1993 Isuzu NPR GMC W4 Chevy 4000 4BD2-T Diesel Engine Manual Isuzu 4BD2-T Engine 6A Cooling System 6B Fuel System 6C Engine Electrical 6D Exhaust 6FENGINE 6A-1 SECTION 6 ENGINE CONTENTS Diesel Fuel injection. Engine Electrical Exhaust. SECTION 6A ENGINE NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. if a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. CONTENTS SUBJEC" Engine Replacement. Rear Engine Mount Replacement Exhaust Brake System Description Operation Diagnosis of Exhaust Brake Exhaust Brake On-Vehicle Service ‘Component Locations. Magnetic Valve Replacem ‘Vacuum Chamber Replacement... Exhaust Brake Valve Replacement .. Accelerator Switch Replacement...6A-2 ENGINE Clutch Switch Replaceme! ENGINE REPLACEMENT [5] Remove or Disconnect (Figures 1-13) 1. Battery negative cable (1) at the battery (figure 1). Main feed wire (5) at the starter solenoid (figure 2), 2. Cooling system drain valve on the bottom rear of the radiator. 3. Engine oil at the oil pan plug. 4. Heater hoses at the water pump and thermostat housing. Refer to COOLING SYSTEM (SEC. 681) in this manual. 5. Air conditioning condenser mounts. Do not disconnect the hoses from the condenser. Secure the condenser forward of the radiator. 6. Air intake pipe (6) with connecting hose (7) from the turbocharger and the air cleaner (figure 3).. [0] important + Tape the inlet opening of the turbocharger to prevent entry of foreign material 1. Battery Negative Cable 2. Battery Positive Cable Figure 1. Battery Cable Identification 3, Battery Cable 4, Solenoid Wire 5. Main Feed Wire 6. Air Intake Pipe 7. Connecting Hose Figure 3, Air intake Pipe to Turbocharger Attachement 7. Air inlet pipe (9) with connecting hoses (10) and (11) from the turbocharger (8) and charge air cooler (12) (figure 4). 8. Air inlet pipe (13) with connecting hose (14) from the intake manifold and the charge air cooler (12) (figure 5). 9. Charge air cooler assembly (12) from the radiator. 10. Automatic transmission cooler tines fromENGINE 6A-3 radiator and transmission (A/T only). Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 11. Heater hoses from the water pump and the thermostat housing. Refer to COOLING SYSTEM (SEC. 6B1). 12. Fan and fan olutch from the fan clutch plate. Refer to FAN (SEC. 683). 13. Radiator hoses from the radiator. Radiator and shroud. Refer to RADIATOR (SEC. 6B2). 14. Air conditioning compressor, generator and water pump belts. Refer to AIR CONDITIONING. (SEC. 1B), COOLING SYSTEM (SEC. 6B1) and ENGINE ELECTRICAL (SEC. 6D) in this manual 45. Fuel lines at the frame near the injection pump. Refer to FUEL SYSTEM (SEC. 6C1). 113. Air Inlet Pipe 114. Connecting Hose 8. Turbocharger 9. Air Inlet Pipe 10. Connecting Hose 11. Connecting Hose 12. Charge Air Cooler Figure 4, Air intel Pipe Attachment 16. Fuel shutoff cable at the injection pump and at the support bracket. Refer to DIESEL FUEL INJECTION (SEC. 6C3). 17. Electrical wires at the oil pressure and engine coolant temperature sending units. Reefer to ENGINE ELECTRICAL (SEC. 6D). 18. Vacuum hoses (16) at the vacuum pump (15) (figure 6). 19. Generator output wire (19) from the generator (18) (figure 7). 20. Generator adjusting bracket (17) (figure 6). Figure 5. Intake Manifold Pipe Attachment 45. Vacuum Pump 16. Vacuum Hose 17. Generator Adjusting Bracket Figure 6. Vacuum Hose Attachment at Vacuum, Pump: 21. Generator (18) and air conditioning compressor (20) as a unit. Do not remove the hoses from the compressor (figure 8). 22. Power steering hoses from the power steering pump. Refer to POWER STEERING (SEC. 383).6A-4 ENGINE 18. Generator 19. Generator Output Wire Figure 7. Wiring at Generator 48. Generator 21 20. AIC Compressor 21. Lett Frame Rail Figure 8. Generator and Air Conditioner (AC) Compressor Removed 23, Shift and select cables from transmission, Refer to AUTOMATIC TRANSMISSION (SEC. 7A) or MANUAL TRANSMISSION (SEC. 78). 24. Clutch slave cylinder. Refer to CLUTCH (SEC.7C). 25. Exhaust brake unit assembly (22) (figure 9). 26. Front exhaust pipe (23) {figure 10). 27. Electrical wiring hamess and connectors. 28. Speedometer cable from transmission. 29. Propeller shaft and parking brake assembly. Refer to MANUAL TRANSMISSION (SEC. 78). 30. Engine mount insulator (24) to engine mount bracket nuts (figure 11). 81. Transmission to frame crossmember side supports (30) (figure 12). 32, Raise the transmission with a jack and remove the clutch housing to transmission bolts. 38, Attach a sling (34) and hoist to the engine assembly (35) (figure 13). 34, Engine by raising front, pulling forward, then turning the engine 90 degrees. MANUAL TRANSMISSION, 22 20. Vacuum Chamber 22. Exhaust Brake Unit Assembly 23, Front Exhaust Pipe Figure 9. Exhaust Brake Installed 23. Front Exhaust P Figure 10. Exhaust Pipe AttachmentENGINE 6A-5 24, Engine Mount Insulator 25. Support 26. Engine Mount Bracket 27. Lower Mount 30 SF Flat Low Model A/T 3 Al 28, Crossmember 29, Engine Mount Insulators 30. Side Supports 31. Upper Mount Assembly 32, Transmission Cover 33, Bracket Figure 12. Transmission Mount6A-6 ENGINE 34. Engine Lifting Swing 35. Engine Assembly Figure 13. Lifting Sting on Engine Be Instat! or Connect (Figures 1-13) NOTICE: See “NOTICE” on page 6A-1 of this, section for steps 7, 8, 9 and 10. 1. Clutch pressure plate assembly and clutch driven plate. Refer to CLUTCH (SEC. 70). 2, Sling (34) and hoist to the engine (35) (figure 13). 3. Support and raise the transmission with a jack. 4. Position and aiign the engine and the transmission input shaft. Keep the flywheel housing and clutch housing parallel with one another. Mate the flywheel and clutch housings. Fabricated pilot studs may help to maintain alignment while connecting the housing. 6. Flywheel to clutch housing bolts except the clutch slave cylinder, wiring hamess bracket, and exhaust brake bracket bolts. Do not torque the bolts yet. 7. Engine mount insulator (29) to the engine mount bracket (31) (figure 11) + Itmay be necessary to loosen the engine mounts from the frame to align the stud to bracket holes. Tighten * The mount insulator nuts to 75 N-m (55 lb-ft). 5. 8. Transmission mount. EX] rigtten * The mount to transmission cover nuts to 69 ‘Nem (51 Ib-ft). 9. Position the clutch slave cylinder, the wiring hamess bracket, and the exhaust brake bracket ‘onto the flywheel to clutch flange. Then install the bolts. Tighten ‘+ Flywheel housing to clutch housing bolts to 81 Nem (60 Ib-ft) 10. Shift and select cable bracket onto the clutch housing. Ei Totten * Bracket bolts to 81 N-m (60 Ib-ft). 11. Parking brake assembly and propeller shaft. Refer to MANUAL TRANSMISSION (SEC. 78). 12. Speedometer cable to the transmission. 18. Power steering hoses and brackets onto the power steering pump. Refer to POWER, STEERING (SEC. 383). 14, Generator and air conditioning compressor onto the cylinder block. 15, Generator adjusting bracket (17) (figure 6). 16. Generator output wire (19) to the generator (18) (figure 7). 17. Vacuum hose (16) to the vacuum pump (15) {figure 6). 18. Electrical wiring harness and connectors. 19. Fuel shutoff cable onto the injection pump. ‘Secure their support brackets. Refer to DIESEL FUEL INJECTION (SEC. 6C3). 20. Fuel lines at the vehicle frame near the injection pump. Refer to FUEL SYSTEM (SEC. 6C’). 21. Generator, water pump and air conditioning compressor belts. Refer to AIR CONDITIONING. (SEC. 1B), COOLING SYSTEM (SEC. 6B1) and ENGINE ELECTRICAL (SEC. 6D). 22 Radiator, tan shroud and radiator hoses. Refer to RADIATOR (SEC. 682). 23. Fan clutch and fan to the fan clutch plate. Refer to FAN (SEC. 683). 