ENGINE

Tier 4

WORKSHOP MANUAL 3CH1/3CJ1

IDE-2399A
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TNV IDI Service Manual

TABLE OF
CONTENTS
Page
Table of Contents ................................................................................... i-i
Introduction ......................................................................................... 1-1
Safety.................................................................................................... 2-1
General Service Information .............................................................. 3-1
Periodic Maintenance ......................................................................... 4-1
Engine .................................................................................................. 5-1
Fuel System ......................................................................................... 6-1
Cooling System ................................................................................... 7-1
Lubrication System ............................................................................. 8-1
Starter Motor........................................................................................ 9-1
Alternator ........................................................................................... 10-1
Electric Wiring ................................................................................... 11-1
Troubleshooting ................................................................................ 12-1

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TABLE OF CONTENTS

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TNV IDI Service Manual

Section 1

INTRODUCTION
This Service Manual describes the service
procedures for the Isuzu C series indirect injection
engine. These engines are certified by the U.S.
EPA, California ARB and/or the 97/68/EC Directive
for industrial use.
Please use this manual for accurate, quick and safe
servicing of the engine. Since the directions in this
manual are for a typical engine, some
specifications and components may be different
from your engine. Refer to the documentation
supplied by the optional equipment manufacturer
for specific service instructions.
Isuzu products are continuously undergoing
improvement. This Service Manual might not
address possible field modifications to the
equipment. Contact an Isuzu Distributor for
answers to any questions relating to field
modifications.

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INTRODUCTION

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TNV IDI Service Manual

Section 2

SAFETY
Page
Safety Statements ........................................................................... 2-3
Safety Precautions .......................................................................... 2-4

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SAFETY

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Safety Statements SAFETY

SAFETY STATEMENTS DANGER

Isuzu is concerned for your safety and your DANGER indicates a hazardous situation
machine’s condition. Safety statements are one of which, if not avoided, will result in death or
the primary ways to call your attention to the serious injury.
potential hazards associated with Isuzu C series
engine operation. Follow the precautions listed
throughout the manual before operation, during
WARNING
operation and during periodic maintenance WARNING indicates a hazardous situation
procedures for your safety, the safety of others and which, if not avoided, could result in death or
to protect the performance of your engine. Keep the serious injury.
labels from becoming dirty or torn and replace
them if they are lost or damaged. Also, if you need CAUTION
to replace a part that has a label attached to it,
make sure you order the new part and label at the CAUTION indicates a hazardous situation
same time. which, if not avoided, could result in minor or
moderate injury.
This safety alert symbol appears
with most safety statements. It NOTICE
means attention, become alert, NOTICE indicates a situation which can cause
your safety is involved! Please read damage to the machine, personal property and/or
and abide by the message that the environment or cause the equipment to operate
follows the safety alert symbol. improperly.

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SAFETY Safety Precautions

SAFETY PRECAUTIONS DANGER

DANGER Fire and Explosion Hazard
• Diesel fuel is flammable and
Scald Hazard
explosive under certain
• Never remove the radiator cap if conditions.
the engine is hot. Steam and hot
engine coolant will spurt out and
seriously burn you. Allow the
engine to cool down before you • When you remove any fuel system component
attempt to remove the radiator to perform maintenance (such as changing
cap. the fuel filter) place an approved container
under the opening to catch the fuel.
• Tighten the radiator cap securely after you
check the radiator. Steam can spurt out • Never use a shop rag to catch the fuel. Vapors
during engine operation if the cap is loose. from the rag are flammable and explosive.

