Isuzu 4BD1 Instruction manual
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ISUZU
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DIESEL
-
ENGIN
;E
4801,
4BD1
-
~T
MODELS .
,•. .. I
(FOR
AUTON,IOT
,IVE.USE)
198Ef- ·
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No:
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.I
!
SECTION
INDEX
'
SECTION
NAME
J
!,
ISUZU 1 GENERAl I
NFORMATION
~
WORKSHOP
MANUAL
2
ENGINE
ASSEMBlY
DIESEL ENGINE
-
~
3
LUBRICATING
SYSTEM
4801
4801-T
I
4 COOliNG SYSTEM
FOREWORD
5 FUEl SYSTEM
lhis
manual incl
udes
special notes, important points, service ..
data, precautions
..
etc
.
that
are
n
ee
ded
for the
main
te
nance, 6
TURBOCHARGER
~.
·adjustments. se
rv
ice
,
removal
and installat
io
n of
components
of
th
e m
ode
ls
titled.
All
information.illustrationsa
nd
specifications
contained
in
t
his
manual
are
based
on
t
he
latest
product
information
availableat
the time
of
publication. 7
The right
is
reserved
to
ma
ke
cha
nges
at
any time without
ELECTRICAL
SYSTEM
notice. '
Arrange.ment
of
t
he
material
is
s
hown
by
the
tab
le
of
contents
on
the
rig
ht·h
and
s
id
e
of
thispage. Black
spot
on
the
first
page
AUXIliARIES I
of
each
sect
i
on
can
be
seen
on
the
edge
of
the
book
be
l
ow
sec·
8
t
ion
title.
Amore
de
ta
il
ed
table
of
con
t
ents
precedes
eachsec-
(POWER
STEERING
OIL
tion
.
PUMP)
Th
is
man
ua
l app
lies
to
the 1986 year and
later
mod
els.
9
SPECIAL
TOOL
LIS
T
I
. 10
TROUBLESHOOTING
11
CONVERSION
TABLE
•
··
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.GJ;NERAL"INFORMATION 1- 1
SECTION 1
GENERAL INFORMATION
CONTENTS
PAGE
General repair
instructions
. .
.........
..
..•......
••
.
..
. .
....
..
...................•..•..
1-
2
How.
to
use
this
manual
..
. .·
....
.
...........•.............................
..
...
..
....
1-
2
Main
data and
specifications
.
..
...........
..
....
.•
....
..
...
.
.....
..
...
..
.....
..
...
..
.
1-
5
Torque sp·
ecifications
....
.....
.
.....
.
.....
.
.....
......
..
....
...
. "·
....
..
. ··
..........
1-
7
How
t"o
tighten
by
angular
tightening
method
....
.
....
...
..
..
.....
.
...
..
...
..
. .
...
..
. .
..
1-
8
Engine repair
kit
..........•....•..............•.•.........................
.
..
•.
.•
. .
.•
.
1-1?
Servicing
..
..•..
•
..
.....
.
.....
.
....
...
.....
.
•..
..•.
....
.
..
.
...
.•..
...
.........•
....
1- 18
Recommended
lubricants
....
.......
.....
..
...
....
..
...
..
....
.
.........
...
.....
.
•...
.
1-26
Engine
oil
viscosity
chart
....
..
...
...
....
..
....
..
...
....
..
.
.........
......
.
.....
..
....
1-26
Adhesive
for
repairs
...•.
...
.
.....
......
.
....
....
.•.
....
..
...
•....
. .
...
•..
.....
.
....
1-26
/
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1-
2
GEN
ERAL INFOR
MA
TION
GENERAL REPAIR INSTRUCTIONS
1. Beforeperformingserviceoperations, disconnect
ground
cablefromthe
battery
to
reducethechance
of
cable
damage and burning due
to
short-circuiting.
2.
The
use
of
propertoolsand special tools where spec
ified
, is Important
for
efficient
an
d reliable service -oper-
ations.
3.
Use
genuine lsuzu pans.