24, Automatic transmission (A/T) cooler lines to the radiator and the transmission (A/T only). Refer to AUTOMATIC TRANSMISSION (SEC. 7A). 25, Front exhaust pipe (23) and exhaust brake unit assembly (22) (figures 9 and 10). 26. Charge air cooler assembly (12) to the radiator. 27. New gasket and the air inlet pipe (18) with connecting hose (14) (figure 5), 28. Air inlet pipe (9) with connecting hoses (10) and (11) to the charge air cooler (12) and turbocharger (8) (figure 4). 29. Air intake pipe (6) with connecting hose (7) (figure 3). 30. Heater hoses at the water pump and thermostat housing. Refer to COOLING SYSTEM (SEC. 681).ENGINE 6A-7 31. Be sure the oil pan plug is tight. install 11.2 {iters (3 gal) of engine oil. The SAE weight will depend on the ambient temperature. Refer to MAINTENANCE AND LUBRICATION (SEC. 0B). 82. Close the radiator drain vaive. Fill the cooling system as described in COOLING SYSTEM (SEC. 681). 33. Connect the main feed wire (5) at the starter, and the battery negative cable (1), at the battery (figures 1 and 2). 34. Check the automatic transmission fluid level and replenish as necessary (Automatic transmission only). Refer to AUTOMATIC TRANSMISSION (SEC. 7A). ENGINE MOUNTINGS DESCRIPTION Cushion-type mountings are used at both the front and rear of the engine on all vehicles covered in this manual. (*Front” refers to the end of engine ‘opposite the flywheel.) Engine mountings are illustrated in figures 11 and 12. MAINTENANCE Engine mountings should be inspected periodically and if found damaged or deteriorated they should be replaced. ‘Check the engine mount brackets for cracks or ‘elongated bolt holes. Replace the brackets if necessary. Check the mounting fasteners for the correct torque. Inspect the rubber parts for deterioration and replace if necessary. NOTICE: Broken of deteriorated mounts can cause misalignment and eventual destruction of certain drive train components. Ifa single mounting is misaligned, damaged, or broken, the remaining mountings are subjected to abnormally high stresses. This may cause breakage or damage to the remaining mountings. FRONT ENGINE MOUNT REPLACEMENT [Remove or Disconnect (Figure 11) NOTICE: When supporting the engine to replace a mount, raise the engine only to height required to provide clearance for mounting removal, Be careful that contro! raising the engine. When replacing a single front mounting, both mountings should be detached before attempting to raise the engine, Failure to do this will place excessive stress on the attached mounting when the engine is raised. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal or crankshaft pulley. Due to the small clearance between the oil pan and the oll pump screen, jacking against the oil pan may cause it to be damaged or bent against the pump screen, resulting in a damaged oil pickup unit. 1. Engine mount bracket (26) attached to cylinder block. 2. Nuts and bolts holding lower mount (27) to frame mount bracket. 3. Engine mount insulator (24) to engine mount bracket nut. 4, Frame bracket to frame nuts and bolts (if necessary.) 5. Engine mount insulator (24) to lower mount (27) nuts and bolts. Ee instatt or connect (Figure 11) NOTICE: See “NOTICE” on page 6A-1 of this section for steps 2 and 5. 4, Lower mount (27) to the engine mount insulator (24). 2. Frame bracket to frame nuts and bolts (it removed). Tighten + Frame nuts and bolts to 38 N-m (28 Ib-tt). 3. Engine mount bracket (26) to the cylinder block. 4. Engine mount insulator (24) and the lower mount assembly (27) to the engine mount bracket (26) with the nut and washer. 5, Lower mount (27) to the frame bracket nuts and bolts. El totter ‘« Frame bracket nuts and bolts to 38 N-m (28 ott).6A-8 ENGINE REAR ENGINE MOUNT REPLACEMENT [3 Remove or Disconnect (Figure 12) NOTICE: When supporting the engine to replace a mount, raise the engine only to height required to provide clearance for mounting removal. Be careful that control finkage and wiring are not damaged from raising the engine. When replacing a single mounting, both mountings should be detached betore ipting to raise the engine. Failure to do this will place excessive stress on the attached mounting when the engine is raised. NOTICE: When raising or supporting the engine for any reason, do not use a jack under the oll pan, any sheet metal or crankshaft pulley. Due to the small clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause it to be damaged or bent against the pump screen, resulting in a damaged oil pickup unit. + Suppor the transmission with a transmission or Jack. The transmission mount is also the rear engine mount. 1. Side supports (30) to crossmember (28), nuts and washers. 2. Transmission cover (32) to upper mount (31) nuts, and washers. 8, Lower the transmission slightly and remove the mount assembly. 4, Nuts and washers and the insulators (29) from ‘the upper mount (31). [FX] instatt or Connect (Figure 12) NOTICE: See “NOTICE” on page 6A-1 of this section for steps 2 and 3. ‘+ Support the transmission with a transmission or garage jack 1, Engine mount insulators (29) to the upper mount assembly (31). 2. Upper mount assembly (31) onto the transmission cover (32). Tighten * Transmission cover nuts to 69 N-m (51 Ib-ft). 3, Raise the transmission and install the side supports (30) onto the frame crossmember (28). Remove the jack. Tighten ‘+ Side support nuts to 41 N.m(30 lb-ft) EXHAUST BRAKE SYSTEM DESCRIPTION ‘The exhaust brake system, when tumed on, in- creases the amount of power absorbed by the engine while coasting with the clutch engaged {figure 14). The main components of the system are: 1. The exhaust brake valve (17). This valve resembles the manifold heat valve used in many gasoline engines. 2, The vacuum chamber (16). 3. The magnetic valve (13), which is an electric solenoid actuated valve. 4, The control switches (6, 10, 11 and 12). 5. The relays (5 and 9). OPERATION Exhaust Brake Refer to figure 14. 1. When the engine starts, the generator turns the charge relay (3) on, which causes the exhaust brake relay (5) to go on via fuse No. 19. 2, When the exhaust brake switch (6) is tuned on, electricity flows via the diode (8) to the exhaust brake control relay (9) and lights the indicator light (7) at the same time. 8. The exhaust brake control relay (9) goes on when the neutral switch (Manual transmission=M/7) or the inhibitor switch (Automatic transmission=A/T) (10) is off (when MIT is in a position other than neutral and AT is in a position other than P or N). 4, When the exhaust brake control relay (9) goes ‘on, a working current flows via the clutch switch (11) and the accelerator switch (12) to the magnetic valve (13), 5. Both the clutch switch (11) and accelerator switch (12) are normally closed. When both clutch and accelerator pedals are in the released position (engine at idle/clutch fully engaged), current flows to the magnetic valve (13). 6. When energized, the magnetic valve (13) ‘opens, allowing vacuum to flow from vacuum pump (14) and tank (15) to the vacuumchamber (16). 7.When supplied with a vacuum source, the vacuum chamber (16) pulls the exhaust brake valve (17) shut. With the engine brake valve shut, exhaust pressure allows the engine to become a more effective brake. 