Isuzu 4BD1 - Injection Pump with Injection Pump Gear; Flange Mounted Injection Pump Removal; Coupling Mounted Injection Pump Removal; Remove of the Air Compressor (if Equipped)

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Table of Contents2
General Information3
General Repair Instructions4
Symbols Used in the Manual6
Main Data and Specifications8
Design Features and General Outline11
Main Engine Parts and Their Function11
Cylinder Head11
Cylinder Body12
Crankshaft12
Pistons13
Valve Mechanism13
Tightening Torque Specifications14
Angular Nut and Bolt Tightening Method15
Major Part Fixing Nuts and Bolts17
Cylinder Head and Cover17
Cylinder Body Diagram18
Oil Pan and Dipstick Diagram19
Camshaft and Rocker Arm Diagram20
Crankshaft, Piston and Flywheel Diagram21
Thermostat and Thermostat Housing Diagram22
Intake and Exhaust Manifold Diagram23
Timing Gear Case and Flywheel Housing Diagram24
Oil Cooler, Oil Filter, and Oil Pump Diagram25
Fuel System Diagram26
Turbocharger Diagram27
Identifications28
Engine Serial Number28
Injection Pump Number28
Maintenance29
Lubricating System Maintenance30
Main Oil Filter Replacement30
Center Bolt Type Removal/Installation30
Cartridge (Spin-On) Type Removal/Installation30
Fuel System Maintenance31
Fuel Filter Replacement31
Injection Nozzle Maintenance32
Spray Condition Check (During Injection Nozzle Tester Operation)33
Water Separator (Water Sedimentor) Check34
Air Bleeding Check34
Cooling System Maintenance35
Valve Clearance and Adjustment35
Cooling Fan Drive Belt Adjustment35
Thermostat Inspection35
Injection Timing37
Flange Mounted Injection Pump Injection Timing Checking and Adjustment37
Injection Timing Checking Procedure38
Coupling Driven Injection Pump Timing Adjustment41
Compression Pressure Measurement43
Turbocharger Inspection44
Engine Repair-Kit (for Non-Turbocharged Engines) Diagram45
Engine Repair Kit (for Turbocharged Engines) Diagram46
Recommended Lubricants47
Engine Oil Viscosity Chart47
Engine Assembly I (Disassembly)49
External Parts Disassembly Steps50
Model 6BD1T Right Side View/Disassembly Steps50
Model 4BD1T View/Disassembly Steps51
Injection Pump with Injection Pump Gear52
Flange Mounted Injection Pump Removal52
Coupling Mounted Injection Pump Removal52
Remove of the Air Compressor (if Equipped)52
Model 6BD1T Left Side View/Disassembly Steps53
Model 4BD1T Left Side View/Disassembly Steps54
Major Components/Disassembly Steps55
Rocker Arm Shaft56
Cylinder Head Bolts56
Crankshaft Pulley Nut56
Taper Bushing (6B Series Only)57
Flywheel57
Major Components II/Disassembly Steps58
Idler Gear59
Cam Shaft59
Crankshaft Bearing Cap59
Rocker Arm and Rocker Arm Shaft View/Disassembly Steps60
Cylinder Head View/Disassembly Steps61
Split Collar Removal61
Piston and Connecting Rod View/Disassembly Steps62
Piston Rings Removal63
Snap Ring and Piston Pin Removal63
Engine Assembly II (Inspection and Repair)65
Cylinder Head Lower Face Warpage Check66
Water Jacket Water Pressure Test66
Valve Stem and Valve Guide Clearance67
Valve Guide Replacement/Removal67
Valve Depression68
Valve Contact Width68
Valve Seat Insert Replacement/Removal68
Valve Seat Installation69
Valve Seat Insert Correction69
Valve Spring Free Length Measurement70
Valve Spring Inclination71
Valve Spring Tension71
Tappet (Cam Follower or Valve Lifter) Inspection71
Push Rod Inspection72
Rocker Arm Correction72
Rocker Arm Shaft and Rocker Arm Inspection72
Rocker Arm Shaft Outside Diameter Measurement72
Idler Gear and Idler Gear Shaft Inspection73
