Isuzu 4BD1 Workshop Manual Download

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Summary of Contents for 4BD1

Page 1: ...Collated to support AULRO com Australia s premier Land Rover Website ISUZU c o l r I I _ DIESEL ENGIN E 4801 4BD1 T MODELS I FOR AUTON IOT IVE USE 198Ef _ Part No IDE2i 40 l ...

Page 2: ...dels titled All information illustrations andspecificationscontainedin this manual are basedon thelatest product information available at the time of publication 7 The right is reserved to make changes at any time without ELECTRICAL SYSTEM notice Arrange ment of the material is shown by the table of contents on the right hand side of this page Black spoton the first page AUXIliARIES I ofeach secti...

Page 3: ...NFORMATION 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 ...

Page 4: ...s 7 Lubricate rotating and sliding faces of the parts with oil or grease before installation 8 When necessary use a sealer on gaskets to prevent leakage 9 Carefully observe all specifications for bolt and nut torques 10 When service operation is completed make a final check to be sure service has been done properly 11 For assurance ofsaf ety always release air pressure solely from the air tanks be...

Page 5: ...I11Hllt01 16f l 1 C Mtl ttt 1 1 1i tt 22 f u o aembtywithw ter po mp l l l olli Ump 23 8olf l 24 eo oou 26 CrHII oullww 21 o 21 04 tono G lf MoOIIc foomooet rt _ _ lt fiii I MIOQ ilt parts contained 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 major component Each unit or part within frame is to be con sidered as a minor compon...

Page 6: ...entified with tool name and or part number The drawing illustrates how the tool is used Important note The symbol indicates the step of ser vice to be followed Refer to the following paragraph for meaning of each symbol Service data and specifications are listed in table 7 In this manual the following symbols are used to indicate the type of service operations to be performed EJ Remove IE Adjustme...

Page 7: ... A T D C degree Injection starting pressure qmkg cm2 psi Lubrication method Oil pump type Oil filter type Lubricating oil capacity Oil cooler 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 drive Comp...

Page 8: ...ous 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 Ltd The exhaust gas temperatue meas maximum allowable temperature measured at turbocharger intake Note The turbocharger uses bolts and nuts based on conventional inch system ...

Page 9: ...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 5 143 2 15 6 23 4 112 8 169 3 18 X 1 5 15...

Page 10: ... 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 the face of parts to be clamped draw an another line C D exteni ling from the line A 8 6 On thefaceofthe parts to be clamped draw a line F G in direction atthe specified angl...

Page 11: ...7 With a torn FORMATION 1 9 ue wren h on the bolthead c tighten the b face of the partsc m ideswith the li the line A Bl o e clamped l drawn on the Example T urn of bolt 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 ...

Page 12: ...ON 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 ...

Page 13: ...ort AULRO com Australia s premier Land Rover Website 2 1 3 1 1 2 22 4 1 4801 TONLY r I I r l 1 I L____i_ 1 9 2 3 13 7 16 6 GENERAL INFORMATION 1 11 INTAKE AND EXHAUST MANIFOLD 4801 T ONLY kg m ft lbs 4 3 6 3 31 1 45 4 ...

Page 14: ... com Australia s premier Land Rover Website 1 12 GENERAL INFORMATION 1 1 2 1 8 0 15 2 123 25 166 3 180 8 1 Lubricate with engine oil CYLINDER BODY AND OTHERS kg m ft lbs 12 5 15 5 90 4 112 1 Lubricate with engine oil 7 9 51 65 ...

Page 15: ...O com Australia s premier Land Rover Website 4 3 6 3 31 1 45 5 GENERALINFORMATION 1 13 CYLINDER BODY AND OTHERS 1 6 2 6 11 6 18 8 kg m ft lbs 2 1 3 1 15 2 22 4 2 1 3 1 15 2 22 4 __ __ _ ______ 1 1 6 2 6 11 6 18 8 1 4BD1 TONLY ...

Page 16: ...com Australia s premier Land Rover Website 1 14 GENERAL INFORMATION CRANKSHAFT AND CAMSHAFT 39 49 282 354 2 1 3 1 15 2 22 4 12 5 15 5 90 112 1 kg m ft lbs Lubricate with engine oil 114 5 17 5 105 125 1 Lubricate with engine oil ...

Page 17: ...Collated to support AULRO com Australia s premier Land Rover Website GENERALINFORMATION 1 15 F UEL SYSTEM kg m ft lbs ...

Page 18: ...Collated to support AULRO com Australia s premier Land Rover Website TURBOCHARGER ...

Page 19: ...asket water pump 6 Gasket tappet chamber cover 7 Gasket tappet chamber bolt 21 Gasket outlet pipe 22 Gasket thermostat housing 8 Gasket oa cooler 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 O...

Page 20: ...and contamination Pull out the oil level gauge rod oil dipstick wipe clean and reinsert it Again pull it out and check that oil level is within high and low level marks Also check oil on the gauge rod for con tamination If the engine has been operated allow 5 minutes for oil to settle down before checking the oil level OIL FILTER 1 Loosen the oil filter byturning it counter clockwise with a filter...

Page 21: ...lts for looseness and retighten as necessary before adj usting tlie valve clear ances Torque Adjustment Adjust the valveclearancesiri the fgllowing mannerusing a feeler gauge Standard clearance cold Intakeand exhaust m T in Turn the crankshaft in a clockwise direction to bring the piston in eitherNo 1 or No 4 cylinder into To p Dead Cen ter TDC on compression stroke by aligning TDC line on the cra...

Page 22: ...ft Jbs 2 3 2 7 16 6 19 5 After adjusting the valve clearances shown in the above drawing turn the crankshaft one full turn in the clockwise direction and align the TDC line with the pointer then adiustthe remaining valve Jearances shown in thisdraw ing FEED PUMP STRAINER 1 Remove the joint bolt at the intake side of the feed pump 2 Screw out the strainer counter clockwise and clean it 3 Install an...

Page 23: ...e Inspection Check the spray condition and injection pressure using a nozzle tester Injectionstarting pressure Adjustment kg cm2 psi 185 2630 Adjust the injection starting pressure in the manner described below 1 Remove the cap nut 2 Turn the adjusting screw to attain the correct injection starting pressure 3 Tighten the cap nut to specified tor que Torque kg m ft lbs 6 8 43 58 Installation 1 lnst...

Page 24: ...ing nuts for looseness and ret ghten if necessary 2 Disconnect the injection nozzle pipe on No 1 cylinder 3 Remove the delivery valve holder delivery valve spring delivery valve seat and delivery valve in the order men tioned 4 Install and tighten the delivery valve holder and seat to specified torque Torque kg m ft lbs 4 4 5 29 33 5 Rotate the crankshaft with crankshaft turning wrench and stop wh...

Page 25: ...rrect follow the nextproce dures without re installation Injection timing adjustment procedure 1 Adjustfuel injection timing byaligning notchedline onthe or on the pulley With the specified mark 1o or 13 exactly Use of mirror is requiretl to see timing marks from below 2 Remove fuel pipe connecting fuel feed pump with fuel fil ter to get access loosen the 4 nuts fixing injection pump housing Then ...

Page 26: ...g m ft lbs 4 4 5 29 33 Over tightening of the delivery valve holder and holder clip will invite malfunction of control rack COMPRESSION PRESSURE Preparation 1 Start and normalize the engine Engine r oolant temperature C F More than 75 1 67 2 Remove the following parts Glow plug connector 4 glow plugs 3 Install adaptor and compression gauge 4 Engage the starter and check that cranking speed is appr...

Page 27: ...ti free ze solution should be a ded to the cooling system according to lowest temper ature anticipated Capacity liters Imp gallon 14 3 1 Fan belt Inspection Check that the belt gives a specified deflection when the intermediate part of the belt is depressed with finger when pushed with a force of 10 kg 22 lbs Deflection mm in 8 1 2 0 32 0 47 Adjustment 1 Loosen the fixing bolts of the generator an...

Page 28: ...OW 40 SAt SW 20 ADHESIVE FOR REPAIRS Liquid gasket adhesives and other chemicals are used in various parts of the engine to prevent leakage of oil water and to prevent the bolts and nuts from loosening and these chemicals are available a lsuzu Motors as lsuzu genuine parts When servicing the engine it is recommended to use lsuzu genuine parts or equivalent ITEMS Liquid gasket Adhesives and sealant...

