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Isuzu 4BD1 User Manual

Isuzu 4BD1
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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 4BD1 Specifications

General IconGeneral
Bore x Stroke102 mm x 118 mm
Compression Ratio17.5:1
Cylinder arrangementInline 4
Cooling systemWater-cooled
Fuel SystemDirect injection
AspirationNaturally aspirated
Engine TypeDiesel
Displacement3.9 L
ValvetrainOHV (Overhead Valve)

Summary

General Information

General Repair Instructions

Details procedures for performing general engine repairs, including safety precautions and tool usage.

Notes on the Format of this Manual

Explains the structure, symbols, and conventions used throughout the workshop manual for clarity.

Main Data and Specifications

Presents key technical data and specifications for various engine models covered in the manual.

Design Features and General Outline

Describes the main design features and general outline of the ISUZU 4B and 6B series industrial diesel engines.

Tightening Torque Specifications

Lists essential tightening torque values for various nuts and bolts used in engine assembly and disassembly.

Angular Nut and Bolt Tightening Method

Explains the procedure for tightening nuts and bolts using an angular method for precise assembly.

Major Part Fixing Nuts and Bolts

Illustrates and specifies torque values for fasteners securing major engine components like cylinder head and cover.

Identifications

Provides guidance on identifying engine models and injection pump specifications for service purposes.

Maintenance

Lubricating System

Covers the general description, oil pump, main oil filter, and oil cooler of the engine's lubricating system.

Fuel System

Details the general description, fuel filter, injection nozzle, and injection pump calibration data for the fuel system.

Injection Nozzle

Explains the disassembly, inspection, repair, and reassembly procedures for the engine's injection nozzles.

Water Separator (Water Sedimentor)

Describes the operation, inspection, and repair of the water separator or sedimentor in the fuel system.

Air Bleeding

Outlines the procedure for bleeding air from the fuel system to ensure proper engine operation.

Cooling System

Covers the general description, water pump, and thermostat of the engine's cooling system.

Valve Clearance Adjustment

Provides detailed steps and specifications for adjusting the valve clearance on the engine.

Rocker Arm Screw Lock Nut Torque

Specifies the correct torque value for the rocker arm screw lock nut during engine assembly.

Injection Timing

Explains the procedure and importance of setting the correct injection timing for optimal engine performance.

Compression Pressure Measurement

Details the method for measuring engine compression pressure to diagnose performance issues.

Turbocharger Inspection

Guides on inspecting the turbocharger for proper function, including checks for air and oil leaks.

Engine Repair Kit (Non-Turbocharged)

Lists the components included in the engine repair kit for non-turbocharged engine models.

Engine Repair Kit (Turbocharged)

Lists the components included in the engine repair kit for turbocharged engine models.

Recommended Lubricants

Provides recommendations for the types and grades of lubricants suitable for different engine configurations.

Engine Oil Viscosity Chart

Presents a chart indicating engine oil viscosity grades suitable for various ambient temperatures.

Engine Assembly I (Disassembly)

External Parts Disassembly Steps (Right-hand Side)

Details the step-by-step procedure for disassembling external engine components from the right-hand side.

External Parts Disassembly Steps (Left-hand Side)

Details the step-by-step procedure for disassembling external engine components from the left-hand side.

Major Components-I

Illustrates and lists the major components of the engine assembly, part one, for disassembly reference.

Major Components-II

Illustrates and lists the major components of the engine assembly, part two, for disassembly reference.

Rocker Arm and Rocker Arm Shaft Disassembly

Provides steps for the disassembly of the rocker arm and rocker arm shaft assembly.

Cylinder Head Disassembly

Details the procedure for safely disassembling the engine's cylinder head and its related parts.

Piston and Connecting Rod Disassembly

Outlines the steps required to disassemble the piston and connecting rod assembly from the engine.

Engine Assembly II (Inspection & Repair)

Cylinder Head Inspection

Describes methods for inspecting the cylinder head for flatness, cracks, and water leakage.

Valve and Valve Guide Inspection

Explains how to inspect valve guides for wear and measure valve depression and contact width.

Valve Spring Inspection

Details procedures for checking valve springs, including free length, inclination, and tension.

Tappet and Push Rod Inspection

Guides on inspecting tappets for wear and push rods for run-out and straightness.

Rocker Arm Shaft and Rocker Arm Inspection

Covers the inspection of rocker arm shafts and rocker arms for wear, damage, and abnormalities.

Camshaft and Idler Gear Inspection

Provides methods for inspecting camshaft journals, bearings, and idler gears for wear and clearance.

