damage.
4. The use of proper tools and special tools, where specified, is important for efficient and reliable performance of service repairs.
5. Use genuine Isuzu parts.
6. Used cotter pins, plastic clips, gaskets, O-rings oil seals, lock washers, and self-locking nuts should be discarded and new ones should be installed. Normalfunction of the parts cannot be maintained if these parts are reused.
7. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing nuts and bolts separate is very important, as they vary in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of the parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for nut and bolt torques.
12. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected.
13. Allow the engine to cool before beginning any service procedure. This will eliminate the danger of fire and possible injury.
14. Hot steam under pressure may escape from the radiator if the coolant is drained while the engine is hot. This can result in serious burns. Allow the engine to cool before draining the coolant.
15. Hot engine oil can cause severe skin burns. Allow the engine to cool before draining the engine oil.
16. While working around a running engine, avoid contact with moving parts and hot surfaces to prevent injury.
17. Wear safety glasses when using compressed air. Flying particles may cause eye injury.
18. Always wear safety goggles when working with fuel to protect the eyes from fuel splash.
19. Test fluid from the injection nozzle tester will spray out of the injection nozzle under great pressure. It can easily puncture a person’s skin. Keep your hands away from the injection nozzle at all times.
20. Do not use your fingers to feel for fuel leaks at fittings. Fuel pressure is high enough to penetrate the skin.

S.V 05/01/2025