Page 29: ...d to support AULRO com Australia s premier Land Rover Website ENGINE ASSEMBLY 2 1 SECTION 2 ENGINE ASSEMBLY CONTENTS PAGE General description 2 2 Disassembly 2 3 Inspection and repair 2 t4 Reassembly 2 32 I _ ...

Page 30: ...Collated to support AULRO com Australia s premier Land Rover Website 2 2 ENGINE ASSEMBLY GENERAL DESCRIPTION This illustration is based on the 4801 T model ...

Page 31: ...l level gauge with guide tube 4 Starter motor S Cooling fan 6 Generator 7 Cooling fan belt 8 Tappet chamber cover 9 Thermostat housing assembly 10 Rubber hose 11 Water pump as sembly A 12 Cylinder head cover 13 Oil pan 14 Fuel injection leak off pipe 1S Fuel pipe 16 Fuel injection pipe 17 Injection nozzle holder 18 Glow plug 19 Fuel filter 20 Intake manifold assembly 21 Oil pipe 22 Oil filter with...

Page 32: ...fety valve assembly Boost X mpensator hose Important operations 1 Turbochi rger related parts Parts removal steps are related as the following chart Heat protector I E xhaust adaptor assembly Fuel cut bracket 2 Exhaust manifold assembly Loosen the exhaust manifold bolts in numeri al sequ ence ...

Page 33: ... removed from each cylinder separate and handle the parts carefully so as not to cause damage to the nozzle end Injection pump assembly Remove the injection pump by loosening 6 through bolts and a nut The through bolt A is hidden behind the hole cover The nut B should be accessed from backward When the injection pump is removed cap or tape the openings to prevent e try of foreign matter into the d...

Page 34: ...od 13 Gear case cover 3 Cylinder head assembly 14 Idle gear 4 Cylinder head gasket 15 Camshaft assembly 5 Flywheel 16 Timing gear case 6 Flywheel housing 17 Crankshaft bearing cap and 7 Rear oil seal assembly crankshaft bearing Lower side 8 Oil pump cover 18 Thrust bearing 9 Oil pump assembly 19 Crankshaft asse nbly 10 Piston and connecting rod 20 Crankshaft bearing Upper side assembly 21 Tappet 1...

Page 35: ...cified Upon removal of the cylinder head assembly with the rocker arm shaft assembly use aspecial toolto loosen the cylinder head bolts Wrench 1 8511 1003 0 5 Flywheel Loosen the flywheel bolts a little at a time in numerical sequence as specified 10 Piston and connecting rod assembly With ascraper remove carbon deposits from the cylinder wall before removing the piston Bring the piston to top dea...

Page 36: ...bly Idle gear end play Standard 0 058 0 115 0 002 0 005 Limit 0 2 0 008 mm in Backlash in gears Crankshaft gear idle gear camshaft gear Standard 0 10 0 17 0 004 0 004 Limit 0 3 0 012 mm in Crankshaft bearing cap and crankshaft bearing Check the crankshaft end play before disassembly mm in Standard 0 15 0 33 0 006 0 013 Limit 0 45 0 018 Loosen the crankshaft bearing cap bolts in unmerical order ...

Page 37: ... com Australia s premier Land Rover Website ENGINE ASSEMBLY 2 9 18 Thrust bearing Remove the thrust bearing using a wire Wire Ma k eyli der No 21 Tappet Mark cylinder number on each tappet after removal I J I I A e 0 ic E H IN ...

Page 38: ...port AULRO com Australia s premier Land Rover Website 2 10 ENGINE ASSEMBLY MINOR COMPONENTS ROCKER ARM BRACKET AND SHAFT ASSEMBLY 5 Disassembly steps 1 Snap ring 4 Spring 2 Bracket 5 Rocker arm shaft 3 Rocker arm 1 1 ...

Page 39: ...1 l l CYLINDER HEAD ASSEMBLY Disassembly steps 1 Spring cap and split key 2 Spring 3 Valve VALVE SPRING e VALVE VALVESEAT 4 Valve stem oil seal 5 Spring seat Important operations Mark cylinder number on each part after removal 1 Spring cap and split key Valve spring compressor 9 8523 14260 ...

Page 40: ... AULRO com Australia s premier Land Rover Website 2 12 ENGINE ASSEMBLY I PISTON AND CONNE CTING ROD ASSEMBLY Disassembly steps 1 Piston ring 2 Snap ring _________________ A 3 Piston pin connecting rod and bearing 4 Piston ...

Page 41: ...nt operations Mark cylinder number on each part after removal PISTON RING PISTON e PISTON PIN CONNECTING ROD L_______________________ 1 Piston ring Using a piston ring remover 2 Snap ring Using a snap ring remover 3 Piston pin and connecting rod Drive out using a brass rod under normal temperature ...

Page 42: ...EAD AND BODY Distortion at mating face Check in six 6 different directions A straight edge and feeler gauge F using a Distortion mm in Standard Limit 0 05 0 020 or less 0 2 0 08 or less When the distortion exceecs specified limit regrind the mating surface within specified limit Regrind amount Limit mm in 0 30 0 012 VALVE VALVE GUIDE AND VALVE SEAT INSERT Contact width mm in Standard Limit 1 5 0 0...

Page 43: ...few minutes then pry off with a screw driver Installation Press a new valve seat insert into the bore using a bench press After installation of the valve seat insert grind finish the seating face with a seat grinder carefully noting the seat ing angle contact width and depression lap the valve and seat as the final step Valve seating angle degree Intake valve 45 Exhaust valve 45 Valve head thickne...

Page 44: ...tandard Limit Intake 0 039 0 068 0 2 O OGlS 0 0027 0 008 Exhaust 0 064 0 093 0 25 0 0025 0 0037 0 010 Valve guide replacement Remover and installer 1 85220 001 0 The height of the valve guide top edge from the cylinder head upper face should be the specified figure Height mm in VALVE SPRING Free length and inclination Inner Free length Outer Inner Inclination Outer 13 9 14 3 0 547 0 563 mm in Stan...

Page 45: ...h Standard Limit 42 0mm 10 9 9 9 Inner 1 65 in 24 03 21 83 44 0 mm 23 0 20 0 Outer 1 73 50 72 44 10 TAPPET Inspect tappets for wear damage or other abnormal con ditions I fi l l Diameter m m in Standard 27 97 27 98 101020 1 1024i lt tl Clearance between tappet and body Standard 0 02 0 054 0 0007 0 0021 Limit 27 92 1 1000 Limit 0 1 0 0039 mm in ...

Page 46: ...SEMBLY Inspect all disassembly parts for wear damage or other abnormal conditions Rocker arm shaft diameter Standard 18 98 19 00 0 7478 0 7486 Rocker arm diameter Standard 9 01 19 03 0 7489 0 7497 Limit 18 85 0 7427 Limit 19 05 0 7505 mm in mm in Clearance between rocker arm shaft and rocker arm mm in Standard 0 014 0 062 0 00055 0 0024 Limit 0 2 0 0079 ...

Page 47: ...ear damage or other abnormal conditions End_p_la_ v ____________ mm in Standard 0 050 0 114 0 0002 0 0045 Camshaft journal diameter Standard 55 94 55 97 2 2040 2 2052 I I Camshaft bearing inside diameter Standard mm in limit 0 2 0 0079 Limit 55 60 2 1906 mm in 56 00 56 03 2 2064 2 2076 Clearance between camshaft journal and bearing Standard 0 03 0 09 0 0012 0 0035 limit 0 15 0 0059 mm in li I I I ...

Page 48: ...ring oil ports with those in cylinder body No 1camshaft bearing front side has two oil portswhile other have only one oil Jort Run out Limit mm in 0 1 0 0039 Camshaft gear If any abnormal conditions are found or if the amount of back lash measured at disassembly is excessive replace the camshaft gear Gearbolttorque kg m ft lbs Gear and thrust plate replacement Removal 5 8840 0086 0 12 5 15 5 9Q 11...

Page 49: ...tandard 44 94 44 97 1 7706 1 7718 Clearance between shaft and gear Standard 0 009 0 060 0 00035 0 0024 CYLINDER LINER Cylinder liner inside diameter Limit 44 84 1 7667 Limit 0 2 0 0019 mm in mm in mm in Measuring point ApproXc 20 mm below top end mm in Standard 102 021 102 060 4 0196 4 0212 Cylinder liner removal Remover 9 8523 1169 0 Remover ankle 9 8523 2557 0 102 2 4 0267 ...