8. If the clutch or accelerator pedal depressed, the clutch switch (11) or accelerator switch (12) ‘opens, or neutral/inhibitor switch (10) is ON, the ‘exhaust brake control relay (9) opens, the power supply to the magnetic valve (13) is interrupted. The magnetic valve close, removing vacuum from the vacuum chamber (16). The vacuum chamber spring then pushes the exhaust brake valve (17) back open. Normal engine operation resumes. ‘The exhaust brake valve is also used to warm up the engine. Automatic Engine Warm-up When the engine coolant temperature is below 40°C (104°F) when the engine is started, a working current is supplied by the QOSIII controller to the upperstream of the accelerator switch (12). But all ENGINE 6A-9 other conditions than the accelerator switch (12) remain unchanged. Therefore, the magnetic valve (13) is turned on and activates the exhaust brake valve (17) to promote the engine warm-up. ‘When the engine coolant temperature rises above the 40°C (104°F) level, the QOSIII controller automatically deactivates the engine warm-up function. Manual Engine Warm-up When the engine warming-up switch (19) goes on with the engine coolant temperature below 70°C (158°R) and the key switch (18) turned on, the Indicator light built into the switch lights up and the ‘engine warming cut relay (20) goes on at the same time. This causes electricity to flow to the magnetic valve (13) and activates the exhaust brake valve (17) to promote the engine warm-up. When the engine coolant temperature rises above the 70°C (158°F) level, the thermo switch (21) and the engine warming cut relay (20) go off simultaneously. The engine warm-up function is ended as a result.6A-10 ENGINE Starter. Relay Coit 1. Batteries 9. Exhaust Brake Control Relay 16. Vacuum Chamber 2. Fusible Link Wire 10. Neutral switch (MT) 17. To Exhaust Brake Valve 3. Charge Relay Inhibitor Switch (A/T) 18. Key Switch 4. Fuse 11. Clutch Switch (M/T only) 19. Engine Warming Switch 5. Exhaust Brake Relay 42. Accelerator Switch 20. Engine Warming Cut Relay 6. Exhaust Brake Switch 18. Magnetic Valve 21. Thermo Switch 7. Indicator Light 14. Vacuum Pump 8 Diode 18. Vacuum Tank ATT: Automatic Transmission MIT: Manual Transmission Figure 14. Exhaust Brake and Engine Warm-up ControlsENGINE 6A-11 DIAGNOSIS OF EXHAUST BRAKE PROBLEM POSSIBLE CAUSE CORRECTION Exhaust Brake does not | 1. Blown fuse. 1. Reploe. Operate 2. improperly adjusted or faulty 2. Adjust or replace. accelerator or clutch switches. 3. Poor connections or corroded 3. Clean or replace. terminals at switches or control valve. 4, Improperly adjusted or seized 4, Adjust, or repair. exhaust brake valve, 5. Vacuum lines kinked, restricted, or | 5. Repair. plugged with ice. 6. Seized vacuum chamber. 6. Repair. 7. Valve linkage broken. 7. Repair 8 Chamber or control valve jammed 8. Melt ice, Darin lines of water. with ioe. 9. Faulty control valve. Valve should 9. Replace. ‘open when 12 volts is applied to terminals. 10. Faulty vacuum chamber. 10. Replace. 11. Broken wire in wiring hemes. 11. Repair. Exhaust Brake Slow to 1. Tighten exhaust brake valve or 1. Free up and lubricate. Operate linkage. 2. Improperly adjusted accelerator or 2. Adjust. clutch switches. Weak Braking Action 1. Improperly adjusted or tight exhaust | 1, Free up and/or adjust. Lubricate brake valve. as needed. 2. Tight linkage. 2. Free up and lubricate. 3. Vacuum lines kinked or partially 8, Repair. plugged with ice. | 4. Leaking fitings at vacuum lines. 4. Tighten. | 5. Leaky vacuum chamber. 5. Replace. Exhaust Brake will not 1. Seized exhaust brake valve or 1, Free up and lubricate, ‘Shut Off (Exhaust Brake linkage. Control Switch “Off") 2. Control valve or chamber jammed 2. Melt ice and drain lines. with ice. 3, Short in wiring harness (12 volts at | 9. Repair. control solenoid regardless of control switch position). 4, Faulty control switch, 4, Replace. Exhaust Brake “On” 1. Improperly adjusted clutch or 1. Adjust. Continuously when accelerator switches. Exhaust Brake Control | 2. Switches improperly wired. 2. Check wiring against witing ‘Switch is “On” (not diagram. Repair as needed. Controlled by Clutch or | 3. Short in wiring hamess. 3, Repair. Accelerator Switches) Engine Overheats or 1. Engine brake valve stuck partially 1. Free up and lubricate or replace. Loses Power closed 2. Engine brake valve adjusted so that | 2. Adjust. itis partially closed.6A-12 ENGINE EXHAUST BRAKE ON-VEHICLE SERVICE COMPONENT LOCATIONS: Refer to figures 15, 16, 17, 18 and 19. * The exhaust brake valve (11), vacuum chamber (10) and related components are located at the left rear of the engine (figure 15). ‘© The magnetic control valve (9) is located inside the left frame rail, rear of the battery box (88) (figure 16). ‘« Tho accelerator switch (6) is located on a bracket above the accelerator pedal (99) (figure 17). ‘+ The clutch switch (7) is located above the clutch pedal (62) (figure 18). For wire color information, refer to WIRING DIAGRAMS (SEC. 8F) in this manual. MAGNETIC VALVE REPLACEMENT [5] Remove or Disconnect (Figure 18) 41, Magnetic valve wires (113). 2. Vacuum lines (114). 8. Bolts, nuts and washers. 4, Magnetic valve (9). eq] tnstalt or Connect (Figure 19) 1. Magnetic valve (9) to frame rail (116). 2. Bolts, washers and nuts. 3. Vacuum lines (114). 4, Magnetic valve wires (113). VACUUM CHAMBER REPLACEMENT This procedure is described under “Exhaust Brake Valve Replacement’. EXHAUST BRAKE VALVE REPLACEMENT [5] Remove or Disconnect (Figures 9, 10 and 15) 1. Separate front exhaust pipe (21) from rear ‘exhaust pipe (53). Reter to EXHAUST (SEC. 6F) 2. Vacuum hose (A) from vacuum chamber (20). 8, Exhaust brake valve and vacuum chamber assembly. 4. Cotter pin, clevis pin and vacuum chamber from valve assembly. 5. Valve assembly from bracket. Repiace the valve assembly as a unit only. * Ifthe exhaust brake valve exhibits wear or damage, it must be replaced as a unit. + Apply penetrating oil to the valve shaft and bushings if the shaft appears sticky. LE] portant ‘+ Do not disturb the setting of the stop bolt. It is factory preadjusted. MANUAL TRANSMISSION 10. Vacuum Chamber 11, Exhaust Brake Valve 21. Front Exhaust Pipe 52. Manifold to Outlet Pipe Nut 53, Rear Exhaust Pipe ‘A. Vacuum Hose and Clamp J AUTOMATIC ‘TRANSMISSION 7838 Figure 15. Engine Brake ValveEq Instat or Connect (Figures 9, 10 and 15) 1. Nuts, clevis and pin to connect vacuum chamber to exhaust brake valve assembly. 2. Exhaust brake unit assembly using new gaskets between the exhaust pipes (figure 9). Tighten + Exhaust nuts to 17 N-m (12 Ibs). 3. Vacuum hose and clamp to the vacuum chamber (20). Overlap the hose on the fitting 30 mm (1.2 in) (figure 9). 9. Magnetic Control Valve 88. Battery Box ENGINE 6A-13 Figure 16. Exhaust Brake Control Valve Location ACCELERATOR SWITCH REPLACEMENT [6 Remove or Disconnect (Figures 17 and 20) 1. Battery negative cable. 2. Connector at accelerator switch (5). 3. Screw. 4, Accelerator switch (5). [eX instant or Connect (Figures 17 and 20) To install follow the removal step in reverse order. 6, Accelerator Switch 98. Accelerator Pedal Assembly Figure 17. Accelerator Switch 7. Clutch Pedal Switch 62. Clutch Pedal Assembly Figure 18. Clutch Pedal Switch6A-14 ENGINE CLUTCH SWITCH REPLACEMENT [iy] Remove or Disconnect (Figures 18 and 20) 1. Battery negative cable. 2. Switch wires, 3. Front switch nut (201) (figure 20). 4. Clutch switch (7) (figure 18). fe] insta or Connect (Figures 18 and 20) 41. Rear switch nut (211) on clutch switch (figure 20). 2, Clutch switch to bracket. 8. Front switch nut (201). Do not tighten. Py adiust The clutch switch must be adjusted so that when the clutch pedal is released, it closes the switch but does not completely depress the switch plunger. If the plunger is completely depressed by the pedal, switch damage may 9. Magnetic Valve result. 88, Battery Box + Fully depress the switch plunger. 