4. Used cotterpins, gaskets. 0-rings, oilseals, lock
washers
andse
lf
Jocknutsshould bediscardedand
new
on
es
used
as
normal function
of
the parts can
not
be maintained
if
these pans are reused.
5.
To
facilitate proper and
smo
oth reassembly,
ke
ep disassembled parts n
eat
ly
in groups.
Keeping bolts a
nd
nutsseparate
is
v
ery
im
po
rtantas
they
vary
in hardnessanddesign depending
on
posit
ion
of
installat
io
n.
6. C
le
anthe
pa
rtsbeforeinspection
or
reassembly.
Also
cleanoilpons.etc.usingcompressedairtomakec
enain
they
are free from restrictions.
7.
Lubricate rotat
ing
and
sl
iding faces
of
the parts
with
oi
l
or
grease before installati
on
.
8. When necessary, use a sealer on gaskets
to
pr
eve
nt
leakage.
9. Carefu
lly
observe all specifications
for
bolt
and
nut
torques.
10. When service oper
at
ion
is
completed, make a final check
to
be sure service h
as
been done properly.
11.
For
ass
ur
ance
of
safety,always rel
ea
se
airpressure
sol
ely fromthe airtanks before
di
sconnecting pipes, hoses
or
other parts f
rom
a
ny
unit
under air pressure.
HOW
TO
USE
THIS
MANUAL
1.
Find the applicable secti
on
by
referring
to
the index.
2. This manual includes a "General information• section in
whi
ch service data. ma
int
enance i
tem
s and specific·
ationswith torques are included.
3.
Each section includ
es
, disassembly, inspectionand repairandreassembly. When the same serviceoperation
app
liesto
more
thanone unit
or
equipme
nt
not
ice
is
insertedstating, "Refer
to
manual forotherunits
or
equip·
me
nt".
4.
In
theremoval andinstallation section.description
of
self-explanatoryitemssuchas removal
of
individualparts
from
theunit
to
ber
em
oved,
is
omittedand
imponant
operationsuch as adjustments. torquesp
ecif
ications.etc.
are dealt
wi
th mainly.
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GENERAL
INFORMATI
ON
1- 3
5.
Each serviceoperation section begins
with
disassembled
view
of
unit
or
equipm
ent
which
isuseful
to
find
com-
pone
nts, service procedure, availabil
ity
and
content
of
repair kits,
etc
.
MAJOR
COMPONENT
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* parts contain
ed
in repair
kit
Parts
to
be removed or installed
as
a
unit
All
units or parts
within
frame are
to
be
con-
sidered
as
a
"majo
r
compon
en
t".
Each unit
or
part within frame is
to
be con-
sidered
as
a
"mi
nor
com
ponent!'.
The numb
er
represen
ts
sequence
of
service
operation.
Removal
of
the parts
wi
thout
number
(excludi
ng
bolts. nuts. washers. gaskets.
cot-
ter pins. etc.) is unnecessary unless re
pl
ace-
ment
is needed.
Where
parts replacement requires a specific
note, instructions are given in "Inspection
and repair".
* indicates repair kit availability.
Name
of
parts listed in sequence
of
service
operation.
• indicates important operation.
Details
of
service operation are described in
the parag
ra
ph " Important operations
".
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• •
1-4
GENERAL INFORMATION
6.
The section
following
illustration(s) deals
with
important service.steps marked
with
•
.a.
".
This section also includes "notes", "use
of
special tools", •service data", etc.
)1
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the
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Item shown in the illustration and
marked
with
"
.A
".
Special tools are Identified
with
tool
name and/
or
part number.
The drawing illustrates
ho
w the
tool
is
used.
Important note.
The symbol indicates the step
of
ser-
vice to
be
followed.
Refer
to
the following paragraph
fo
r
meaning
of
each symbol.
Service data and specifications are
listed
in
table.
7.
In
th
is manual,
th
e
followi
ng
symbo
ls are used
to
indicate
the
type
of
servi
ce
operations
to
be
perform
ed.