Page 50: ...y a final load of 2500 kg 5513 lbs Standard fitting interference mm in 0 001 0 019 0 00004 0 00075 The use of dryice to coolthe cylinder liner will invite con traction facilitating smooth installation of the cylinder liner It ll Amount of projection Standard mm in Cylinder liner inside diameter Minimum diameter 102 021 102 040 4 0196 4 0204 102 041 1 02 060 4 0204 4 0212 0 03 0 10 0 001 2 0 0039 m...

Page 51: ...ndard mm in 0 057 0 075 0 0022 0 0030 Piston ring Clearance between piston ring and ring groove 4801 model mm in Standard Limit 1st compression 0 085 0 11 0 2 0 0033 0 0043 0 008 2nd compression 0 030 0 055 0 15 0 0012 0 0022 0 006 Oil 0 03 0 07 0 15 0 001 0 003 0 006 4801 T model mm in Standard Limit 1st compression 0 105 0 13 0 2 0 0041 0 0051 0 008 2nd compression 0 040 0 075 0 15 0 001 6 0 003...

Page 52: ...008 0 016 Oil 0 2 0 4 0 008 0 016 Piston pin diameter Standard 35 000 35 005 1 3790 1 3792 mm in Limit 1 5 0 059 1 5 0 059 1 5 0 059 Limit 34 95 1 3 0 mm in Interference between piston pin and piston pin hole Clearance mm in 0 005 0 0002 or less CONNECTING ROD AND BEARING Distortion or misalignment Connecting rod aligner per 100 mm mm in Standard limit 0 05 0 0002 or less 0 2 0 0079 ...

Page 53: ...7 1 3800 Clearance between piston pin and connecting rod mm in Standard 0 012 0 025 0 00047 0 00098 Bushing replacement Limit 0 05 0 0002 Removal Use a suitable bar and bench press or hammer Installation Use a suitable bar and bench press After installing a new bushing finish the bushing bore with a pin hole grinder Bearing spread Limit mm in 68 0 2 68 ...

Page 54: ... 924 63 944 2 5167 2 5175 Procedure for measuring the clearance between crank shaft pin and connecting rod Install bearings and cap Tighten the connecting rod bearing cap bolts to the speci fied angle mm in 1st step kg m ft lbs 2nd step degree Torque 4 0 29 so so Inside diameter Apply engine oil to bearing then measure the connecting rod big end inside diameter Nominal diameter mm in 64 I 2 52 Cle...

Page 55: ...e must be no traces of oil on the surfaces to be inspected 2 Prepare a 5 10 solution of ammonium cuprous chlo ride dissolved in distilled water 3 Use aspot glassrod to apply the solution to the surface to be inspected Hold the surface to be inspected perfectly horizontal to pre ent the solution from running Note Donotallowthe solution tocome in contactwith the oil ports and their surrounding area ...

Page 56: ...he main bear ing cap inside diameter Nominal diameter mm in 80 3 15 Clearance between crankshaft journal and bearing mm in Standard Limit 4801 0 039 0 090 0 0015 0 0035 0 11 0 025 0 076 0 0043 4801 T 0 001 0 0 0030 Crankshaft for 4801 T engine can not be reground because it is finished with tufftride method Forthe crankshafton 4801 T no attemptshould be made to grind finish the faces of the journa...

Page 57: ... the cran ksh ft Crankshaft for 4801 Tengine can not be bench pressed because it is finished with tufftride method Bearing spread Limit mm in 85 0 3 35 Tension Check to see if the bearing has enough tension so that finger pressure is needed to fit the bearing into position Crankshaft gear If any abnormal condi ions are found or if the amount of backlash measured at disassembly is excessive replace...

Page 58: ...3 0 Pilot bearing replacement Removal Remover 9 8523 1812 0 Installation Installer 5 8522 0024 0 FlYWHEEL AND HOUSING REAR OIL SEAL Thickness Stand rd 30 9 31 1 1 217 1 225 Ring gear replacement limit 30 1 182 mm in Removal Use a suitable brass rod and a hammer Installation With a gas burner heatthe ring gearuntil heat expansion takes place then install it using a hammer ...

Page 59: ...t Removal pry off or pull out Installation Installer 9 8522 1254 0 When the crankshaft face in contact with the oil seal is worn the contact portion on the crankshaft can be changed by driving into the deeper position GEAR CASE COVER Oil seal replacement Removal pry off or pull out Installation Installer 9 8522 0034 0 ...

Page 60: ...ustralia s premier Land Rover Website 2 32 ENGINE ASSEMBLY l l REASSEMBLY INTERNAL PARTS MINOR COMPONENTS PISTON AND CONNECTING ROD ASSEMBLV Reassembly steps 1 Piston 2 Piston pin connecting rod and bearing 3 Snap ring 4 Piston ring ...

Page 61: ... operations 1 Piston Heat the piston to about 60 C using a piston heater or equivalent 2 Piston pin and connecting rod Refer to the alignment hstructions given in the left figure 3 Snap ring Install the snap ring using a snap ring installer 4 Piston ring Install the piston ring using a piston ring installer The face with the mark NPRM or OPh should be turned up for the 1st and 2nd compression ring...

Page 62: ...e stem oil seal a 3 Valve lntak valve Exhauf valve Oo 5 a J 4 1 a 4 Springs a 5 Spring cap and SPlit key Important operations 2 Valve stem oil seal Install valve stem oil seals after lubricating them with clean engine oil Installer 1 85221 005 0 3 Valve Install the intake and exhaust valves in the proper posi tions Take care not to interchange the valves ...

Page 63: ...SEMBLY 2 35 Springs Install the valve springs with their close pitched painted side end down 5 Spring cap and split key Valve spring compressor 9 8523 1426 0 When split keys are installed tap on valve stem end lightly w ith a plastic hammer to insure correct seating of split keys ...

Page 64: ...lated to support AULRO com Australia s premier Land Rover Website 2 36 ENGINE ASSEMBLY ROCKER ARM BRACKET AND SHAFT ASSEMBLY Reassembly steps 1 Rocker arm shaft 4 Bracket 2 Spring 5 Snap ring 3 Rocker arm ...

Page 65: ... 5 Thrust bearing 6 Crankshaft bearing cap and crankshaft bearing Lower side 7 Timing gear case A 8 Camshaft assembly 9 Piston and connecting rod assembly 10 Oil pump assembly 11 Oil pump cover 18 12 Idle gear 13 Timing gear case cover 14 Crankshaft pulley 15 Crankshaft front nut and washer 16 Flywheel housing 17 Rear oil seal assembly 18 Flywheel 19 Cylinder head gasket 20 Cylinder head assembly ...

Page 66: ...ing is not provided with either oil groove or hole while all other bearings have the oil groove and hole upper side or the oil groove lower side 4 Crankshaft The crankshaft should be installed so that the end with the crankshaft gear is turned front of engine 5 Thrust bearing Thrust bearings should be installed so that their oil grooves are turned to the rotating face of crankshaft 6 Crankshaft be...

Page 67: ...ue kg m ft lbs 23 25 166 3 180 8 7 Timing gear case Torque kg m ft lbs 2 1 3 1 15 2 22 4 8 Camshaft assembly Tighten the thrust plate bolts through the camshaft gear hole Torque kg m ft lbs 2 1 3 1 15 2 22 4 9 Piston and connecting rod assembly Set the piston ring to the recommended positions The piston front mark should be turned to the front of the block Piston ring compressor 9 8522 1251 0 ...

Page 68: ...and con necting rod Tighten the connecting rod bearing cap bolts to the speci fied angle mm in 1st step kg m ft lbs 2nd step degree Torque 4 0 29 60 90 Oil pump assembly Install the oil pump after filling it with engine oil Torque kg m ft lbs 4 3 6 3 31 1 45 5 1 1 12 Idle gear Use thrust collar fixing bolts as guide The oil port should be turned to the camshaft ...

Page 69: ...d so that the chamfer side is turned to the front Crankshaft front nut Wrench 41 mm Torque kg m ft lbs 39 49 282 354 16 Flywheel housing 17 Rear oil seal assembly Apply a liquid gasket Belco Bond No 4 or equivalent to the shaded area in the drawing Torque Flywheel housing Rear oil seal assembly kg m ft lbs 12 5 15 5 90 4 112 1 2 1 3 1 15 2 22 4 18 F Iyw h ee 1 Torque kg m ft lbs 14 5 17 5 105 125 ...