• Always check the level of the engine coolant • Wipe up any spills immediately.
by observing the reserve tank. • Wear eye protection. The fuel system is under
• Failure to comply will result in death or pressure and fuel could spray out when you
serious injury. remove any fuel system component.
• Only use the key switch to start the engine.
DANGER • Never jump-start the engine. Sparks caused
Explosion Hazard by shorting the battery to the starter terminals
• Keep the area around the battery may cause a fire or explosion.
well-ventilated. While the engine • If the unit has an electric fuel pump, when you
is running or the battery is prime the fuel system, turn the key switch to
charging, hydrogen gas is the ON position for 10 to 15 seconds to allow
produced which can be easily the electric fuel pump to prime the system.
ignited. • If the unit has a mechanical fuel pump, when
• Keep sparks, open flame and any other form you prime the fuel system, operate the fuel
of ignition away while the engine is running or priming lever of the mechanical fuel pump
battery is charging. several times until the fuel filter cup is filled
• Never check the remaining battery charge by with fuel.
shorting out the terminals. This will result in a • Only fill the fuel tank with diesel fuel. Filling
spark and may cause an explosion or fire. Use the fuel tank with gasoline may result in a fire
a hydrometer to check the remaining battery and will damage the engine.
charge. • Never refuel with the engine running.
• If the electrolyte is frozen, slowly warm the • Keep sparks, open flames or any other form of
battery before you recharge it. ignition (match, cigarette, static electric
• Failure to comply will result in death or source) well away when refueling.
serious injury. • Never overfill the fuel tank.
• Fill the fuel tank. Store any containers
containing fuel in a well-ventilated area, away
from any combustibles or sources of ignition.

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Safety Precautions SAFETY

DANGER (Continued) DANGER

• Be sure to place the diesel fuel container on Crush Hazard
the ground when transferring the diesel fuel • When you need to transport an
from the pump to the container. Hold the hose engine for repair, have a helper
nozzle firmly against the side of the container assist you to attach it to a hoist
while filling it. This prevents static electricity and load it on a truck.
buildup which could cause sparks and ignite
fuel vapors.
• Never stand under a hoisted engine. If the
• Never place diesel fuel or other flammable hoist mechanism fails, the engine will fall on
material such as oil, hay or dried grass close you, causing death or serious injury.
to the engine during engine operation or
shortly after shutdown. • Failure to comply will result in death or
serious injury.
• Before you operate the engine, check for fuel
leaks. Replace rubberized fuel hoses every WARNING
two years or every 2000 hours of engine
operation, whichever comes first, even if the Sever Hazard
engine has been out of service. Rubberized • Keep hands and other body parts
fuel lines tend to dry out and become brittle away from moving/rotating parts
after two years or 2000 hours of engine such as the cooling fan, flywheel
operation, whichever comes first. or PTO shaft.
• Never remove the fuel cap with the engine
running. • Wear tight-fitting clothing and keep your hair
• Never use diesel fuel as a cleaning agent. short or tie it back while the engine is
running.
• Place an approved container under the air
bleed port when you prime the fuel system. • Remove all jewelry before you operate or
Never use a shop rag to catch the fuel. Wipe service the machine.
up any spills immediately. Always close the • Never start the engine in gear. Sudden
air bleed port after you complete priming the movement of the engine and/or machine
system. could cause death or serious personal injury.
• Wear eye protection. The fuel system is under • Never operate the engine without the guards
pressure and fuel could spray out when you in place.
open the air bleed port.
• Before you start the engine make sure that all
• If the unit has an electric fuel pump, turn the bystanders are clear of the area.
key switch to the ON position for 10 to 15
• Keep children and pets away while the engine
seconds, or until the fuel coming out of the air
is operating.
bleed port is free of bubbles, to allow the
electric fuel pump to prime the system. • Check before starting the engine that any
tools or shop rags used during maintenance
• If the unit has a mechanical fuel pump,
have been removed from the area.
operate the fuel priming pump several times
until the fuel coming out of the air bleed port • Failure to comply could result in death or
is free of bubbles. serious injury.
• Failure to comply will result in death or
serious injury.

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SAFETY Safety Precautions

WARNING WARNING
Exhaust Hazard! Exposure Hazard
• Never operate the engine in an • Wear personal protective
enclosed area such as a garage, equipment such as gloves, work
tunnel, underground room, shoes, eye and hearing protection
manhole or ship’s hold without as required by the task at hand.
proper ventilation.
• Never block windows, vents, or other means • Never wear jewelry, unbuttoned cuffs, ties or
of ventilation if the engine is operating in an loose-fitting clothing when you are working
enclosed area. All internal combustion near moving/rotating parts such as the
engines create carbon monoxide gas during cooling fan, flywheel or PTO shaft.
operation. Accumulation of this gas within an • Always tie back long hair when you are
enclosure could cause illness or even death. working near moving/rotating parts such as a
• Make sure that all connections are tightened cooling fan, flywheel, or PTO shaft.
to specifications after repair is made to the • Never operate the engine while wearing a
exhaust system. headset to listen to music or radio because it
• Failure to comply could result in death or will be difficult to hear the alert signals.
serious injury. • Failure to comply could result in death or
serious injury.
WARNING
Alcohol and Drug Hazard WARNING
• Never operate the engine while Burn Hazard
you are under the influence of • If you must drain the engine oil
alcohol or drugs. while it is still hot, stay clear of
the hot engine oil to avoid being
burned.
• Never operate the engine when you are
feeling ill. • Always wear eye protection.
• Failure to comply could result in death or • Wait until the engine cools before you drain
serious injury. the engine coolant. Hot engine coolant may
splash and burn you.
• Keep your hands and other body parts away
from hot engine surfaces such as the muffler,
exhaust pipe and engine block during
operation and shortly after you shut the
engine down. These surfaces are extremely
hot while the engine is operating and could
seriously burn you.
• Failure to comply could result in death or
serious injury.

