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Isuzu 4BB1 User Manual

Isuzu 4BB1
216 pages
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INDUSTRIAL
INDUSTRIAL
DIESEL ENGINE
DIESEL ENGINE
4B-6B SERIES
4B-6B SERIES
4BB1-4BD1-6BB1-6BD1-6BG1
4BB1-4BD1-6BB1-6BD1-6BG1
4BD1T-6BD1T-6BG1T
4BD1T-6BD1T-6BG1T
MODELS
MODELS
WORKSHOP MANUAL
ISUZU MOTORS LIMITED
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Table of Contents

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Isuzu 4BB1 Specifications

General IconGeneral
BrandIsuzu
Model4BB1
CategoryEngine
LanguageEnglish

Summary

General Information

General Repair Instructions

Provides guidance for performing service operations on the engine, including safety precautions and tool usage.

Main Data and Specifications

Presents key technical data and specifications for various engine models, including dimensions and capacities.

Design Features and General Outline

Details the fundamental design aspects and overall layout of the ISUZU 4B and 6B series industrial diesel engines.

Tightening Torque Specifications

Lists the specified torque values for various nuts and bolts used in engine assembly and disassembly.

Maintenance

Lubricating System

Covers procedures for oil filter replacement, including disassembly and reassembly steps, and torque specifications.

Fuel System

Details the disassembly, inspection, and repair of the fuel filter and injection nozzle systems.

Cooling System

Explains the adjustment of the cooling fan drive belt, thermostat inspection, and valve clearance adjustment procedures.

Injection Timing

Outlines the procedures for checking and adjusting the injection timing of the fuel injection pump.

Engine Assembly I (Disassembly)

External Parts Disassembly Steps

Provides step-by-step instructions and diagrams for the disassembly of external engine components.

Major Components

Illustrates and lists major engine components, including the cylinder head, crankshaft, and timing gear case.

Piston and Connecting Rod Disassembly Steps

Details the procedure for safely removing piston rings, snap rings, and the piston pin from the connecting rod.

Engine Assembly II (Inspection & Repair)

Cylinder Head Inspection and Repair

Covers inspection methods for cylinder head warpage, height, and water jacket pressure testing.

Valve Guide Inspection and Repair

Explains the measurement of valve stem and guide clearance and the process for valve guide replacement.

Crankshaft Inspection and Repair

Details the inspection and measurement procedures for crankshaft journals, crankpins, and bearings.

Cylinder Body and Liner Inspection

Describes the measurement and inspection of cylinder bores, liners, and their projection.

Engine Assembly III (Reassembly)

Piston and Connecting Rod Reassembly

Provides instructions for assembling pistons, connecting rods, piston rings, and bearings with proper lubrication.

Cylinder Head Reassembly

Guides through the reassembly of cylinder head components, including valve stem seals, valves, springs, and manifolds.

Major Component Reassembly I

Illustrates the reassembly sequence for major engine components like crankshaft, camshaft, and timing gears.

Engine Tuning Operation

Outlines the procedures for tuning the engine after reassembly, including electrical connections and initial startup.

Lubricating System

Oil Pump

Details the disassembly, inspection, repair, and reassembly of the engine oil pump assembly.

Main Oil Filter

Covers the disassembly, inspection, and reassembly of the main engine oil filter.

Oil Cooler

Explains the disassembly, inspection, and reassembly procedures for the engine oil cooler.

Cooling System

Water Pump

Provides instructions for the disassembly, inspection, repair, and reassembly of the engine water pump.

Thermostat Inspection

Describes the inspection procedure for the thermostat to ensure proper engine cooling system operation.

Fuel System

Fuel Filter

Details the disassembly, inspection, and reassembly of the fuel filter, including its components.

Injection Nozzle

Covers the disassembly, inspection, and reassembly of the injection nozzle assembly.

Injection Pump Calibration Data

Provides essential data and test conditions for the calibration of the fuel injection pump.

Turbocharger

Turbocharger Identification

Explains how to identify turbocharger models and locate key information on the nameplate.

Rotor Shaft Play Inspection

Details the procedures for inspecting axial and radial play of the turbocharger rotor shaft.

Air Compressor

Air Compressor Disassembly Steps

Outlines the steps for disassembling the air compressor, including important operational notes.

Air Compressor Inspection and Repairs

Covers inspection methods for cylinder bore wear, piston clearances, and ring gaps of the air compressor.

Air Compressor Reassembly Steps

Provides step-by-step instructions for the reassembly of the air compressor, including bearing installation.

Engine Electricals

Starter Motor Identification

Explains how to identify starter motor models and their key identification plates.

Starter Motor Main Data and Specifications

Presents detailed technical data and specifications for different starter motor models.

Alternator Identification

Describes how to identify alternator models and locate information on their identification plates.

Alternator Main Data and Specifications

Provides comprehensive technical data and specifications for various alternator models.

Troubleshooting

Hard Starting

Diagnoses causes and provides remedies for engine starting problems, covering various potential issues.

Unstable Low Idling

Addresses causes and solutions for unstable engine idling, including fuel system and valve clearance checks.

Insufficient Power

Helps diagnose and resolve issues leading to reduced engine power, checking air, fuel, and compression.

Excessive Fuel Consumption

Identifies causes of high fuel usage, such as fuel system leaks, improper timing, and air filter restrictions.

Overheating

Provides troubleshooting steps for engine overheating issues, checking cooling system components and fuel injection timing.

Abnormal Engine Noise

Helps diagnose various engine noises, including knocking, gas leakage, and slapping sounds.

Special Tool List

Special Tool Listings

Lists specialized tools required for engine maintenance and repair, including part numbers and page references.

Conversion Table

Length Conversions

Provides conversion factors between millimeters, inches, feet, and meters for length measurements.

Pressure Conversions

Offers conversion values between pounds per square inch (psi) and kilograms per square centimeter (kg/cm²).

Temperature Conversions

Includes conversion charts for temperatures between Fahrenheit and Centigrade scales.

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