Page 70: ... 5 68 7 76 0 47 0 54 2 11 0 12 0 Reused 7 5 86 8 4801 T Lubricate the head bolts with Mos2 grease and tighten them to the specified angle Torque kg m ft lbs 1st step 2nd 1 tep 3rd step 7 50 6 9 65 1 Note There are two lengths of head bolts The shorter ones must be used on injection pump side 22 Rocker arm shaft assembly Tighten the rocker arm shaft bolts a little at a time in numerical sequence as...

Page 71: ...A 6 Injection pump assembly A 7 Oil filter with bracket 8 Glow plug 9 lnjectior nozzle holder 6 10 Cylinder head cover 11 Thermostat housing assembly 6 12 Water pump assembly 13 Cooling fan belt 14 Cooling fan 6 15 Intake manifold assembly 16 Fuel filter _ 11 Exhaust manifold assembly 18 Oil level gauge with guide tube 19 Rubber hose 20 Oil pipe 21 Fuel pipe 22 Fuel injection pipe 23 Fuel injectio...

Page 72: ...er body and oil pan install oil pan gasket then install the oil pan Bolt torque g m ft lbs 1 1 2 1 8 0 15 2 2 Tappet camber cover Torque kg m ft lbs 1 6 2 6 11 6 1 8 8 3 Starter motor Torque kg m ft lbs 7 6 9 6 55 0 69 4 6 Injection pump assembly Torque kg m ft lbs 2 1 3 1 15 2 22 4 Only the bolt with arrow mark should be accessed from b ackward 7 Oil filter with bracket Torque kg m ft lbs 4 3 6 3...

Page 73: ... kg m ft lbs 2 25 2 75 16 3 19 9 9 Injection nozzle holder 10 11 Adjust the injection starting pressure with the adjusting screw using a nozzle tester Use new gaskets and dust covers The flange n uts should be tightened after tightening the injection pipe sleeve nuts Torque kg m ft lbs 2 25 2 75 16 3 19 9 Cylinder head cover Bolt torque kg m ft lbs 1 6 2 6 11 6 18 8 Tighten the bolts in numerical ...

Page 74: ...ater pump assembly Apply liquid gasketBelcoBond No 4 or equivale nt tothe gasket before installation 13 Cooling fan belt Adjust the fan belt tension 15 Intake manifold assembly 17 The gasket sholud be installed so tnat the side with the projection is positioned rearward and upward Torque kg m ft lbs 1 6 2 6 11 6 18 8 xhaust manifold assembly The g sketshould be installed so thatthe sidewith TOP ma...

Page 75: ...orque kg m ft lbs 1 6 2 6 1 1 6 18 8 Fuel pipe When installing the fuel pipes avoid interchanging the check valve and joint bolts Torque kg m ft lbs 2 0 2 5 14 18 Fuel injection pipe Torque kg m ftlbs 2 9 3 2 21 0 23 1 Over tightening of the delivery valve holder holder clip and injection pipe nut will invite malfunction of control rack Delivery valve holder torque kg m ft lbs 4 0 4 5 29 33 ...

Page 76: ...BlY 23 Turbo charger related parts Parts installation steps are refered as the following chart Heat protector Inlet rubber hose r Fuel cut bracket Safety valve assembly Boost compensator hose Oil drain pipe Torque kg m ft lbs 0 5 1 0 4 7 Oil feed pipe Torque kg m ft lbs 1 2 1 6 8 7 11 6 ...

Page 77: ...Collated to support AULRO com Australia s premier Land Rover Website rger assembly l i I Turbocha Torque kg m ft lbs ENGINE ASSEMBLy 2 49 ...

Page 78: ...Collated to support AULRO com Australia s premier Land Rover Website LUBRICATING SYSTEM 3 1 SECTION 3 LUBRICATING SYSTEM CONTENTS PAGE General description 3 2 Oil pump 3 3 Oil filter 3 5 Oil cooler 3 6 ...

Page 79: ...er Land Rover Website 3 2 LUBRICATING SYSTEM LUBRICATING SYSTEM Full flow filter r I I Over flow valve relief valve pump Oil Slr ainer OIL PUMP l Orilice 1 2mm 0 047in GENERAL DESCRIPTION Oil pan OIL FILTER Benerv I 4B01 T I only I I I I I I I I I L ...

Page 80: ...ver Website LUBRICATING SYSTEM 3 3 OIL PUMP 1 11 1 DISASSEMBLY AND REASSEMBLY Disassembly steps 1 Strain9r 2 Strainer case 3 Cover 4 Reliefvalve assembly 5 Vane 6 Rotor assembly Reassembly steps To reassemble follow the disassembly procedures in reverse order ...

Page 81: ...tor set pin shaft rotor vane Standard mm in 0 050 0 1 14 0 0020 0 0045 Check the clearance between the rotor and vane If the measured value is beyond the standard value replace the rotor set Standard mm in 0 14 0 0055 or less Check the clearance between the vane and pump body If the clearance is excessive replace the entire pump assembly Standard mm in 0 20 0 30 0 008 0 Q12 Check the clearance bet...

Page 82: ...RO com Australia s premier Land Rover Website LUBRICATING SYSTEM 3 5 OIL FILTER 1 11 1 REMOVAL AND INSTALLATION Removal steps 1 Main oil filter 2 Partial oil filter Installation steps 2 Partial oil filter 1 Main oil filter 2 ...

Page 83: ... Land Rover Website 3 6 LUBRICATING SYSTEM Disassembly steps 1 Element 2 Bolt OIL COOLER l l DISASSEMBLY INSPECTION AND REPAIR Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found through inspection ...

Page 84: ...sembly steps A 1 Element A 2 Bull LUBRICATING SYSTEM 3 7 l l REASSEMBLV Important operation Installation 1 Element Torque l g m ft lbs 2 1 3 1 1 5 2 22 4 2 Bolt Tighten the bolts in numerical sequence as specified T _o _r_qu _e ___ kg _m l_tl_bs__ _L__ 2 _ 1_ 3 1 1 5 2 22 4 ...

Page 85: ...Collated to support AULRO com Australia s premier Land Rover Website I COOLING SYSTEM 4 1 SECTION 4 COOLING SYSTEM CONTENTS PAGE General descripti on 4 2 Water pump 4 3 Thermostat 4 8 I ...

Page 86: ...Collated to support AULRO com Australia s premier Land Rover Website 4 2 COOLING SYSTEM GENERAL DESCRIPTION THERMOSTAT ...

Page 87: ...e WA T E R P U M p CO OJLILING SYSTEM 4 3 l l DISASSEMBLY DisassemblY steps 1 Cover 2 Impel 3 er 4 6ulley center us1 thrower l w I 2 Repair kit 5 6 7 Snap ring Spindle bearin Seal mit 9 and spacer washer and seal Important operations 2 Impeller ver 9 RS 1 f 097 0 Remo ...

Page 88: ...lley center Use a bench press and a suitable rod 5 Snap ring Remove the snap using a snap ring pliers 6 Spindle bearing and spacer Remove the spindle with bearings using a bench press and suitable remover 7 Seal unit washer and seal Remove the seal unit using a bench press and Suitable remover ...

Page 89: ...ection or parts replacement ifwear damage orany otherabnormal conditions are found through inspection Seeled side outward E1 w Bearing replacement procedure Removal Use a bench press Installation Use a bench press for the front and rear bearings installa tion The bearings should be so installed that their sealed side are turned outwards ...

Page 90: ...nd spacer t 2 Washer seal and seal unit 3 Snap ring 4 Dust thrower Repack whh multipurpose type grease Sealed side outward t 5 Pulley center t 6 Impeller 7 Cover Important operations 1 Spindle bearing and spacer Repair kit Repack the bearings with multipurpose tvr P orease before installing into the pump body Install the above asse nbly using a bench press Installer 9 8522 1140 0 ...

Page 91: ...ond No 4 to the surface in contact with the pump body 3 Snap ring Install the snap ring using a snap ring pliers 5 Pulley center Use a bench press Press in until it stops 6 Impeller Install the impeller using a bench press so that the clear ance between the impeller and body is held within the specified value Standard mm in 0 3 0 8 0 012 0 031 ...

Page 92: ... COOLING SYSTEM THERMOSTAT I L I INSPECTION AND REPAIR Make necessarycorrection or parts replacementifwear damage or anyother abnormal conditions are found through inspection Valveopeningtemperature C F 80 84 176 183 Valve lift Standard Approx 10 mm at 95 C 0 4 in at 203 F ...