113. Magnetic Valve Wires + Adjust the switch in its bracket until 0.5 to 1 144, Vacuum Lines mm (0.02 to 0.04 in) clearance exists between 116. Frame Rail the fully depressed switch plunger and the contact area on the clutch lever (dimension Figure 19. Exhaust Brake Control Valve 19) (figure 20). + The switch should exhibit an open circuit (no continuity) when the accelerator pedal is depressed approximately 0.75 mm (0.03 in). The test may be made with a test light or an ohmmeter connected to the switch plug connector. 19 I | Ol 18 palieaaaia 47.4 mm (0.18 in) 17 18. 2.0 02.8 mm (0.07 t0 0.11 in) F 49. 0.5to 1 mm (0.02 to 0.04 in) Max. Stroke 201. Front Nut 201 211 211. Rear Nut F. Clutch Pedal Lever G. Clutch Switch Figure 20. Servicing Clutch SwitchENGINE 6A-15 4, Wires at the clutch switch. Tighten 5. Battery negative cable. ‘+ The switch nuts to 18 N-m (13 Ib-f). Connect the switch wires. SPECIFICATIONS FASTENER TORQUES LA1 Nem (30 thet) swneBB Nem (28 Ib) -75 N-m (55 lb-ft) “69 Nem (51 lb-ft) “81 Nem (60 It) “AA Nem (80 lb-ft) 47 Nem (12 lb-ft) veve4 Nem (13 Ib-t) Front Engine Mount Bracket to Engine Bolts and Nuts Front Engine Mount to Frame Nuts and Bolts Front Engine Mount to Engine Bracket Nut... Rear Engine Mount to Transmission Nuts Fiywheel Housing to Clutch Housing Bolts Side Support Nuts. Se Exhaust Brake to Exhaust Pipes Nuts Clutch Switch NutISUZU ENGINE 6A6-1 SECTION 6A6 ISUZU ENGINE NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a tastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result. CONTENTS Statement on Cleanliness and Care .BAG- 2 Description Lubrication System. Diagnosis of Isuzu Diesel Engi Engine Will Not Turn Over Engine Turns Over Slowly but Does Not Start.. “6AG- 4 Engine Cranks Normally but Does Not Start. GAG 4 Engine Cranks Normally but is Difficult to Start. BAG: 4 Inconsistent idle Speed (Engine “Lopes”) GAG 4 i GAG 4 see BAG> 4 Engine Misses at All Speeds SAG- § Engine Misses on One Cylinder... GAG- 5 Lack of Power or Performance. GAG. 5 Excessive Exhaust Smoke. “GAG- 5 Engine Fails to Reach Operating Temperature, SAG- 6 Engine Overheats AS 6 Low Oil Pressure.. sn GAG- 6 High Oil Pressure. GAG- 6 Burned, Sticking or Bro} GAG- 6 Excessive Fuel Consumptior wn BAB- 6 GAG 7 Engine Noises AG. 7 Compression Check... SAG- 9 Maintenance 6AG- 9 Valve Adjustment SAG- 9 Turbocharger Maintenance... -6A6-10 Changing the Crankease Oil and Oil 6AG-12 Isuzu Engine On-Vehicle Service -6AG-12 Statement on Cleanliness and Care. ns BAG12, Charge Air Pipe Replacement... -6AC-15 Intake Manifold Replacement ‘GAG-15, ‘Turbocharger Replacement 5A6-15 Exhaust Manifold Replacement .. 6A6-17 Cylinder Head Cover Replacement sn GAC-1B Valve Seal and Components Replacement . GAG-19 Valve Train Component Replacement. SA6-206A6-2 ISUZU ENGINE Glow Plug Replacement Crankcase Breather Replacement... Cylinder Head. Piston, Connecting Rod and Liner.. Vibration Damper Replacement ‘Timing Cover Replacement Oil Pan Replacement Oil PUMP Timing Gear Replacement ‘Camshaft and Bearings. Flywheel Replacement Rear Crankshaft Seal Replacement Flywheel Housing Replacement Crankshaft and Main Bearings. Oil Jet Replacement .. Specifications... Fastener Torques Engine Specifications... Special Tools. GENERAL INFORMATION STATEMENT ON CLEANLINESS AND CARE * An engine is a combination of many machined, honed, polished, and lapped surfaces with very fine tolerances. * Whenever valve train components, cylinder head, cylinder, crankshaft, or connecting rod ‘components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Any time the air cleaner or hose or connection is. removed, the intake opening must be covered. This will protect against the entrance of foreign material which could follow the intake passage into the cylinder and cause extensive damage when the engine is started. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. ‘+ Whenever the fuel injection pump or line are removed or disconnected, care must be taken to prevent the entry of dirt into the pump, lines, and injectors. The entry of even a small amount of dirt ‘or other foreign material into the fuel injection system may cause serious damage. * It should be kept in mind, while working on the engine, that the 12-volt electrical system is capable of violent and damaging short circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. * Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. * Cover or otherwise protect exposed electrical connections to prevent damage from oll and fuel. + When raising or supporting the engine for any reason, do not use a jack under the oil pan. due to the smail clearance between the oil pan and the oil pump screen, jacking against the oil pan may cause it to be bent against the pump screen resulting in a damaged oil pickup unit.ISUZU ENGINE 6A6-3 DESCRIPTION The Isuzu model 4BD2-TC engine is used in vehicles covered by this manual. ‘The engine is an in-line, four-fuel cylinder, four- stroke, water-cooled and in-direct-fuelinjection, turbocharged diese!. The bore is 102 mm (4.02 in); the stroke is 118 mm (4.65 in). The total displacement is 3.856 liter (235.3 cu.in.). The compression ratio is 21: The forged crankshaft is supported by five precision insert main bearings. Crankshaft thrust is taken at the #4 main bearing. ‘The connecting rods have precision insert-type ‘crankpin bushings (tod bearing). The piston pins are retained by snap rings. ‘The pistons have two compression rings and one oll control ring. The pistons are cooled by oil jets. Dry-type liners are used. The liners are chromefaced for long life. ‘The camshaft is supported by three plain bearings. The camshaft is gear driven. Motion is transferred to the overhead valves by flat-aced, cylindrical, solid vaive liters, pushrods, and shaft- type. adjustable rocker arms. ‘The cylinder head is rebuildable, with replaceable valve guides and seats. LUBRICATION SYSTEM A gear-type oil pump is used. The engine is equipped with both full-flow and bypass filters. An oil cooler is provided to help cool oll temperatures. Major moving parts are supplied with oil from @ large oil gallery in the cylinder block. The lubrication schematic is shown in figure 1 ui Pressure Switen 49 KPa si) Fore Kay Switeh re O) © tatey © 127 «Pa4199 pa) ou preseure + ‘natstorUsnt —+[overiow vane wna Fier +[ocoater Syndr Boy 03 Galan, |-—+[ pase Fier ae ens) Tuo lon eure | fwicton |[ simi | neiae chase ve ta | imo” || Geer || oe 860 kre T Goze | oie I ] eter) (Serre on pum jive | | (008m img wai | | Engine Oi pan Figure 1. Lubrication System Schematic6A6-4 ISUZU ENGINE DIAGNOSIS OF ISUZU DIESEL ENGINE ENGINE WILL NOT TURN OVER 4, Dead or weak battery. 2. Loose or Corroded connections in starter circuit. Check battery terminals, starter motor Connections, etc. Faulty starter of solenoid. Faulty or broken wiring or engine control switch. Hydrostatic lock (liquid in combustion chambers). Remove the injectors and check for presence of fluid. 6. Seized pistons, bearings, etc. ENGINE TURNS OVER SLOWLY BUT DOES NOT START wee 1. Weak battery. 2. Corroded or poor connections in starter circuit. Check battery terminals, starter motor connections, etc. 3, Faulty starter motor. 4, Undersized battery or cable. 5. Oil viscosity too heavy. 6. Tight bearings, pistons, ete. ENGINE CRANKS NORMALLY BUT DOES NOT START 1. Fuel tank empty. 2. Engine stopper fuse blown. 3. Check for fuel flow at the injector lines. Loosen all the fuel lines at the fuel injector. Crank the engine and observe the fuel flow. If there is fuel flow, bleed the fines until free of, air bubbles and retighten the fittings. Itthere is no fuel flow: a. Fuel filter clogged. In tow temperature conditions, this may be caused by fuel waxing Replace the filter and bleed the system. Use winter grade fuel if necessary. b. Restricted or kinked fuel lines. Replace, reroute or repair as necessary. c. Fuel lines leaking. Check all fittings and tighten as necessary. d. Transfer (lift) pump faulty. 