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4HK1-6HK1

ISUZU ENGINES

SERVICE MANUAL

Bur • Issued 05-2006

Printed in U.S.A. • Book/Form Number 9-44061 NA

Summary of Contents for 4HK1-6HK1

Page 1: ...SERVICE MANUAL Revised 05 2006 Issued 02 2006 9 44061 NA Replaces 9 44060 NA 4HK1 6HK1 ISUZU ENGINES...

Page 2: ...4HK1 6HK1 ISUZU ENGINES SERVICE MANUAL Bur Issued 05 2006 Printed in U S A Book Form Number 9 44061 NA Copyright 2006 CNH America LLC All Rights Reserved Find manuals at https best manuals com...

Page 3: ...e WI 53403 U S A CNH America LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold Al...

Page 4: ...Company reserves the right to make changes in the specification and design of the machine with out prior notice and without incurring any obligation to modify units previously sold The description of...

Page 5: ...n units belonging to other system Quantity To convert from IS Into Others Multiply by Quantity To convert from IS Into Others Multiply by Lenght mm in 0 03937 Pressure MPa kgf cm2 10 197 mm ft 0 00328...

Page 6: ...al Information 0A 1 GENERAL INFORMATION General Information Contents General Information 0A 2 Service Precautions 0A 2 Reading the model 0A 6 General information 0A 7 Find manuals at https best manual...

Page 7: ...of fire heat 4 Do not perform painting work or leave the engine running for long periods of time in an enclosed or badly ventilated indoor workshop 5 Always use the correct specialized tool indicated...

Page 8: ...using a scraper then clean each of the parts to completely remove oil water and dirt etc from the various surfaces Using the specified type of liquid gasket apply new liquid gasket to each of the sur...

Page 9: ...es should be dry 2 Apply Loctite to the top 1 3 of the screw 3 Tighten the bolt to the correct tightening torque Important After tightening the bolt do not apply excessive torque or try to rotate the...

Page 10: ...ck and crankcase bearing and also the bearing and install the cylinder block to the crankcase Gently rest the crankshaft on the cylinder block and rotate it approximately 30 degree to stabilize it Cut...

Page 11: ...0A 6 General Information Reading the model Engine number stamping position 4HK1 WSHK0185...

Page 12: ...ched it shows that the part has reached its full limit and must be replaced or repaired Front rear left right upper lower These show each orientations of parts installed to the vehicle when looking fr...

Page 13: ...nit control unit ECM Engine Control Module Engine control module EGR Exhaust Gas Recirculation Exhaust gas recirculation Exh EXH Exhaust Exhaust Ft FRT Front Front FWD Forward Forward F C Fuel Cut Fue...

Page 14: ...of kgf 2 Some conversion results may be rounded off to 1 or 2 decimal places Converting expressions of quantity When converting prefixes such as k kilo or m mili are used 200 kgf cm2 19 620 kPa 19 6 M...

Page 15: ...51 0 76 5 5 2 7 8 56 9 84 3 5 8 8 6 62 7 94 0 6 4 9 6 M14 1 5 76 5 114 7 7 8 11 7 83 0 124 5 8 5 12 7 93 2 139 3 9 5 14 2 100 8 151 1 10 3 15 4 M14 2 71 6 106 9 7 3 10 9 77 2 115 8 7 9 11 8 88 3 131...

Page 16: ...71 4 107 2 7 3 10 9 71 6 106 9 7 3 10 9 79 5 119 2 8 1 12 2 M14 1 5 106 2 158 8 10 8 16 2 114 9 172 3 11 7 17 6 113 8 170 6 11 6 17 4 123 4 185 1 12 6 18 9 M14 2 100 6 149 8 10 3 15 3 108 2 162 2 11 1...

Page 17: ...ad bolt Un refined 8 8 11 Flange bolt 8 8 12 Flange bolt 8 8 13 Hexagon head bolt 9 8 9T 14 Hexagon head bolt 9 8 9T 15 Flange bolt 9 8 9T 16 Flange bolt 9 8 9T Flare nut Pipe diameter tightening torq...

Page 18: ...General Information 0A 13 Taper screw from connectors brass N m kgf m Screw size PT R 1 8 PT R 1 4 PT R 3 8 PT R 1 12 2 0 14 7 0 2 1 5 4 9 15 7 0 5 1 6 9 8 16 7 1 0 1 7 9 8 17 7 1 0 1 8...

Page 19: ...1A 70 Removal 1A 70 Inspection 1A 71 Installation 1A 72 Special Tool 1A 74 Cylinder Head 1A 75 Components 1A 75 Removal 1A 75 Disassembly 1A 79 Inspection 1A 82 Reassembly 1A 88 Installation 1A 94 Tor...

Page 20: ...160 Oil Cooler 1A 162 Components 1A 162 Removal 1A 163 Disassembly 1A 164 Reassembly 1A 164 Installation 1A 165 Oil Pan 1A 168 Components 1A 168 Removal 1A 168 Installation 1A 169 Oil Pump 1A 171 Com...

Page 21: ...liquid gasket completely and clean it up thoroughly so that no oil water or dust may be clung to them Then apply the designated liquid gasket to each place anew before assembly Surfaces covered with l...

Page 22: ...1A 4 ENGINE MECHANICAL 4HK1 6HK1 How to read the model 4HK1 Name 1 Cast The Engine Model 2 Stamp An Engine Number...

Page 23: ...cap is of the ladder frame structure and tightened up under the plastic range rotation angle method Cylinder liner The cylinder liner is selected to match an internal diameter of a bore of the cylinde...

Page 24: ...stored in ECM Fuel filter with sedimenter It is a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between light oil and water which comes with a...

Page 25: ...ly and make sure that the tip of the adjusting screw touches the end of valve axis and the movement of the thickness gauge has become tight Then check if the end of the valve axis on the opposite side...

Page 26: ...cylinder is the compression TDC that with mark 4HK1 6HK1 Cylinder No 1 2 3 4 Valve arrangement IN EX IN EX IN EX IN EX No 1 cylinder Compression top dead center position No 4 cylinder Compression top...

Page 27: ...ssure inspection Warm up the engine Remove a negative terminal of the battery and remove all the glow plugs Remove the harness connector for the fuel injector built on the lower head cover no fuel wil...

Page 28: ...compression gauge of the special tool Remove a negative terminal of the batteries Install a harness connector for the fuel injector built on the lower head cover Install all the glow plugs Install th...

Page 29: ...g system Lubricating type Pressure type Oil pump type Gear type Volume of lubricating oil L qts 13 0 13 7 20 5 21 7 Oil filter type Full flow filter cartridge type Oil cooling type Built in water cool...

Page 30: ...JCB and Sumitomo products 900 Valve clearance Intake 0 4 0 016 cold mm in Exhaust 0 4 0 016 cold Ignition type Compressed ignition Injection order 1 5 3 6 2 4 Lubricating system Lubricating type Pres...

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