Page 93: ...Collated to support AULRO com Australia s premier Land Rover Website FUEL SYSTEM 5 1 SECTION 5 FUEL SYSTEM CONTENTS PAGE General description 5 2 Injection pump 5 3 Injection nozzle 5 10 Fuel filter 5 13 ...

Page 94: ...Collated to support AULRO com Australia s premier Land Rover Website 5 2 FUEL SYSTEM GENERAL DESCRIPTION l ...

Page 95: ... 11 Bolt front side six 4 Intake manifold 10 Grommet 5 Engine control cable 13 Bracket 6 Fuel pipe feed pump to filter 8 Fuel pipe filter to injection pump 7 Fuel return pi 7 Fuel return pipe 8 Fuel pipe filter to injection pump 6 Fuel pipe feed pump to filter 9 Hole cover 5 Engine control cable 10 Grommet 4 Intake manifold 1 Bolt front iue 5i 3 Fuel injection pipe 12 Bolt rear side one 2 Fuel lea...

Page 96: ...ning 6 through bolts and a nut The thro h bolt is hidden behind the hole cover The nut should be accessed from backward Important operations Installation 14 Injection pump Install the injection pump assembly so that the notched line on the automatic timer align with the arrow mark on the timing gearcase cover Iftiming gear train getsmisalignment tu rn the crankshaft in a clockwise direction to bri...

Page 97: ...Collated to support AULRO com Australia s premier Land Rover Website FUEL SYSTEM 5 5 4 Inta ke manifold Torque kg m ft lbs 1 6 2 6 11 6 18 8 ...

Page 98: ...of in use D K K C P No 105780 0000 Bosch type No DN12SD12T D K K C P No 105780 2080 Bosch type No EF8511 9A 175 kg cm2 2489 psi Outside dia 6mm 0 236 in x Inside dia 2mm 0 078 in Length 600 mm 24 in 1 6 kg cm2 23 psi SAE standard test diesel fuel SAE J967d or IS04113 35 45 C 95 113 F IDENTIFICATIONS PLATE AND NUMBER Pump No 101 NP PE 6A95 LICENCE BOSCH l IdentificatiOn number When agjusting the vo...

Page 99: ...ity Adjusting Control rack Pump speed Strokes Injection volume Variance Fixed Remarks point position mm r p m cc 1 000 st A 11 3 950 1000 67 3 70 3 2 5 Rack Basic H About 9 5 290 1000 6 7 9 3 14 0 Rack A R1 11 3 950 1000 67 8 69 8 Lever Basic B 10 95 1600 1000 67 0 70 2 Lever c 11 15 1300 1000 70 9 74 1 Lever 0 11 05 650 1000 48 7 51 9 Lever E 11 4 500 1000 49 9 53 9 Lever Timing Advance Specifica...

Page 100: ...e of in use D K K C P No 105780 0000 Bosch type No DN1 2SD12T D K K C P No 105780 2080 Bosch type No EF8511 9A 175 kg cm2 2489 psi Outside dia 6mm 0 236 in x Inside dia 2mm 0 078 in Length 600 mm 24 in 1 3 kg cm2 18 psi SAE standard test diesel fuel SAE J967d or 1504113 40 45 C 104 113 Fl IDENTIFICATIONS PLATE AND NUMBER 0 I A I o 3RG Pumo No 101 NP PE 6A95 I LICENCE BOSCH When adjusting the volum...

Page 101: ...101401 0660 with Boost compresator Injection Quantity Injection volume Variance I Fixed Remarks cc 1 000 st 69 6 72 8 2 5 Rack Basic 6 7 9 3 14 0 Rack I 70 2 72 2 Lever Boost pressure Above 11 OmmHg I Boost pressure 49 7 Lever I Above 11 OmmHg 29 7 Lever 78 0 I Lever Boost pressure I I Above 11OmmHg Above 90 0 1 Lever Timing Advance Specification Pump Speed rpm Degree for Angle of Lead deg 11200 1...

Page 102: ...ssure of 165 kg cm2 2346 psi if there is no leakage the nozzle is satisfac tory Nozzle spray pattern Turn the handle oftesterclockwise until it isseated Hav ing moved the nozzle tester lever several times abruptly check the spray pattern at a lever speed of 4 6 times per second or more CAUTION When using the nozzle tester test fluid will spray out of injectionnozzle atgreatpressure w hich can easi...

Page 103: ...lng screw 4 Washer 5 Nozzle spring_ FUEL SYSTEM 5 11 DISASSEMBLY i Y y 1 2 3 4 5 I __ _ j 6 Push rod I Hetam1ng nut 8 Injection nozzle 9 Connector 10 Gasket Important operation 8 Injection nozzle Keep nozzle assembl t removed from the nozzle body separate from other ur its to maintain proper needle valve and body combinations ...

Page 104: ...askets and install new one Clean the nozzle and nozzle holder with clean diesel fuel Check them for worn out corrosion lnrl rlarnage and replace if necessary Carbon deposit on the tip end of the needle valve and injection holes should be cleaned using nozzle cleaning kit j 1REASSEMBlY 9 I 8 I 7 3 6 4 l_ _ j Disassembly steps 1 Gasket 6 Nozzle spring 2 Connector 7 Washer 3 Injection nozzle 8 Adjust...

Page 105: ... DISASSEMBLY 2 Removal steps 1 Fuel filter cartridge 2 Fuel filter body IL itl INSPECTION AND REPAIR Make necessary correction or parts replacement ifwear damage or any other abnormal conditions are found through inspection l l REASSEMBLY To reassemble follow the disassembly procedure in reverse order ...

Page 106: ...g pressure adjustment w g Important operations 3 Injection nozzle The locating pin on nozzle mustbe aligned with the holein nozzle holder body 4 Retaining nut Torque kg m ft lbs 6 8 43 58 8 Adjusting screw Make an adjustment after installation of the adjusting screw Injection starting prcscure kg cml psi 185 2630 10 _c_a_ p_n_u_t Torque kg m ft lbs 4 5 29 36 ...

Page 107: ...Collated to support AULRO com Australia s premier Land Rover Website TURBOCHARGER 6 1 SECTION 6 TURBOCHARGER CONTENTS PAGE General description 6 2 Removal 6 3 Inspection and repair 6 4 Installation 6 5 ...

Page 108: ...Collated to support AULRO com Australia s premier Land Rover Website 6 2 TURBOCHARGER GENERAL DESCRIPTION ...

Page 109: ...Collated to support AULRO com Australia s premier Land Rover Website TURBOCHARGER 3 E REMOVAL 1 Intake duct 2 Intake rubber hose 3 Heat protector 4 Fixing nuts and bolts 5 Oil pipe ...

Page 110: ...ply the specified pressure to the actua tor Check the control rod operation Note The engine mustbe off not running during this proce dure Control rod operation kg cm2 psi 0 9 12 8 680 mmHg Pressure gauge 5 8840 0075 0 2 Boost pressure 1 Remove the hose at the compressor blower side 2 Attach a pressure gauge to the compressor blower side 3 Attach the tacilometer lead wire to the No 1 nozzle holder ...

Page 111: ...he turbine shaft by hand to check for abnor mal noise and excessive play 3 Check each of the flange and oil pipe connections on the turbine the center and the compressor housing for oil leaks Note The engine must be off not running and cold during this inspection procedure 1 1 INSTALLATION To install the turbocharger follow the removal procedure in the reverse order ...

Page 112: ...rt AULRO com Australia s premier Land Rover Website ELECTRICAL SYSTEM 7 1 SECTION 7 ELECTRICAL SYSTEM CONTENTS PAGE Starter motor 7 2 Alternator and regulator 7 9 Vacuum pump 7 32 Glow plugs 7 33 Control resistor 7 33 I ...

Page 113: ...ted voltage Rated output Rating Direction of rotation As viewed from pinion side Type of clutch V kW Sec Terminal voltage No load V No load current Max A Number of revolutions Min No load rpm r Pinion gear Module 12 2 5 30 Clockwise Roller 11 170 3 800 Number teeth 11 Outside diameter mm in 40 5 1 59 Distance of travel mm in 81 0 032 Yoke Outside diameter mm in 90 3 54 Armature Outside diameter mm...