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Safety Precautions SAFETY

WARNING WARNING
Burn Hazard Shock Hazard
• Batteries contain sulfuric acid. • Turn off the battery switch (if
Never allow battery fluid to come equipped) or disconnect the
in contact with clothing, skin or negative battery cable before
eyes. Severe burns could result. servicing the electrical system.
Always wear safety goggles and
protective clothing when • Check the electrical harnesses for cracks,
servicing the battery. If battery abrasions, and damaged or corroded
fluid contacts the eyes and/or connectors. Always keep the connectors and
skin, immediately flush the terminals clean.
affected area with a large amount
of clean water and obtain prompt • Failure to comply could result in death or
medical treatment. serious injury.
• Failure to comply could result in death or WARNING
serious injury.
Entanglement Hazard
WARNING • Stop the engine before you begin
High-Pressure Hazard to service it.
• Avoid skin contact with the
high-pressure diesel fuel spray
caused by a fuel system leak such
as a broken fuel injection line. • Never leave the key in the key switch when
High-pressure fuel can penetrate you are servicing the engine. Someone may
your skin and result in serious accidentally start the engine and not realize
injury. If you are exposed to high- you are servicing it. This could result in a
pressure fuel spray, obtain serious injury.
prompt medical treatment. • If you must service the engine while it is
• Never check for a fuel leak with your hands. operating, remove all jewelry, tie back long
Always use a piece of wood or cardboard. hair, and keep your hands, other body parts
Have your Isuzu Distributor repair the and clothing away from moving/rotating parts.
damage. • Failure to comply could result in death or
• Failure to comply could result in death or serious injury.
serious injury.
WARNING
To prevent possible eye injury,
always wear safety glasses while
servicing the engine.

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SAFETY Safety Precautions

WARNING CAUTION
Fume/Burn Hazard Be sure to secure the engine solidly to prevent
• Always read and injury or damage to parts due to the engine
follow safety related falling during work on the engine.
precautions found on
containers of CAUTION
hazardous substances
Pinch Hazard
like parts cleaners,
primers, sealants and Carefully rotate the alternator
sealant removers. toward the cylinder block while
loosening the V-belt. Failure to
• Failure to comply could result in death or comply may result in minor or
serious injury. moderate injury.
CAUTION CAUTION
Coolant Hazard
If any oil pump component clearance exceeds
• Wear eye protection its limit, the oil pump must be replaced as an
and rubber gloves assembly.
when you handle long
life or extended life
NOTICE
engine coolant. If
contact with the eyes • Only use diesel fuels recommended by Isuzu for
or skin should occur, the best engine performance, to prevent engine
flush eyes and wash damage and to comply with EPA/ARB warranty
immediately with requirements.
clean water.
• Only use clean diesel fuel.
• Failure to comply may result in minor or
moderate injury. • Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
CAUTION debris could get into the fuel system causing it to
clog.
Flying Object Hazard
• Always wear eye protection when NOTICE
servicing the engine and when
using compressed air or high- If any problem is noted during the visual check, the
pressure water. Dust, flying necessary corrective action should be taken before
debris, compressed air, you operate the engine.
pressurized water or steam may
injure your eyes. NOTICE
• Failure to comply may result in minor or Never hold the key in the START position for longer
moderate injury. than 15 seconds or the starter motor will overheat.