EJ
Remove
IE
Adjustment
El
Install
ril
Clean
l·!·l
Disassemble w Pay close attention -
im
portant
l·!·l
Rea
sse
mble
~
Tighten
to
specified torque
g Align
the
marks
~
Use essential
tool
(s)
8 Correct direction
~
Use available tool(s)
[1!1
Inspe
ct
8 Lubricate
with
oil
~ Take measurement
61
Lubrica
te
with
grease
8.
The service standard is
in
dicated
in
term:s
of
"Standard" and
"Limit"
.
The"standard"means theassemblystandardand standardrangewithinwhich the partsareconsideredservic
e-
able.
"Limit"
indicates the
limit
value (Correction
or
replacement
is
necessary when
meas
urement
is beyond
this
limit.)
9. In this manual, the
comp
onents and parts are
pri
nted in singu
lar
form.
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GENERALINFORMATION
1-5
MAIN DATA AND SPECIFICATIONS
Items
Engine type
Combustion chamber type
Cylinder liner type
Timing gear system
No.
of
piston rings
No.
of
cylinders -Bore x Stroke
Total piston displacement
Compression ratio
Engine dimensions
{length x
width
x height)
Engine
we
ight
:
dry
Fuel injecti
on
timing B.T.D.C.
Fuel injection
order
Type
of
fuel used
Idle speed
Compression pressure
mm(in.)
cc(cu.in.)
(to 1J
mm(
i
n.
)
kg(lbs.)
(Degree)
(rpm)
kg/cm
2(psi)
Intake
and
exhaust valve clearance (at cold) mm(in.)
Intake valve
Exhaustvalve
Injection
pump
type
Go
vernor
type
Fuel feed
pump
type
Injection nozzle type
open
at
B.T.D.C. degree
close
at
A.B.D.C. degree
open
at
B.B.D.C.
degree
close
at
A.T.D.C.
degree
Injection starting pressure[qmkg/cm2(psi)
Lubr
ic
ation method
Oil
pump
type
Oil
fi
l
te
r
type
Lubricating oil capacity
Oil cool
er
type
Cooling
method
Cooling
water
capacity
Water
pump
type
Thermostat
type
Turbocharger type
Compression type
liters(imp.gal)
liters (imp.gal)
I
4801
4801-T
Water-cooled, 4-cycle
in
line overhead valve
Direct injection type
Dry t'(pe (chomard liner)
Gear
dr
ive
Compression ring 2, Oil ring 1
4-
102 X 118
3856
(235.2)
17
795
X 701 X 720
(31
.3
X
27
.6 X 28.3) 806 X 672 X 785
(31.7 X
26
.5
X 30.9)
322.5 (711) 327 (721)
13"
10
.
1-3-4-2
Hi
gh
-speed diesel fuel (SAE No.
2)
555-
605 1
575-625
31
(441)
at
200
rpm
0.4 (0.016)
28
62
70
28
BOSH
in-line A type,
with
automatic
timer
RLD-K Mechanical type
KE
Mechanical type
Hole type (with 4 orifices)
185
(2631)
Pressurized c
ir
culation
Trocho
id
Cartridge-paper element
8.0 (1.8)
Pressu
ri.zed
circulation
Water
cooled
14
(3.1)
Impeller type
Waxpellet
type
(with jiggle valve)
RH
·B6A
Radial
outward
-f
low
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1- 6
GENERAL
INFORMATION
4801
Maximum
pe
rmissible speed (continuous) (rpm)
Pressure ratio (Maximum)
*Exhaust gas temperature
Weight
kg
(lbs
.)
Manufacturer's name
4801-T
130,000
2.8
750
4.5
(9
.9
)
lshikawajima-Harima Heavy
lndistries Co., L
td
.
* The exha
ust
gas temperatue meas maxi
mum
allowable tempera
tur
e measured
at
turbocharger intake. ·
Note: The turbocharger uses bolts a
nd
nut
s based
on
conventional
in
ch system.
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GENERAL
INFORMATION
1-7
TORQUE SPECIFICATION
STANDARD BOLTS
The torque val
ues
given in the
following
table should be applied where a particular
to
rque is
not
specified.
kg·m(ft.lbs.)