Page 114: ...ollated to support AULRO com Australia s premier Land Rover Website ELECTRICAL SYSTEM 7 3 TORQUE SPECIFICATIONS Manufacturer s code no 028000 6561 kg m ft lbs 0 27 0 47 1 95 3 40 J a T 0 7 1 2 5 06 8 68 ...

Page 115: ...lended or characteristics will be deteriorated Manufacturer s code no 028000 6561 No Lubricating points Recommended lubricant Bilateral surface of drive pinion and idler and idler gear Teeth surface of gears Nippondenso No 50 grease Ball bearings Aeroshell 1 SHELL 1 Felt washer 2 Roller Aerosheii7A SHELL 3 Retainer 4 Steel ball Beacon 325 ESSO 5 Return spring ...

Page 116: ...Collated to support AULRO com Australia s premier Land Rover Website ELECTRICAL SYSTEM 7 6 CIRCUIT ARRANGEMENT Manufacturer s code no 028000 6561 BATTERY ...

Page 117: ...se brush spring on brush holderside and pull the brush partway offthe commutator and hold itin thatposi tion by setting brush spring against the brush 4 Ifthe housing yoke or end frame is fitted tightly and does not come off easily tap on the circumference of the parts lightly with a plastic hammer or soft faced hammer Manufacturer s code no 028000 6561 13 Disassembly steps 1 Nut 12 Lock plate 2 C...

Page 118: ...ECTRICAL SYSTEM 7 7 Important operation 21 Magnetic switch 1 The hexagonal nuts on terminal bolts must not be loos ened IL ij l INSPECTION AND REPAIR Make necessary correction or parts replacement ifw ear damage or any other abnormal condition are found through inspection ...

Page 119: ...r exercise care so as not to cause damage to the brusht 3 Properly align the setting marks applied to the yoke or end frame at disassembly before tightening 4 Tighten fixing bolts screws and nuts to the specified torques Manufacturer s code no 028000 6561 17 Reassembly steps 1 Magnetic switch 12 Armature 2 Return spring 13 Yoke 3 Steel ball 14 Brush holder 4 Clutch 15 Brush 5 Roller 16 Cover 6 Ret...

Page 120: ... REG BUILT IN Hitachi Ltd Japan A lsuzu part number 8 Manufacturer s code number C Rated voltage D Manufacturer s production mark REGULATOR lsuzu part no Manufacturer s code no 5 81200 132 0 100210 1150 8 94175 448 1 LR170 401 11 Hitachi regulator is identified with the mark printed on the cover as illustrated II A B c II o A lsuzu part number 8 Manufacturer s code number C Rated voltage D Manufac...

Page 121: ...anufocturer no REGULATOR Engine model lsuzu part no Voltage regulator Regulated voltage Yoke gap Core gap Point gap Relays Yoke gap Core gap Point gap Vl A rpm rpm Amp Nolt rpm Volt rpm mm in l l mm in mm in mm in mm in M mm in mm in mm in mm in mm in mm in 4801 5 81200 132 0 100210 1150 12 40 850 10000 5000 40 14 3500 14 820 1020 Clockwise Negative 90 3 54 4 0 0 16 12 5 0 49 5 5 0 22 42 0 1 65 41...

Page 122: ...and Rover Website Alternator Combined regulator Alternator Manufactuer s code no 100210 1150 026000 251 0 I F r I ELECTRICAL SYSTEM 7 11 Alternator indicator light N I I I I _L E _ _ _j l Regulator Manufactuer s code no LR1 70 401 _ 0 5J IF E I E T I _L ...

Page 123: ...Collated to support AULRO com Australia s premier Land Rover Website 7 12 ELECTRICAL SYSTEM TORQUE SPECIFICATIONS ALTERNATOR Manufacturer s c ode no 100210 1150 kg m ft lbs ...

Page 124: ...Collated to support AULRO com Australia s premier Land Rover Website ELECTRICAL SVSTEM 7 13 Manufacturer s code no LR170 401 ...

Page 125: ...e parts in original position apply a setting mark across the drive end frame and rear end frame 2 Clamp the rotor in vise when removing pulley nut Use a soft jawed vise to prevent to prevent damaging rotor assembly 3 Keep insulation washers neatly in sequence of removal to avoid installing them in wrong position 4 When disconnecting stator coil leads from rectifiers using asoldering iron melt sold...

Page 126: ...0 4 Through bolt 11 5 Rear end frame 12 6 Screw 13 7 Retainer plate 14 ELECTRICAL SYSTEM 7 15 Bearing lock nut 15 Terminal Rotor 16 Drive end frame Ball bearing 17 Stator Screw 18 Brush holder Cord clip 19 Insulator Nut 20 Rectifier Insulator Important operation 8 Bearing lock nut Remove bearing lock nut by turning clockwise The loci nut has left hand thread ...

Page 127: ... using a soldering iron solder quickly and use long nose pliers or equivalent to l llow for heat dissipation 2 When installing terminal bolts and rectifier fixing nuts be sure insulation washers are in place 3 When fitting the rotor slip ring underthe brushes hold the brushes in raised position byfitting a piece of hard wire into guide holes in the drive and frame or rear end frame 4 Install a gui...

Page 128: ...er s code no 100210 1150 I Reassembly steps 1 Rectifier 11 Ball bearing 2 Insulator 12 Rotor 3 Brush holder 13 Bearing Jock nut 4 Stator 14 Retainer plate 5 Drive end fram 15 Screw 6 Terminal 16 Rear end frame 7 Insulator 17 Through bolt 8 Nut 18 Key 9 Cord clip 19 Pulley and fan 10 Screw 20 Pulley nut ...

Page 129: ...e parts in original position apply a setting mark across the drive end frame and rear end frame 2 Clamp the rotor in vise when removing pulley nut Use a soft jawed vise to preventto prevent damaging rotor assembly 3 Keep insulation washers neatly in sequence of removal to avoid installing them in wrong position 4 When disconnecting stator coil leadsfrom rectifiers using asoldering iron melt solder...

Page 130: ...01 3 14 4 Disassembly steps t 1 Vacuum pump assembly t 2 Through bolt t 3 Pulley and rotor assembly t 4 Rear cover and stator assembly t 5 Pulley nut 6 Pulley 7 Fan 8 Spacer 9 Rotor I 2 10 Rear ball bearing 11 Bearing retainer 12 Front ball bearing 13 Front cover t 14 Rear cover t 15 Stator and diode assembly t 16 Diode assembly 17 Stator ...

Page 131: ...ove the rotor and vane in the order mentioned 2 Through bolt Remove the through bolts and separate the body into front and rear sections When separating exercise care so as not to allow stator coils to come off the rear cover 3 Pulley and rotor assembly 4 Rear cover and stator assembly Take care not to damage the oil seal when removing the rear cover Taping the splines will provide some protection...

Page 132: ...then remove the screw inside the stator Separate the stator and rear cover Note the position of insulation washers to insure reas sembly into original position 16 Diode assembly Separate the diodes from the stator by melting away sol der on stator coil diode and N terminal leads When melting solder hold the lead wire with longnosepli ers to prevent heat from being transferred to the diodes ...

Page 133: ...replacement if wear damage or any other abnomal condition are found through inspection Measure the outside diameter of the slip rings mm in Standard Limit 34 6 1 362 33 6 1 323 Continuity test Check the rotor coil resistance across the slip rings If no continuity exists replace the rotor Ground test Check for continuity across the slip ring and rotor core or shaft If a continuity exists the parts ...

Page 134: ... 0 787 mm in Limit 6 0 24 Brushes are provided with a line whrch indicates the limit of usage DIODE Check for continuity across the terminals example across BAT and U If a continuity exists the dio de is in satisfactory co ndition Ifno continuity exists the diode is defective Make a test with the polarities reversed If no continuity exists the diode is in satisfactory condition If a continuity exi...

Page 135: ...ty Negative side No continuity IC REGULATOR Measuring instruments to be prepared Battery standard voltage 12V 2 pes 20V 26V Take the following measurements with the instruments connected as shown in the illustration V2 Measure thevoltage across the terminals E Fwhile varying resistance gradually from zero using var iable resistor Then check that abrupt voltage increase from less to more around 2V ...

Page 136: ... zero using variable resistor Then check it when voltage increases abruptly Standard voltage at zo c 68 F V 14 9 16 5 If measured voltage deviates from the standard value replace the regulator VACUUM PUMP Visual check Inspect the following parts for wear damage or other abnormal conditions Measure the length of vanes Standard mm in 12 5 13 5 0 492 0 531 Measure the inside diameter of housing Stand...