4. Air filter clogged. 5. Air inlet tube clogged. 6. No compression due to stuck valves, broken pistons, etc. Perform the “Compression Check” later in this section. 7. Engine stopper faulty. 8, Low or no voltage to glow plugs. ENGINE CRANKS NORMALLY BUT IS DIFFICULT TO START 1. Air in the fuel system. Bleed the system as outlined in DIESEL FUEL INJECTION (SEC. 6C3) in this manual. 2, Restricted or insufficient fuel supply. 8, Clogged fue! filter. in low temperature conditions, this may be caused by fuel waxing. Replace the filter and bleed the system as ‘outlined in DIESEL FUEL INJECTION (SEC. 6C3) in this manual. Use winter grade fuel it necessary. INCONSISTENT IDLE SPEED (ENGINE “LOPES”) 1. Idle speed set too low. 2. Burned, leaking or sticking valves. Perform the “Compression Check later in this section. 8. Incorrect vaive adjustment, 4. Incorrect injection timing. 5, Restricted exhaust. 6. Camshaft lobes worn. 7. Faulty governor. Have inspected by a qualified technician. ENGINE MISSES AT IDLE Fuel System Problems 1. Faulty injector 2. Poor quality fuel. 3. Dirty air cieaner. 4, Faulty injection pump. Mechanical Problems 1. Low compression due to leaky valves, broken rings, etc. Perform the “Compression Check” later in this section, 2. Incorrect valve adjustment. 3, Exhaust restriction. 4. Leaky valve guide(s). 5. Worn camshatt lobe(s). 6. Intake restriction. ENGINE MISSES AT HIGH SPEEDS Fuel System Problems 1. Restricted fuel filter. 2. Plugged air cleaner. 3. Poor quality fuel. 4. Faulty fuel pump.ISUZU ENGINE 6A6-5 5. Intermittent or insufficient delivery of fuel to the injection pump caused by restricted lines, etc. 6. Faulty injectors. 7. Faulty injection pump. Mechanical Problems 1. Restricted exhaust system. 2. Incorrect valve adjustment. 3. Sticking valves. 4. Broken or weak valve springs. ENGINE MISSES AT ALL SPEEDS Fuel System Problems 4. Water or dirt in fuel. 2. Dirty air filter. 8. Fuel filter plugged. 4. Poor quality fuel. 5. Faulty fuel (transfer) pump. 6. Clogged or faulty injectors. 7. Faulty fuel injection pump. Have inspected by a qualified technician. Mechanical Problems 1. Low compression. Perform the “Compression Check’ later in this section. Some causes of low compression are: a. Sticking valves. b. Broken valve spring, c. Valve held open by improper adjustment or binding valve train, 2. Restricted exhaust. 3, Engine brake exhaust valve stuck shut. 4, Worn camshaft lobes. ENGINE MISSES ON ONE CYLINDER 1. Faulty or plugged injector. 2. Stuck valve. 8. Broken valve spring. 4, Broken or faulty rings or piston. Perform the “Compression Check’ later in this section. LACK OF POWER OR PERFORMANCE if applicable, also refer to “Excessive Exhaust Smoke" later in this section. Fuel System Problems 1. Dirty air cleaner. 2. Accelerator linkage binding, loose or improperly adjusted. This may not allow full fuel delivery from injection pump. 3. Fuel supply not sufficient. Replace the fuel fitter ‘and bleed the fuel system. Tighten fuel line connections. 4, Fuel ines restricted. 5, Faulty fuel (transfer) pump. 6. Poor quality fuel. 7. Improper injection pump timing. 8, Pressure relief valve on injection pump not working properly. Replace. 9. Faulty fuel injectors, or injection pump. Have inspected by a qualified technician. Mechanical Problems 1. Poor engine compression. Perform the “Compression Check" later in this section. . Exhaust brake valve stuck shut. . Bumed or sticking vaives. Weak valve springs. Incorrect valve adjustment. Incorrect vaive timing. - Worn camshaft lobes. - Faulty turbocharger. Air leaks at turbocharger turbine housing or intake manifold. 9. Air fiter plugged. 10. Restricted exhaust system. eNonaen Miscellaneous Problems 4. Engine overheating. 2. Preignition, 3. Clutch slippage. 4. Excessive rolling resistance due to dragging brakes, tight whee! bearings, underinfiated tires, etc. 5. Incorrect rear axle ratio. 6. Oversize tires. 7. Inaccurate speedometer (gives impression of lack of performance). 8, Overloaded vehicle. 9. Excessive exhaust back pressure, EXCESSIVE EXHAUST SMOKE Black or Gray Smoke 1. Improper or poor fuel. 2. Excess or irregular fuel delivery. Have the injection pump inspected by a qualified technician, 3. Air filter clogged. 4. Valve clearance incorrect, Adjust as outlined later in this section, 5. Fuel injection pump aneroid improperly adjusted, or damaged (California and high- altitude certified engines only). Have inspected by a qualified technician. . Fuel injection nozzle restricted. Injection pump improperly timed. Malfunctioning turbocharger. exe6A6-6 ISUZU ENGINE Blue Smoke Generally caused by the presence of lube oil in the combustion chambers resulting from: 4. Too much lube oil in crankcase. 2. Air cleaner restriction. 3, Valve guide seals faulty 4, Excessive crankcase pressure due to clogged breather or breather tube. 5. Worn pistons or rings. Perform the “Compression Check’ later in this section. 6. Connecting rod (big end) bearing clearance excessive. 7. Intemal turbocharger seal leakage. White Smoke 1. Improper fuel 2. Leakage between cylinder and head. 3. Low compression (usually a valve problem). 4. Incorrect injection and pump timing ENGINE FAILS TO REACH OPERATING TEMPERATURE 1. Faulty engine coolant temperature gage or sending unit. 2. Faulty cooling system thermostat. ENGINE OVERHEATS |. Low oil level. Improper grade or type of oll used. Cooling fan belts broken. - Use of a winter front. Faulty engine coolant temperature gage or sending unit. . Faulty cooling system thermostat. . Excessive exhaust back pressure. - Excessive rolling friction due to dragging brakes, low tire pressure, etc. 8. Excessive engine friction due to tight pistons, bearings, ete. 9. Exhaust brake valve stuck shut. 10. Plugged radiator or deposits on water jacket walls. LOW OIL PRESSURE Shut The Engine Down Immediately 1. Low oil level. 2. Improper oil type or viscosity. 8. Overheated engine. 4, Loose connections in oil lines. 5. Oil pump screen or pickup tube clogged. 6. Air leak in oil pump. May be caused by improper assembly, loose oil pickup tube, oF loose cover. 7. Faulty pressure sending unit. 8. Excessive main bearing clearance. 9. Malfunctioning oil pump. Replace. pepe Now 10. Oil gallery plug missing, 11, Relief vaive stuck open. HIGH OIL PRESSURE 1. Oil too heavy. 2. Main oil galleries on the pump pressure side plugged. 3. Oil pressure relief vaive clogged. Reliet valve spring too strong 4. Sending unit or gage faulty BURNED, STICKING OR BROKEN VALVES 1, Overspeeding of the engine. 2, Improper valve adjustment. 8. Excessive exhaust back pressure. 4, Weak valve springs. 5. Improper valve face width. 6. Incorrect vaive seat width. 7. Out-of-round valve seats. 8, Deposits on valve seats, valve guides, or valve stems. 9. Warped vaives. 