Rocker Arm Shaft and Rocker Arm Clearance Check73
Camshaft Inspection74
Cylinder Liner Bore Measurement75
Cylinder Liner Projection Inspection76
Cylinder Liner Replacement76
Cylinder Bore Measurement77
Cylinder Liner Grade Selection77
Cylinder Body Inside Diameter Measurement77
Cylinder Liner Outside Diameter Measurement78
Cylinder Bore and Cylinder Liner Outside Diameter Combinations78
Cylinder Liner Installation79
Piston Grade Selection79
Cylinder Liner Bore Measurement/Piston Outside Diameter80
Cylinder Liner Bore and Piston Clearance81
Piston Ring and Piston Ring Groove Clearance82
Piston Ring and Piston Groove Clearance82
Piston Ring Gap82
Piston Pin Outside Diameter83
Piston Pin and Piston Clearance83
Piston Pin and Piston Pin Hole Clearance83
Connecting Rod Alignment84
Piston Pin and Connecting Rod Small End Bushing Clearance84
Connecting Rod Bushing Replacement84
Connecting Rod Bearing Inspection85
Crankshaft and Bearing Inspection86
Crankshaft Journal and Crankpin Outside Diameter86
Crankshaft Journal and Bearing Clearances87
Crankshaft Journal Bearing Inside Diameter88
Connecting Rod Bearing Inside Diameter88
Crankshaft Run-Out89
Main Bearing and Connecting Rod Bearing Tension89
Crankshaft Regrinding89
Crankshaft Regrinding Procedure90
Crankshaft Grinding Limit90
Plastigage Clearance Measurement91
Crankshaft Journal Bearing Clearance91
Crankshaft Pin Bearing Clearance92
Crankshaft Tufftriding Inspection92
Oil Seal Wear Ring Replacement (6BD1T, 6BG1, 6BG1T)93
Crankshaft Gear Inspection93
Crankshaft Gear Replacement94
Flywheel and Flywheel Housing (Rear Oil Seal) Inspection94
Rear Gear Inspection/Replacement/Installation94
Flywheel Housing Oil Seal Replacement94
Timing Gear Case Cover Inspection95
Crankshaft Front Oil Seal Replacement95
Engine Assembly III (Reassembly)97
Piston and Connecting Rod Reassembly Steps - Minor Component98
Pistons Heating/ Connecting Rod Installation99
Piston Pin Snap Ring Installation99
Piston Ring Installation99
Connecting Rod Bearing Installation99
Cylinder Head Reassembly Steps100
Valve Stem Oil Seal Installation101
Intake and Exhaust Valves Installation101
Intake and Exhaust Valve Springs Installation101
Spring Seat Split Collar Installation101
Intake Manifold and Gasket Installation102
Exhaust Manifold and Gasket Installation102
Rocker Arm and Rocker Arm Shaft Reassembly Steps104
Major Component Reassembly Steps I105
Oil Jet Installation106
Crankshaft Bearing Configuration106
Crankshaft Installation106
Thrust Bearing Installation106
Crankshaft Bearing Cap Installation107
Timing Gear Case Installation107
Camshaft/Thrust Plate Bolts Tightening107
Idler Gear Shaft Installation107
Idler Gear Installation108
Piston and Connecting Rod Installation108
Oil Pump and Coupling Installation109
Flywheel Housing Installation109
Oil Pan Installation110
Oil Cooler Installation110
Major Component Reassembly Steps II111
Flywheel Installation112
Injection Pump and Injection Pump Gear Assembly112
Air Compressor Installation112
Tappet Chamber Cover Installation113
Water Pump Installation113
Cylinder Head Gasket/Bolt Installation113
Rocker Arm and Rocker Arm Shaft Installation115
External Parts Reassembly Steps (Left-Hand Side)116
Cylinder Head Cover Installation117
Fan Belt Adjustment117
Starter Motor Installation117
Turbocharger Mounting Flange Gasket Positioning118
Turbocharger Nuts Tightening118
Oil Drain Pipe Installation118
Oil Feed Pipe Installation119
Turbo Adaptor Tightening119
External Parts Reassembly Steps (Right-Hand Side) - Model 6BD1T120