Page 137: ...e onto the valve with a screw driver and check that valve operates smoothly OIL SEAL Inspection Che9k inner face of the rear cover for traces of oil leakage Also check inner face of the oil seal for wear or damage Replacement 1 Using a screw driver remove oil seal from rear cover side 2 Install a new oil seal using oil seal installer ...

Page 138: ...ent to allow for heat dissipation 2 When installing terminal holts and rectifier fixing nuts be sure insulation washers are in place 3 When fitting the rotor slip ring under the brushes hold the brushes in raised position by fitting a piece of hard wire into guide holes in the drive and frame or rear end frame 4 Install aguide bar through holesin drive end frame and rear end frame for alignment of...

Page 139: ... LR170 401 15 14 16 Reassemply steps Stator 10 Spacer 2 Diode assembly 11 Fan 3 Starter and diode assembly 12 Pulley 4 Rear cover 13 Pulley nut 5 Front cover 14 Rear cover and stator 6 Front ball bearing assembly 7 Bearing retainer 15 Pulley and rotor assembly 8 Rear ball bearing 16 Through bolt 9 Rotor 4 17 Vacuum pump assembly ...

Page 140: ...m the outer ring as the ring is mounted on the eccentric groove of the outer ring Upon assembling rotate the ring to a position where this protrusion is at a minimum then assemble the ring Limit mm in 0 65 0 0256 In addition inspect the bearing of the rear cover Should any irregularitybe present replace the rear cover at the same time 13 Pulley nut Clamp the rotor in a vise and install the pulley ...

Page 141: ...ar cover flange for alignment them install the through bolts 17 Vacuum pump assembly Position the rotor with the serrated boss turned up on the center plate and housing Align the holes in center plate and rotor Install vanes into slits in rotor The vanes should be nstalled with round side turned out ward After installation of O ring install the center plate by turn ing it If the holes in housing a...

Page 142: ...ralia s premier Land Rover Website ELECTRICAL SYSTEM 7 31 Install and fix the housing to the generator using 3 volts Pour engine oil pee or so in through the filler port then check that generator pulley can be turned smoothly with hand ...

Page 143: ...s illustration is based on the 4801 engine Rotor Vane MAIN DATA AND SPECIFICATONS Engine model Pump type Theretical derively Maximum allowable speed Direction of rotation Weight cc rev in3 rev rpm kg lbs 4801 4BD1T Oil cooled vane type pump 31 1 89 10 000 I 30 1 83 11 000 Clockwise as viewed from coupling side 2 2 4 85 0 9 1 98 ...

Page 144: ... Rated current Time taken before 8oo c is reacned V A n Sec CONTROL RESISTOR 5 81410 023 0 10 5 6 7 5 1 8 20 25 MAIN DATA AND SPECIFICATIONS lsuzu part no Rated voltage Rated current Internal resistance Time taken before 8oo c is reached lnsulaton resistance Saturation temperature V A n Sec Mn C 9 8253 0041 0 12 26 0 028 0 032 20 25 1 or higher 1000 or lower ...

Page 145: ...m Australia s premier Land Rover Website AUXILIARIES 8 1 SECTION 8 AUXILIARIES POWER STEERING OIL PUMP CONTENTS PAGE General description 8 2 Main data and specification 8 2 Disassembly 8 3 Inspection and repair 8 4 Reassembly 8 5 ...

Page 146: ...SPECIFICATION Item Pump type V Theoritical delivery volume cc rev in3 rev Relief valve preset pressure kg cm2 psi Preset delivery volume liter min UK gallon min at 200 rpm Pump operating speed Pump to crankshaft speed ratio to 1 Weight dry rpm kg lbs Centifugal vane 12 2 0 732 85 1208 8 1 8 450 4000 0 89 25 28 4 3 9 48 ...

Page 147: ...l l DISASSEMBLY 5 Disassembly steps 1 Outer connector and 0 ring 10 Side plate 2 Plug and 0 ring 11 0 rings 3 Relief valve 12 Spring 4 Spring 13 Snap ring 5 Gear 14 Shaft with bearing 6 Cover 15 Snap ring 7 0 ring 16 Collar 8 Cartridge assembly 17 Oil seal 9 Knock pin 18 0 ring 19 Body ...

Page 148: ...17 Oil seal Use a suitable brass drift IL O I INSPECTION AND REPAIR Makenecessary correction or parts replacementifwear damage or anyother abnormal conditionsarefound through inspection Bearing replacement procedure Removal Remove the snap ring and then remove the bearing using a bench press and a suitable rod Installation Use a bench press and a suitable rod ...

Page 149: ... 1 Body 2 0 ring 3 Oil seal 4 Collar 5 Snap ring 6 Shaft with bearing 7 Snap ring 8 Spring 9 Oil seals 10 Side plate AUXILIARIES 8 5 j j REASSEMBLV 11 Knock pin 12 Cartridge assembly 13 0 ring 14 Cover A 15 Gear 16 Spring 17 Relief valve 18 Plug and 0 ring 19 Outer connector and 0 ring ...

Page 150: ...Collated to support AULRO com Australia s premier Land Rover Website 8 6 AUXILIARIES Important operation 15 Gear Torque kg m ft lbs 8 10 58 72 ...

Page 151: ...Collated to support AULRO com Australia s premier Land Rover Website SPECIAL TOOL LIST 9 1 SECTION 9 SPECIAL TOOL LIST CONTENTS PAGE Special tool list 9 2 I ...

Page 152: ...1169 0 Cylinder liner remover JKM 1021 9 8523 2557 0 4 EN 8 Cylinder liner remover ankle JKM 1022 5 9 8523 2554 0 Cylinder liner installer 1 III JKM 1024 9 852 1 0141 0 6 OT 3 Crankshaft gear remover try JKM 1026 Cg I 9 8522 0033 0 7 1 JKM 1027 Crankshaft gear installer I 5 8840 2000 0 8 OT 6 Crankshaft pilot earing remover I JKM 1026 9 5 8522 0024 0 Crankshaft gear installer JKM 3035 9 8522 1254 ...

Page 153: ...KM 1035 13 w 9 8521 0063 0 Crankshaft pulley remover JKM 3222 14 w 9 8521 Q063 0 Crankshaft pulley remover JKM 3222 15 1 85221 005 0 Valve stem oil seal installer JKM 1 030 16 9 8522 1251 0 Piston ring compressor JKM 1102 17 9 8521 0097 Q Water pump impeller remover JKM 1031 18 a a 9 8522 1140 0 Water pump bearing installer JKM 1032 19 51 1 85111 0030 Cylinder head bolt wrench JJ JKM 1002 20 5 884...

Page 154: ...ch 1 JKM 1017 T 1 1IJ 23 J 33895 ACG checker Built in IC regurator I 1 5 85253 001 0 I 24 Clutch pilot aligner u na J 24547 I 5 8840 2000 0 I 25 OT 7 Crankshaft pilot bearing remover I J 5822 I I 26 5 8522 0024 0 Crankshaft pilot bearing installer JKM 3035 27 5 8840 2058 o Servo unit support plate 0 JKM 20580 28 9 8523 1733 0 Handle JKM 3250 i 0 OT 3 9 8511 4307 0 Handle JKM 3146 1 l OT 6 5 8840 0...

Page 155: ...Collated to support AULRO com Australia s premier Land Rover Website SPECIAL TOOL LIST 9 5 ITEM NO ILLUSTRATION PART NO PART NAME OT 7 5 8840 0084 0 Sliding hammer J 2619 01 Big ...

Page 156: ...Collated to support AULRO com Australia s premier Land Rover Website TROUBLESHOOTING 10 1 SECTION 10 TROUBLESHOOTING CONTENTS PAGE Engine assembly 10 2 Lubricating system 10 11 I ...

Page 157: ...gine startability is more or less affected by the environmental temperature conditons I c Chect operation of pre heating circuit Check injection nonles CheCk valve clearances Check compreS iOn pres sure in eac h cylinder IHard starting Checl level of fuel in fuel tank against fuel gauge Check notched line on injection pump flange for proper alignment Check to see if fuel is reaching injection nozz...

Page 158: ...heek accelerator el lntrol cable for binding or twisting Checl seal on max mum speed stop bolt and full load adjust bolt Check to see if accelerator control lever is in contaCt with maximum weed stOP bolt Check exhaust muffler and oip for r trictions Chec1 to see if air has been removed eomoletely from fuel filter Check fuel p pes for being collapse or loose connect ons Check fuel tank breather fo...