10. Broken valve guide. EXCESSIVE FUEL CONSUMPTION There are a number of factors that will contribute to excessive fuel consumption. One of the most important of these is the driving habits of the operator. ‘When the operator habitually makes “jack-rabbit” starts and stops, “rides” the brake (or clutch) pedal, overloads the vehicle, drives at excessively high speed for prolonged periods, falls to hold a consistent throttle position (continuously accelerates, then coasts) and/or operates the vehicle under short run conditions (cold engine) the majority of the time, this could be the problem. Vehicle air resistance at high speeds has a major effect on fuel consumption. Head winds, excessively high speeds, or added frontal area will cause an increase in fuel consumption. When it has been determined that the operator is not at fault, make a fuel consumption test using a calibrated fuel measuring device. The amount of fuel used to drive the vehicle a measured distance should be recorded. Then record the amount of fuel used to return to the starting point. An average of the two readings should be used in determining the fuel ‘consumption. The vehicle odometer should be checked over a measured mile for proper calibration. If it has been determined that a problem does exist, refer to the following:ISUZU ENGINE 6A6-7 Fuel System Problems 1, Loose fittings or leaking hoses. 2. Fuel tank cap missing. 3, Clogged air cleaner. 4. Faulty fuel injection nozzle or injection pump. Mechanical Problems 1. Clutch slippage. 2. Excessive rolling resistance (low tires, dragging brakes, etc.) 3. Incorrect valve adjustment. 4, Excessive exhaust back pressure. 5. Loss of compression, due to worn rings, pistons, bumed valves, etc. Perform the “Compression Check’ later in this section, 6. Improper rear axle ratio. 7. Wrong speedometer gear. 8. Improper tire size. EXCESSIVE OIL CONSUMPTION Internal Leakage 1. Poor quality oil. A poor quality oil may become too thin when the engine is hot. 2. Improper oil viscosity. 3. Oil dilution due to faulty fuel injection pump or fuel pump. 4, Excessive orankease pressure. 5. Excessive valve-to-valve guide clearance and/or faulty valve guide seals. 6. Worn pistons or piston rings. Piston rings stuck in their grooves. 7. Excessive connecting rod bearing clearance. 8. Internal turbocharger leaks: a. Intemal turbocharger seal leakage on the turbine (exhaust) side. Check the oil drain line for blockage. If none is found, check the crankcase breather and tube for clogging or other obstruction. If none is found, check for excessive ring blow-by. If these items are satisfactory, the turbocharger internal seals are faulty. Replace the turbocharger. b. Internal turbocharger seal leakage on the compressor (intake) side. Check for a plugged air filter or obstruction in the air inlet pipe. If not found, the turbocharger intemal seals are faulty. Replace the turbocharger. External Leakage Recurring external oil leaks from gaskets or seals may be caused by excessive crankcase pressure due to blocked crankcase breather or vent hose. It is a good practice to check the oil level, breather and hose whenever a seal or gasket leakage problem occurs. Check gasket and seal areas to determine the point of leakage. Replace parts as necessary. ENGINE NOISES ‘When diagnosing engine noise problems, be careful that noises caused by accessories are not faken for engine noise. Removal of accessory drive belts will eliminate any noises caused by these units. In general, engine noises are either synchronized to engine speed or one-half engine speed, Those that are timed to engine speed are sounds that have to do with the crankshatt, rods, pistons, and wrist pins. ‘The sounds emitted at one-half engine speed are valve train noises. The use of a stethoscope will often aid in locating ‘an engine noise. Caution must be exercised, however, because noise will travel to other metal parts not involved in the problem. No definite rule or test can be listed that will positively determine the source of a noise complaint. Fuel pumps, flywheels, drive belts, or carbon built up in the combustion chamber may contribute to noisy engine operation. The following information can therefore be used only as a general guide to noise diagnosis. There is no substitute for experience. Noisy Main Bearing A loose main bearing is indicated by a powerful, but dull, thud or knock when the engine is under load. If all main bearings are loose, a noticeable chatter will be audible, The thud occurs regularly every other revolution. ‘The noise is loudest when the engine is “lugging” or under heavy load. The sound is heavier and duller than a connecting rod noise. Low oil pressure also accompanies this condition. If a bearing is not quite loose enough to produce a knock by itself, the bearing may knock if oil is too thin or if there is no oil at the bearing, Regular noise—worn bearings, endthrust bearings. Crankshaft end play—intermittent rap or knock that is sharper than a loose main bearing. Repeated disengagements of the clutch may cause a change in the rep. regular—worn Causes of Noisy Main Bearings 1. Insufficient oil supply. 2. Low oil pump pressure, 8. Thin or diluted oil. 4, Excessive bearing clearance. 5. Excessive crankshaft end play.6A6-8 ISUZU ENGINE 6. Out-of-round crankshaft journals. 7. Sprung crankshatt. 8. Excessive belt tension. 9. Loose crankshaft pulley. 10. Loose flywheel or torque converter. Noisy Rod Bearings Rods with excessive clearance knock under all speeds and under both idle and load conditions. At the early stage of looseness, rod noise may e be confused with piston siap or loose pins. Rod knock noise increases in intensity with engine speed. Low oil pressure also accompanies this condition. Causes of Noisy Rod Bearings 1. Excessive bearing clearance. 2, Worn crankpin. 3, Lack of oil (thin or diluted). 4. Low oil pressure. 5, Journals out-of-round. 6. Misaligned rod. 7. Connecting rod bolts not tightened correctiy. Noisy Timing Gears Ahhiigh frequency light knock that is difficult to isolate without a sound detecting device. It is about the same intensity whether the engine is idling, at high speeds or under load. Causes of Noisy Gi 1. Gears misaligned. 2. Excessive backlash 3. Chipped tooth. 4. Gears loose on hubs or shafts. 5, Teeth meshed too tight (new oversized gear). 6. Too much end play in the camshaft or crankshaft. 7, Front camshatt bearing clearance excessive. rs. Noisy Pistons Piston pin, piston, and connecting rod noises are difficult to tell apart. A loose piston pin causes a sharp double knock that is usually heard when the engine is idling. However, on some engines the knock becomes more noticeable at 25 to 35 mph (40 to 56 km/h) on the road. Cause of Piston Noi 1. Worn or loose piston pin or bushing. 2, Improper fit of pin. (Listen for a light ticking or tapping noise. More noticeable with no load on engine. May disappear completely under load. Generally piston pin noise can be noticed on deceleration of the engine.) 3. Piston-to-oylinder bore clearance excessive (sounds very similar to tappet noise). One indication of piston siap is a decrease in noise as the engine warms up. Piston slap is always louder when the engine is cold. 4, Lack of lubrication. 5. Carbon deposits on top of piston strike cylinder head. 6. Worn or broken piston ring land (most noticeable during acceleration). 7. Broken or cranked piston. 8, Engine overheating. 9. Poor fuel 10. Excessive rod bearing clearance. 11. Misaligned connecting rods. 12. Worn rings, cylinder walls, low ring tension, broken rings, out-ot-round or tapered bores. 18. Excessive side clearance of rings in groove, clearance between rings and groove and/or ring gap. 14. Undersize piston installed 15. Wrong type and/or size rings installed. 16. Cylinder bores tapered or eccentric. 17. Insufficient ring gap clearance. 18. Piston 180 degrees out of position Noisy Valve Michanism 1. Sticking or warped valves. 2. Bent pushrods. 8. Dirty worn, or Scored parts (rocker arms, etc.).. 4, Damaged valve lifter and/or camshatt lobes. 5. Insufficient or poor oil supply to valve mechanism (thin, foaming, or diluted). 6. Excessive valve stem-to-guide clearance. 