Bo
lt
@
G)
®
Identification
Bolt
diameter x pitch
4T
7 T
9T
(mm)
(lo
w carbon stee
l)
(High carbon steel) (Alloy steel)
6 X 1.0
0.4-
0.8
( 2.9-
5.8)
0.5-
1.0 ( 3.
6-
7.2) -
8 X 1.25
0.8-
1.8 ( 5.8-13
.0)
1.2-
2.3!
8.7-
16.6) 1.7- 3.1 ( 12.3-
22.4)
10 X 1.25
2.1
-3.5 (
15.2-
25.3)
2.8-
4.7 (
20.3-
34.0)
3.8-
6.4 ( 27
.5-
46.3)
*10 X 1.5 2.0- 3.4 ( 14.5-24.6)
2.8-
4.6 ( 20.3- 33.3)
3.7-
6.1 ( 26.8-44.
1)
12 X 1.25
5.o-
7.5 1
36.2-
54.21 6.2- 9.3 ( 44.
8-
67.3)
7.7-11.6
( 55.7-83.9)
•12 X 1.75 4
.6-
7.0 ( 33.3-
50
.6) 5.
8-
8.6 ( 42
.0-
62.2) 7.3-10.9 ( 52.8-78.8)
14 X 1.5
7.8-
11
.7 ( 54.6-84.6) 9.5-14.2 ( 68.
7-
102.7) 11.6-17.4 ( 83.9-125.9)
*14 X 2.0
7.3-10.9
( 52.8-78.8) 9.
o-13
.4 165.
1-
96.9)
10.9-16.3
(
78.8-
117.9)
16 X 1.5 10.6-16.0 ( 76.7-115.7)
13.8-20
.8 ( 99.8- 150
.4)
16.3
-24
.5 (117.9-177.2)
•16
X 2.0 10.2- 15.2 ( 73.8-109.9)
13.2-19.8
(
95.5-14
3.2)
15.6-23.4
(112.8-169.3)
18 X 1.5
15.4
-23.0
(11
1.4-166.4) 19.
9-29.9
(143.9-216.
3)
23.4-:35.2 (169.3-254.
6)
20 X 1.5
21
.0- 31.6 (
151
.
9-228.6
)
27.5-41
.3
(1
98.9-298.7) 32.
3-48.
5 (233.6-350.8)
22 X 1.5 25.
6-42.2
(1
85.2-305.2) 37.0
-55
.5 (267.6-401.4)
43
.
3~.9
(3
13.2-
46
9.4)
24 X 2.0
36.6-55
.0 (264.7-397.8) 43.
9-72.5
(
31
7.5-524
.4)
56.5-84.7
(4
08.7-
612.6)
The
aster
i~k
*indicates
that
the
bolt
sare u
se
dfor female-threaded partsthatare made
of
soft
materialssuch
as
cast·
ing, etc.
'·
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1-8
GENERAL
INFORMATION
Center line-
Another line·
->~
HOW
TO TIGHTEN BY ANGULAR
TIGHTENING METHOD
1.
Wash bolts and/or nuts clean
to
remove.oil, grease, etc.
completely.
2.
Apply
a
coat
of
molybdenum
disulfide
grease
to
threads
and setting face
of
bolts and/or nuts.
3. With a torque wrench tighten bolts and/or nuts
to
the
specified torque (snug torque).
4. Draw a line (A-B) across the center
of
·each bolts.
5.
On theface
of
parts to
be
clamped draw
an
another line
(C-D)
exteni;ling
from
the line (A-8).
6.
On
thefaceofthe
partsto
be
clamped,
draw
aline
(F-G)
in
direction
at
thespecifiedangle (Q)
to
theline (A-B) across
the center
(E)
.
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GENERAL
IN
7. With a
torn
FORMATION
1 9
.,ue
wren
h ·
onthe
bolt
head .c , tighten the b
face
of
the
partsc~m~ides
withthe
li~~
(~~~~
the line
(A
·Bl
o e clamped. l
drawn
onthe
Example· T
· urn
of
b
olt
(or
nut
) is . .direction
of
t.
h .
1
9 temng
30
° .