Page 159: ...e speed Is lower than specified range On moclels with air conditioning check operatton of fast idle control device Check accelerator control cable for binding or twisting Check setting of accelerator lever for looseness Chec k to see if air or water in fuel filter has been removed eompletely Check notched line on injection pump fla1ge for proper alignment Check engine mounting for loosening or cra...

Page 160: ...ne is thoroughly wormed up I Check air cleaner for restrictions I Check to see if air or water has been removed completely from fuel filter Check sealing on fu11 load adjust bolt Check exhaust muffler and pipes for restrict ions Cheek to see if fuel in use i inferior in Quahty eck injection timing D J Check injection noz ztes j Check valve clearances Fuel spray pattern Injection starting p e re 18...

Page 161: ...of gases into cooling water circuit due to defective gasket excessive volume of fuel injection incorrect injection timing deposit of carbon within the combustion chambers are but some of the causes of engine over heating which are often overlooked IEngine overheating j 0 ICheck le l ofcoolant in radiator 0 I Check condition of coolant 0 I Check h05es for leakage I 0 I Check water pump for teakage ...

Page 162: ...eek injection timlng Cf ledc injcc tion nou le Fuel spray pattern Injection starting pre Sure 185kg cm1 2631P il Check compression pressure in each eytindttr Stenderd value 31kg em 441P il Value indicating need for servic ing 22 23kg cm1 313 327 psi Check to see tf fuel in use i s in4 fertor in quality Rt adju st or replace injection pump Abnormal engine noite IContinuout f oi NoiM indiceting ges ...

Page 163: ... results of road test are satisfactory trouble in the fuel system is suspected To determine the condition of the fuel system check fuel spray condition and inje tiun starling pr ssure using a nozzle tester Fuel consumption excessive C c air cle Jncr for n str c SJ __ Ch t k s il l CHt lu ll load Cjust in b oJt J Q ICheck tuel ipes for 1 0 L Check en ine idling peed I J jcht ck to see if fut 110 e ...

Page 164: ...ons A trace of oil is normally found around the valve head is localized to hat area when internal oil leakage is present IOil consumption excessive IOil eating I I 0 ICheck oil le l ICh ck drain plug for looseness ICheck oil pipos for leak Check oil seal retainer and oil filter seat gasket for 1eakage Check rubber gaskets in cylinder head cover oil pan and oil pump for leakage ICheck cylinder head...

Page 165: ...ef valve sticking Replace relief valve Obstruction in oil pump gauze filter Clean or replace gauze filter Oil pump driven and drive gear worn Replace oil pump assembly Oil pipe cracked broken or loosely Correct or replace connected Oil pump defective Replace oil pump assembly Crankshaft bearings or connecting rod Replace Bearings worn excessively Oil pressure gauge defective Correct or replace Oil...

Page 166: ...rior of radiator Gases leaking into water jacket due to Check cylinder head and replace broken cylinder head gasket gasket Engine over cooling Thermostat defective valve not Replace thermostat closing completely Frequent replenish Radiator leaking Correct or replace ment is needed Radiator hoses loosely connected or Retighten clips or replace hoses damaged Radiator cap valve spring weakened Correc...

Page 167: ...54 64 2 5197 89 3 5039 7132 5 S563 23132 18 2563 IS 0 5906 40 1 5748 6 2 5591 90 3 5433 15 64 5 9531 47 64 18 6531 16 0 6299 41 1 8142 6 2 5984 91 3 5827 1 4 6 3500 31 4 19 0500 17 0 6693 4 2 1 6535 67 2 6378 92 3 6220 17 64 6 7469 49 64 19 4469 18 0 7087 43 1 6929 68 2 6772 93 3 6614 9 32 7 14 38 25 32 19 8438 19 0 7480 44 1 7323 69 2 7165 94 3 7008 19 64 7 406 5 1 64 20 2406 20 0 7874 45 1 7717 ...

Page 168: ... 298 5564 301 8373 305 1181 308 3990 311 6798 314 9606 318 2415 321 5223 324 8032 90 100 328 0840 331 3648 334 6457 337 9265 341 2074 344 4882 347 7690 3 51 0499 354 3307 357 6116 100 MILES TO KILOMETERS miles 0 1 2 3 4 5 6 7 8 9 miles km km km km km km km km km km 1 609 3 219 4 828 6 437 8 047 9 656 11 265 12 875 14 484 10 16 093 17 703 19 312 20 921 22 531 24 140 25 750 27 359 28 968 30 578 10 2...

Page 169: ... 15 810 15 965 16 120 16 275 16 430 16 583 16 740 16 895 100 VOLUME CUBIC INCHES TO CUBIC CENTIMETERS in l 0 1 2 3 4 5 6 7 8 9 inl cm lec cm ccl em21ce cm lce cm cc cm1 cc cml cc em ce em Ieel cm cc 16 387 32 774 49 161 65 548 81 935 98 322 114 709 131 097 147 484 10 163 871 180 258 196 645 213 032 229 419 245 806 262 193 278 580 294 967 311 354 10 20 327 741 344 128 360 51 5 376 902 393 290 209 6...

Page 170: ... 22 4546 1 22 7188 22 98 30 2 3 2471 123 5113 1 so 90 1 23 7755 24 039 7 243038 24 5680 24 8321 2 0963 25 3605 25 6247 25 6889 26 1 530 90 100 264172 i 26 6814 1 269455 21 zo91 27 4739 2 7 7381 28 oo22 28 2664 28 5306 26 7947 1oo GALLONS IMP l TO LITERS lmp g l 0 1 2 3 4 5 6 7 8 9 Imp gal liters Jitets li1ers liters liters hte li1ers iters liters liters 4 5459 90918 13 6377 18 1836 22 7295 2 7 2 7...

Page 171: ...200 621 202 825 205 030 207 234 209 439 211 644 213 848 216 053 218 258 90 100 220 462 222 667 224 87 1 227 076 229 281 231 485 233 690 235 895 238 099 240 304 100 KILOGRAMS TO NEWTON kg 0 1 2 3 4 5 6 8 9 kg N N N N l N N N N N N 9 81 19 61 29 42 39 23 49 03 58 84 68 65 78 45 88 26 10 98 07 107 87 117 68 127 4g 137 29 147 10 156 91 166 71 176 52 186 33 10 20 196 13 205 94 215 75 225 55 235 36 245 ...

Page 172: ... 40 1251 62 1265 85 80 90 1280 07 1294 20 1308 52 1322 74 1336 96 1351 19 1365 41 1379 63 1393 85 1408 08 90 100 1422 30 1436 52 1450 75 1464 97 1479 1jl 1493 42 1507 64 1521 86 1536 08 15 iO l1 100 KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL kg em 0 1 2 3 4 5 6 7 8 9 kg em KPa KPa KPa KPa KPa KPa KPa KPa KPa KPa 98 1 196 1 294 2 392 3 490 3 588 4 686 5 784 5 882 6 10 980 7 1078 7 1176 8 1274 ...

Page 173: ... 694 37 701 6 708 83 716 07 90 100 723 30 730 53 737 71 745 00 752 23 759 47 766 70 773 93 781 16 788 40 100 KILOGRAMMETERS TO NEWTONMETERS kg m 0 1 2 3 4 5 6 7 8 9 kg m N m N m N m N m N m N m N m N m N m N m I 9 81 19 61 29 42 39 23 49 03 58 84 68 65 78 45 88 26 10 98 07 107 87 117 68 127 4 9 137 29 147 10 156 91 166 71 176 52 186 33 10 20 196 13 205 94 215 75 225 55 235 36 245 17 254 97 264 78 ...

Page 174: ... 7 228 108 9 286 141 1 344 173 3 440 226 7 CENTIGRADE TO FAHRENHEIT c F c f c F c O f c f c f c O f c f 50 58 0 18 0 4 14 57 2 46 114 8 78 172 4 110 230 0 142 287 6 174 345 2 49 56 2 17 1 4 15 59 0 47 116 6 79 174 2 111 231 8 143 289 4 175 347 0 48 54 4 1 6 3 2 16 60 8 48 118 4 80 176 0 112 233 6 144 291 2 176 348 8 47 52 6 15 5 0 17 6 6 49 120 2 81 177 8 113 235 4 145 293 0 177 350 6 46 50 8 14 6...

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Isuzu 4BD1, Workshop Manual

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