Injection Nozzle Installation121
Fuel Injection Pipe and Fuel Leak off Pipe Installation121
Oil Filter Installation121
Fuel Pipe, Fuel Return Pipe, Intake Pipe Installation122
Injection Timing Adjustment122
Engine Tuning Operation123
Engine Sectional View125
Lubricating System127
Lubricating System - General Description128
Oil Pump Disassembly129
Oil Pump Drive Gear Inspection130
Oil Pump Driven Gear Inspection130
Main Oil Filter Disassembly/Inspection and Repair131
Lubricating System Reassembly132
Center Bolt and Drain Plug Installation132
Oil Cooler Disassembly, Inspection and Repair133
Lubricating System Reassembly Steps134
Oil Cooler Element Installation134
Cooling System135
Cooling System - General Description136
Water Pump Disassembly Steps137
Impeller/Pulley Center/Snap Ring Removal138
Spindle, Bearing, Spacer/Seal Unit, Washer and Seal Removal138
Bearing Replacement139
Cooling System Reassembly Steps140
Spindle, Bearing, and Spacer Installation141
Snap Ring/Pulley Center Installation141
Seal Unit, Washer and Seal Installation141
Impeller/Pulley Installaton142
Thermostat Inspection and Repair142
Fuel System143
Fuel System - General Description144
Fuel Filter Disassembly/Inspection and Repair145
Injection Nozzle Disassembly147
Push Rod Spring Check148
Nozzle Holder Push Rod Check148
Injection Nozzle Check148
Fuel Filter Reassembly Steps149
Injection Pipe Connector/Injection Nozzle/Retaining Nut Check150
Injection Starting Pressure Adjustment150
Nozzle Holder Cap Nut Check151
Injection Pump Calibration Data152
Identification Plate and Product Serial Number152
Test Conditions Required for the Fuel Injection Amount Adjustment152
Inj. Pump Calibration Data153
Governor Adjustment154
Turbocharger155
Turbocharger - General Description156
Turbocharger Identification157
Rotor Shaft Play Inspection158
Rotor Shaft Axial Play Measurement158
Air Compressor159
Air Compressor Sectional View/Main Data160
Air Compressor Disassembly Steps161
Air Compressor Inspection and Repair162
Air Compressor Reassembly Steps164
Connecting Rod/Bearing Cover Installation165
Cylinder Body/Cylinder Head Installation165
Engine Electricals167
Starter Motor Identification168
Nikko Identification Plate168
Hitachi Identification Plate168
Starter Motor Main Data and Specifications169
Starter Motor Sectional View171
Starter Motor Exploded View172
Alternator Identification173
Alternator Main Data and Specifications174
Regulator Main Data and Specifications176
Alternator Sectional View177
Alternator Exploded View178
Troubleshooting179
Hard Starting180
Starter Inoperative180
Starter Motor Operates but Engine Does Not Turn over181
Engine Turns over but Does Not Start, Fuel Is Being Delivered to the Injection Pump182
Engine Turns over but Does Not Start183
Unstable Low Idling184
Unsufficient Power187
Excessive Fuel Consumption190
Overheating193
White Exhaust Smoke195
Dark Exhaust Smoke196
Oil Pressure Does Not Rise197
Abnormal Engine Noise199
Engine Knocking199
Gas Leakage Noise199
Continuous Noise200
Slapping Noise201
Special Tool List203
Conversion Table207
Length Conversion Table207
Area Conversion Table209
Volume Conversion Table209
Mass Conversion Table211
Pressure Conversion Table212
Torque Conversion Table213
Temperature Conversion Table214

Isuzu 4BD1 - Injection Pump with Injection Pump Gear; Flange Mounted Injection Pump Removal; Coupling Mounted Injection Pump Removal; Remove of the Air Compressor (if Equipped)

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