1/12
of
turn
1/6
of
a
turn
1/4
of
a
turn
1
/2
of
a
turn
360° One full turn
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1-10
GENERAL INFORMATION
FIXING TORQUE
CYLINDER HEAD
AND
COVER
2.0-3.0(14.5-21.7)
12.3-2.7(16.6-19.5)
1
Lubricate with engine oil
4B01 New
9.5-10.5
(68.7-76.0)
Reusoel 11.0
-12.0
(79.5-86.8)
Lubricate with MOS2 grease
4BD1·T
1----
-
---
-
--
-;
7 (50
.6)-
9 (65.1)
-90°-120°
...........
Rear
4.3-6.3(11.6-18.8)
MOS2 grease : Molybdenum disulfide grease
kg·m(ft.lbs.)
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GENERAL
INFORMATION
1-17
ENGINE REPAIR KIT
1. Gasket ; cylinder head 16. Gasket ; oil filter
2.
Gasket ; head cover bolt 17. Gasket ; oil pump pipe
3.
Gasket ; head cover
18.
Gasket ; oil filter pipe
4. Gasket ; drain cock 19. Gasket ; injection oil pipe
5.
Ga
sket ; relief valve
20.
Gasket ; water
pump
6. Gask
et
; tappetchamber cover
7. Gasket ; tappetchamber
bolt
21.
Gasket ; outlet pipe
22.
Gasket ; thermostat housing
8.
Gasket ;
oa
cool
er
23.
Gasket ; intake manifold
9. Gasket ; oil
pump
cover
24.
Gasket ; inlet pipe
10. Oil seal ; crankshaft rear
25.
Gasket ; exhaust manifold
11. Gasket ; retainer
26.
Gasket ; leak
off
pipe
12.
Gasket ;
case
to
cylinder block 27. Gasket ; fuel filter
13.
Gasket ; gear case cover
28.
Oi
l seal ; crankshaft
front
14.
Gasket ; oil pan drain plug
29.
Gasket ; injection
pump
bracket
15.
Gasket ; oil pan 30. Gasket ; nozzle holder
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1- 18
GE
NERAL
IN
FO
RM
ATION
SERVICI
NG
ENGINE OIL
Dr
aining
Drain
from
the
enginecrankcase
comple
te
ly
by
re
moving
thedrain plug onthe
low
er part
of
the oil pan, main oilfil·
ter and partiol
flow
oil filt
er
whilt: the engine is
hot
.
Re
filling
Then fill
into
theengine crankcase
from
thefiller
pqrtwith
new
engine oil
of
the specified grade.
Whenthe engine crankcaseis filled
to
the high level
mark
on
the
oil dipstick, startand l
et
the
engine
idle
for
a
few
minut
es.
Stop
the engine and recheck the oil level and
replenish,
if
necessary.
En
gine oil capacity
lit
er
(Imp gallon) 8.0 (1.8)
Engine oil level and contami
na
ti
on
Pull
out
the
oil level gauge rod (oil dipstick),
wipe
clean
and rein
sert
it.
Again pull it
out
and check thatoil level is
wi
thin
high and
lowlevel marks. Alsocheckoilon
the
gaugerod
for
con-
tamination.
If
the engine has been operated,allow5minutes
for
oi
l to
sett
le
down
before checking
th
e oil level.
OIL FILTER
1. Loosen
the
oilfilter
by
turningit c
ount
er
-clockwise
with
a
filt
er
wrench.
2. With a rag
wipe
clean thefitting face
of
the oil cooler. so
that
new
oil filter
ca
n be
se
ated properly. ••
3. Li
ght
ly oil the
0-ring
and turnin oil
fiiter
untilsealingface
is frtted againstthe 0 -ring.
Turn 1·1/4
turns
further
with
the
filterwrench.
FUEL FILTER
Replacement
1.
Loosen the fuel filter turning
it
counter-clockwise
with
a
filterwrench.
2.
With a rag w
ip
e clean the fitting fa
ce
onthe upper cover,
so
th
at
new
fuel filter can
be
seated properly.
This manual suits for next models
1
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