7. Valve lifter incorrectly fitted to bore size. Noisy Fan Belt 1. Balt worn or burned. 2. Wrong belt. Does not fit pulley grooves properly. 8. Belt or pulley dirty or sticky with gummy oil. 4. Pulley bent, cracked or broken. 5. Belt pulleys misaligned. Miscellaneous Noises Loose Flywheel A thud or click that is usually irregular. To test, run the engine at about 20 mph (32 kmv/h) and shut off the engine. If thud is heard, the flywheel may be loose. Excessive Crankshaft End Play A rather sharp rap that occurs at idling speed, but may be heard at higher speeds also. The noise should disappear when clutch is disengaged. Engine Vibration 1. Unequal compression in cylinders. 2. Missing at high speed.8. Damaged engine mounts. 4. Faulty front engine pulley. 5. Engine support loose on frame or cylinder block. 6. Unbalanced or sprung crankshaft. 7. Excessive engine friction due to tight pistons, etc. COMPRESSION CHECK 1. Be sure the batteries are fully charged. 2. Start the engine. Run the engine until itis at operating engine coolant temperature. Stop the engine. 3. Remove the four glow plugs, as outlined later In this section. 4, Be sure the injection pump is in the “No Fuel” position. To do this remove the “Engine Stop” fuse from the fuse box before cranking the engine. The fuse is number 11 5. Install Adapter J-26999-20 into a glow plug hole, as shown in figure 2. 6. Connect Compression Gage J-26999-12 to the adapter. 7. Crank the engine and record the reading. Allow six compression strokes per cylinder. Normal—compression builds up quickly and evenly to specified compression on each cylinder. Piston rings leaking—compression low on first stroke. Tends to build up on following strokes but does not reach normal. ISUZU ENGINE 6A6-9 NOTICE: Do not add oil to any cylinder to compression test, as extensive damage may result. 8. The correct production pressure reading is 3043 kPa (441 psi). The reading should not fall below 2160 kPa (313 psi). These readings require a cranking speed of 200 rpm. 9. Perform the test on the remaining cylinders. 10. Install the glow plugs, as outlined tater in this section. 11. Insiall the "Engine Stop" fuse. 360. J-26099-12 361. J-26999-20 Figure 2. Checking Engine Compression MAINTENANCE Refer to MAINTENANCE AND LUBRICATION (SEC. 08) in this manual for service intervals and recommended lubricants. VALVE ADJUSTMENT 1. The adjustment is to be made with the engine stopped and cold. 2. Remove the cylinder head cover as outlined later in this section. 3, Tum the crankshatt in the direction of normal rotation until both rocker arms on the number one (front) cylinder are loose, and the TOC (Top Dead Center) timing notch on the vibration damper is aligned with the “T” mark (figure 3). 4, With the crankshatt in this position, the valves indicated in figure 4 can be adjusted. If the timing marks are aligned at “T” mark and the number one cylinder valves have no clearance, then the number four cylinder is in the compression-firing position. Adjust the valves as shown in figure 6 5. Refer to figure 5. Use a 0.4 mm (0.016 in) feeler ‘gage for both intake and exhaust valves. a, Loosen the jam nut. b. Tum the adjusting screw until the feeler ‘gage can be inserted with a light drag between the rocker arm and valve.GA6-10 ISUZU ENGINE Figure 3. Timing Mark at Top Dead Center ©. Hold the adjusting screw in this position and tighten the jam nut. Correct torque is 25 N-m (19 lb-ft}. d. Recheck the clearance. 6. Tum the crankshaft one full turn in the direction of normal rotation. Align the “T” mark with the timing notch (figure 3). With the crankshaft in this position, the valves indicated in figure 6 can be adjusted. Adjust as outlined in step 5. 7, Install the cylinder head cover as outlined later in this section. Figure 4. Valve Adjustment-Sequence (1) Figure 6. Valve Adjustment-Sequence (2) TURBOCHARGER MAINTENANCE The following items should be checked at the intervals outiined in MAINTENANCE AND LUBRICATION (SEC. OB) in this manual. [P] inspect (Figure 7) — Turbocharger to exhaust manifold connection (A) for leakage and mounting nut torque (figure 7a). — Turbocharger oil drain pipe(B) for damage and connection for leakage (figure 7a). — Turbocharger to adapter connection (C) for leakage (figure 7b). — Oil feed pipe (D) for damage and connection for, leakage (figure 7b). — Water feed pipes (E) for kinks or damage and connection for leakage (figure 7b). inlet hose and pipe (F) for damage and. connection for looseness or leakage (figure 7b).Charge air hoses and pipe between the turbocharger and the charge air cooler (G) for kinks or damage and connection for looseness or leakage (figure 7b). Charge air hose and pipe between the charge air cooler and intake manifold (H) for kinks or damage and connection looseness or leakage (figure 7c). Charge air cooler assembly for damage and mounting nut tightness (figure 74). Turbocharger for vibration or abnormal noises during engine operation. Exhaust smoke. Blue smoke may indicate, among other things, oil leakage past internal turbocharger seals. Refer to “Excessive Oil Consumption” under “Diagnosis of Isuzu Dieset Engine” previously in this manual. [2] portent + If the engine has not been running for a long period of time, it is recommended that the turbocharger bearings be lubricated BEFORE starting the engine. Proceed as follows: 4. Clean around the turbocharger oil feed line (item D, figure 7b) 2. Disconnect the turbocharger oll feed jine. ‘Take care not to allow dirt into the oi! passage. 3. Pour about 125 mi (4-02) of clean engine oil into the turbocharger oil passage. 4, Disconnect the air inlet pipe. Turn the turbocharger compressor wheel by hand to distribute the oil. Reconnect the air intet pipe. LX] important *» Any time the intake air pipe, charge air pipe, or turbocharger are removed, the intake opening must be covered. This will protect against the entrance of foreign material that could seriously damage the turbocharger or follow the intake passage into the cylinder and cause extensive engine damage when started, ISUZU ENGINE 6A6-11 Nal - A’ TorBocharger to Exhaust Manifold |p. Connection Ly B, Turbocharger Oil Drain Pipe Figure 7a. Turbocharger Attachments Inspection (1) [Fo CY C. Turbocharger to Adapter Connection- D, Oil Feed Pipe E. Water Feed Pipe F. Air Inlet Hose and Pipe G. Charge Air Hose and Pipe Figure 7b. Turbocharger Attachments Inspection (2) H. Charge Air Hose and Pipe Figure 7c. Turbocharger Attachments Inspection (3)6A6-12 ISUZU ENGINE 4. OiFiter 2. OilFilter Adaptor Figure 8. Oil Filter Location ‘CHANGING THE CRANKCASE OIL AND OIL FILTER + The oil filter is located at the right rear of the engine (figure 8). + Itis recommended that the oil filter be changed at each oil change. * The oil filter is a spin-on type. [a5] Remove or Disconnect (Figure 8) + Drain the crankcase oil * Oil filter (1). Use a strap wrench, [Ea] Clean (Figure 8) * Oil filter gasket surface on the oil filter adaptor (2). [rq] insta! or Connect (Figure 8) 1. Apply engine oil to the filter gasket face. 2. Oil filter (1). 3, Hand tighten filter until filter gasket contacts face of adaptor (2). 