Cylinder Liner Inspection and Measurement

Details procedures for inspecting cylinder liner projection and measuring cylinder bore dimensions.

Crankshaft Inspection and Clearances

Covers inspection of crankshaft journals and crankpins, including bearing clearances and run-out.

Oil Seal Wear Ring Replacement

Explains the procedure for replacing oil seal wear rings on the crankshaft.

Engine Assembly III (Reassembly)

Piston and Connecting Rod Reassembly

Details the step-by-step process for reassembling the piston and connecting rod components.

Cylinder Head Reassembly

Provides instructions for the correct reassembly of the engine's cylinder head and its associated parts.

Rocker Arm and Rocker Arm Shaft Reassembly

Guides on the reassembly of the rocker arm and rocker arm shaft assembly.

Major Component Reassembly I

Illustrates and outlines the reassembly steps for major engine components, Part I.

Major Component Reassembly II

Illustrates and outlines the reassembly steps for major engine components, Part II.

External Parts Reassembly (Left-Hand Side)

Details the step-by-step procedure for reassembling external engine components from the left-hand side.

External Parts Reassembly (Right-Hand Side)

Details the step-by-step procedure for reassembling external engine components from the right-hand side.

Engine Tuning Operation

Describes the procedure for tuning the engine after reassembly to ensure optimal performance.

Lubricating System

General Description

Provides an overview of the lubricating system, its function, and key components.

Oil Pump

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

Main Oil Filter

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

Oil Cooler

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

Cooling System

General Description

Provides an overview of the cooling system, its function, and main components.

Water Pump

Details the disassembly, inspection, repair, and reassembly procedures for the engine's water pump.

Thermostat

Covers the inspection and function of the engine's thermostat.

Fuel System

General Description

Provides an overview of the fuel system, its function, and key components.

Fuel Filter

Details the disassembly, inspection, repair, and reassembly of the engine's fuel filter.

Injection Nozzle

Explains the disassembly, inspection, repair, and reassembly procedures for the engine's injection nozzles.

Injection Starting Pressure Adjustment

Outlines the procedure for adjusting the injection starting pressure of the injection nozzles.

Injection Pump Calibration Data

Presents calibration data and specifications for the engine's injection pump.

Turbocharger

General Description

Provides an overview of the turbocharger, its function, and its identification.

Turbocharger Identification

Explains how to identify turbocharger models and their specifications using the nameplate.

Rotor Shaft Play Inspection

Details the procedure for inspecting rotor shaft play (axial and radial) in the turbocharger.

Air Compressor

General Description

Provides an overview of the air compressor, its main data, and functions.

Disassembly Steps

Details the step-by-step procedure for disassembling the air compressor.

Inspection and Repairs

Covers the inspection and repair procedures for various components of the air compressor.

Reassembly Steps

Details the step-by-step procedure for reassembling the air compressor.

Engine Electricals

Starter Motor Identification

Explains how to identify starter motor models using their identification plates.

Starter Motor Specifications

Presents the main data and specifications for different starter motor models.

Alternator Identification

Explains how to identify alternator models using their identification plates.

Alternator Specifications

Presents the main data and specifications for different alternator models.

Troubleshooting

Hard Starting

Troubleshooting guide for diagnosing and resolving issues related to hard engine starting.

Unstable Low Idling

Troubleshooting guide for diagnosing and resolving issues causing unstable or low engine idling.

Insufficient Power

Troubleshooting guide for diagnosing and resolving issues related to reduced engine power output.

Excessive Fuel Consumption

Troubleshooting guide for diagnosing and resolving issues causing high fuel consumption.

Excessive Oil Consumption

Troubleshooting guide for diagnosing and resolving issues related to excessive engine oil consumption.

Overheating

Troubleshooting guide for diagnosing and resolving engine overheating problems.

White Exhaust Smoke

Diagnoses causes and provides remedies for white smoke emitted from the engine exhaust.

Dark Exhaust Smoke

Diagnoses causes and provides remedies for dark smoke emitted from the engine exhaust.

Oil Pressure Does Not Rise

Troubleshooting guide for diagnosing why engine oil pressure is not rising.

Abnormal Engine Noise

Diagnoses causes and provides remedies for abnormal noises produced by the engine.

Special Tools List

Special Tool List

Lists specialized tools required for engine maintenance and repair procedures.

Conversion Table

Length Conversion

Provides conversion factors for length measurements between different units.

Metric to Imperial Conversion

Facilitates conversion of measurements from metric to imperial units and vice versa.

Distance Conversion

Offers conversion tables for distances between kilometers and miles.

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