4. Turn filter an additional 2/3 tur. 5. Oil pan drain plug. + Fill the crankease with the proper quality and grade of oil. Refer to MAINTENANCE AND LUBRICATION (SEC. 0B) in this manual. inspect + Crankcase oil level. Add oil as needed. ISUZU ENGINE ON-VEHICLE SERVICE STATEMENT ON CLEANLINESS AND CARE * An engine is a combination of many machined, honed, polished, and lapped surfaces with very fine tolerances. + Whenever valve train components, cylinder head, cylinder, crankshaft, or connecting rod components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. * Any time the intake air pipe, charge air pipe, or turbocharger is removed, the intake opening must be covered. This will protect against the entrance of foreign material that could seriously damage the turbocharger, or follow the intake passage into the cylinder and cause extensive damage when the engine is started. + When any intemal engine parts are serviced, care and cleanliness are important. A liberal coating of engine cil should be applied to friction areas during assembly to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if notspecifically stated. + Whenever the fuel injection pump or fines are removed or disconnected, care must be taken to prevent the entry of dirt into the pump, lines, and injection nozzle. The entry of even small amounts of dirt or other foreign material into the fuel injection system may cause serious damage. + It should be kept in mind, while working on the ‘engine, that the 12-volt electrical system is capable of violent and damaging short circuits, ‘When performing any work where electrical terminals could possibly be grounded, the ground ISUZU ENGINE 6A6-13 cable of the battery should be disconnected at the battery. * Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to the wire harness or other electrical parts. + Cover or otherwise protect exposed electrical connections to prevent damage from oil and fuel. + The cylinder head and connecting rod cap bolts must be tightened using the angle method, as. instructed. NEVER attempt to convert the angle torque figures to torque wrench figures.6A6-14 ISUZU ENGINE 1. Clamp 2. Connecting Hose 3. Connecting Hose 4, Bolt 8, Charge Air Pipe 6. Connecting Hose 7. Bolt & Bolt 9. Nut 10. Gasket 11. Intake Manifold 42. Nut 13. Bolt 14, 16, 18, 19, 20. 21. 22. 24. 26. Gasket Nut Exhaust Adapter 17. Bolt Nut Turbocharger Gasket Exhaust Manifold Heat Shield Bolt Nut Cylinder Head Seal Ring Figure 9. Manifolds, Turbocharger and ComponentsISUZU ENGINE 6A6-15 CHARGE AIR PIPE REPLACEMENT Refer to “Statement on Cleanliness and Care” previously in this section, [i] Remove or Disconnect (Figure 8) 4. Clamps (1). 2. Connecting hoses (2) and (3). 3. Bracket bolts (4) and washers and charge air pipe(s). 4, Clamps (1). 5, Connecting hose (6). 6. Charge air pipe bolts (77. 7. Bracket bolts (8). 8. Charge air pipe (9). 9. Gasket (10). [Ey] inspect (Figure 9) ‘+ Hoses (2), (8) and (6) for deterioration, or damage. * Charge air pipes (5) and (9) for damage. Ey insta! or Connect (Figure 8) 1, Gasket (40) to the intake manifold (11). 2. Charge air pipe (9). 3, Bolts (7) and washer. EQ] tionten * Bolts (7) to 26 N-m (20 Ib-tt). 4, Bracket bolts (8). 5. Connecting hose (6). 6.Clamps (1). 7. Charge air pipe (5) and bracket botts (4). 8. Connecting hoses (2) and (3). 9. Clamps (1). INTAKE MANIFOLD REPLACEMENT [bx] Remove or Disconnect (Figure 8) 1. Charge air pipe (9) as outlined in “Charge Air Pipe Replacement” previously in this section. 2. Engine control cable bracket from the intake manifold (11). 3. Fuel injector lines from the fuel injectors and injection pump. 4, Nuts (12) and bolts (19). 8. Intake manifold (11). 6. Gasket (14) and discard. [EB] inspect (Figure 9) ‘* Intake manifold (11) for cracks or damage to gasket surfaces. > instatt oF Connect (Figures 9 and 10) 1. Gasket (14) as shown in figure 10. 2. Intake manifold (11). 8. Nuts (12) and bolts (13). QI Tianten + Nuts (12) and bolt, a litte at a time, to 19 Nm (14 Ib-f). 4, Fue! injector lines to the fuel injectors. Tighten ‘* Fuel injector tine nuts to'26 N-m (20 Ib-tt). &. Engine control cable bracket to the intake manifold. 6. Engine stop cable brackets to the intake manifold. 7. Charge air pipe (6) as outlined previously in this, section. A, Tab on Top of Gasket B. Rear of Gasket Figure 10. Intake Manifold Gasket Installed Postion TURBOCHARGER REPLACEMENT Refer to “Statement on Cleanliness and Care” previously in this section. Remove or: (Figures 9, 11, onnect 2 and 13) 1, Heat shield (22) bott (figure 9). 2. Exhaust pipe to exhaust adapter Nuts (15) (figure 9) 3. Exhaust adapter (16) to exhaust manifold bolts, (17) (figures 9 and 13). 4, Turbocharger air inlet pipe (810) (figure 11). 5. Oil feed line (280) (figure 11). 6. Charge air pipe clamps (1) (figure 9) 7. Waier feed and drain lines (300) (figure 12).6A6-16 ISUZU ENGINE 8. Oil drain line (280) (figure 12). 9, Turbocharger to exhaust manifold nuts (18) (figures 9 and 13). 10. Turbocharger (19) (figure 9). 41. Exhaust adapter (16) (figures 9 and 13). 310 19. Turbocharger 280. Oil Supply Line 310. Air Inlet Pipe Figure 11. Turbocharger Oil Feed Line Attachment Inspect (Figure 9) — Turbocharger (19) housing for cracks or damage. — Gasket surfaces for damage. — Seals and gaskets for damage. — Turbine and compressor blades for damage or carbon buildup. — Airand exhaust exit openings for oil or wetness. — For grinding or roughness when spinning turbine and compressor wheels by hand. — For evidence of turbine or compressor blades contacting the shroud or housing. If any of the above conditions exist, the turbocharger must be replaced or repaired by an authorized repair facility. Play in radial clearance. Moving the rotor in the radial clearance, measure the play by a dial gage. ‘+ Measure the play at several points while letting the rotor revolve, + Use only the flat dial gage attachment. Do not use the pointed one. * Attach the turbocharger and dial gage firmly. Service limit is 0.140 ram (0.0055 in). if excessive, replace the turbocharger. Measure Play in axial clearance. Moving the rotor in the axial clearance, measure the play by a dial gage. Oil outler Figure 11a. Radial Clearance Measurement + Measure the play at several points while letting the rotor revolve. * Attach the turbocharger and dial gage firmly. Service limit is 0.097 mm (0.0038 in). If excessive, replace the turbocharger. Figure 11b. Axial Clearance MeasurementISUZU ENGINE 6A6-17 4 280 Sp 300 ©) ingle }}|( oie uy 4 290 19. Turbocharger Ory _ 280. Oil Supply Line =o,27 Ao: 290. Oil Drain ae 300. Water Feed Line Figure 12. Turbochager Oil Drain Attachment el pa 16. Exhaust Adapter 17. Exhaust Adapter Bolts 18. Turbocharger to Manifold Nuts Figure 13. Turbocharger Mounting Attachment [Eq instatt or Connect (Figures 9, 11, 12 and 13) 1. Exhaust adapter (16) to turbocharger (19). 2. New gasket (20) and turbocharger (19) to ‘exhaust manifold (21) (figure 9). Tighten + Nuts (18) to 26 Nem (20 Ib-tt) figure 13) 3. Turbocharger oil drain line (290) (figure 12). Tighten + Bolts (290) to 19 Nm (14 Ib-tt), 4, Water supply and drain lines (300) (figure 12) Tighten * Fitting (300) to 21 N-m (15 Ib-tt). 5, Charge air pipe connecting hoses (6) and clamps (1) to turbocharger (19) (figure 9). 6. Turbocharger oil supply line (280) to turbocharger (19) (figure 12). Tighten + Fitting (280) to 14 Nem (122 Ib-in). 7. Ait inlet pipe (310) to turbocharger (19) (figure 6. Exhaust adapter (16) to exhaust manifold @1){figure 9). Tighten + Bolts (17) to 21 Nem (15 Ib-ft) 9. New gasket and exhaust pipe to exhaust adapter (16) (figure 9) Tighten ‘+ Nuts (15) to 87 N-m (27 lb-ft) 10, Heat shield (23) to exhaust adapter (16) (figure 9). EXHAUST MANIFOLD REPLACEMENT [Ay Remove or Disconnect (Figure 9) 1. Turbocharger (19) as outlined previously in this section. 2. Heat shield (22) 3. Bolts (23), nuts (24) and washers. Loosen bolts as shown in figure 14. 4, Exhaust manifold (21). 5. Gaskets (24). Inspect (Figure 9) ‘* Exhaust manifold (21) and cylinder head (26) for ‘racks or damage to gasket surfaces.