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Safety Precautions SAFETY

NOTICE NOTICE
Make sure the engine is installed on a level surface. If any indicator illuminates during engine operation,
If a continuously running engine is installed at an stop the engine immediately. Determine the cause
angle greater than (25°) in any direction or if an and repair the problem before you continue to
engine runs for short periods of time (less than operate the engine.
three minutes) at an angle greater than (30°) in any
direction, engine oil may enter the combustion NOTICE
chamber causing excessive engine speed and
white exhaust smoke. This may cause serious • Only use the engine oil specified. Other engine
engine damage. oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
NOTICE
Observe the following environmental operating • Prevent dirt and debris from contaminating the
conditions to maintain engine performance and engine oil. Carefully clean the oil cap/dipstick and
avoid premature engine wear: the surrounding area before you remove the cap.

• Avoid operating in extremely dusty conditions. • Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
• Avoid operating in the presence of chemical engine oil.
gases or fumes.
• Never overfill. Overfilling may result in white
• Avoid operating in a corrosive atmosphere such exhaust smoke, engine overspeed or internal
as salt water spray. damage.
• Never install the engine in a floodplain unless
proper precautions are taken to avoid being NOTICE
subject to a flood. • Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
• Never expose the engine to the rain.
cause an internal buildup of rust and scale and/or
shorten engine life.
NOTICE
• Prevent dirt and debris from contaminating the
Observe the following environmental operating engine coolant. Carefully clean the radiator cap
conditions to maintain engine performance and and the surrounding area before you remove the
avoid premature engine wear: cap.
• The standard range of ambient temperatures for • Never mix different types of engine coolants. This
the normal operation of Isuzu C series engines is may adversely affect the properties of the engine
from +5 °F (-15 °C) to +113 °F (+45 °C). coolant.
• If the ambient temperature exceeds +113 °F (+45
°C) the engine may overheat and cause the NOTICE
engine oil to break down.
• Never overfill the engine with engine oil.
• If the ambient temperature is below +5 °F (-15 °C)
• Always keep the oil level between the upper and
the engine will be hard to start and the engine oil
lower lines on the oil cap/dipstick.
may not flow easily.
• Contact your Isuzu Distributor if the engine will be
operated outside of this standard temperature
range.

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SAFETY Safety Precautions

NOTICE NOTICE
For maximum engine life, Isuzu recommends that New engine break-in:
when shutting the engine down, you allow the
engine to idle, without load, for five minutes. This • On the initial engine start-up, allow the engine to
will allow the engine components that operate at idle for approximately 15 minutes while you check
high temperatures, such as the turbocharger (if for proper engine oil pressure, diesel fuel leaks,
equipped) and exhaust system, to cool slightly engine oil leaks, coolant leaks, and for proper
before the engine itself is shut down. operation of the indicators and/or gauges.
• During the first hour of operation, vary the engine
NOTICE speed and the load on the engine. Short periods
of maximum engine speed and load are
Never use an engine starting aid such as ether.
desirable. Avoid prolonged operation at minimum
Engine damage will result.
or maximum engine speeds and loads for the
next four to five hours.
NOTICE
• During the break-in period, carefully observe the
• Always be environmentally
engine oil pressure and engine temperature.
responsible.
• During the break-in period, check the engine oil
and coolant levels frequently.

• Follow the guidelines of the EPA or other NOTICE

governmental agencies for the proper disposal of • Never attempt to modify the engine’s design or
hazardous materials such as engine oil, diesel safety features such as defeating the engine
fuel and engine coolant. Consult the local speed limit control or the fuel injection quantity
authorities or reclamation facility. control.
• Never dispose of hazardous materials • Failure to comply may impair the engine’s safety
irresponsibly by dumping them into a sewer, on and performance characteristics and shorten the
the ground, or into ground water or waterways. engine’s life. Any alterations to this engine may
affect the warranty coverage of your engine.
• Failure to follow these procedures may seriously
harm the environment.
NOTICE
NOTICE Protect the air cleaner and electric components
from damage when you use steam or high-
Never engage the starter motor while the engine is
pressure water to clean the engine.
running. This may damage the starter motor pinion
and/or ring gear.
NOTICE
Never use high-pressure water or compressed air
at greater than 28 psi (193 kPa; 19686 mmAq) or a
wire brush to clean the radiator fins. Radiator fins
damage easily.

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Safety Precautions SAFETY

NOTICE NOTICE
Never attempt to adjust the low or high idle speed • When the engine is operated in dusty conditions,
limit screw. This may impair the safety and clean the air cleaner element more frequently.
performance of the machine and shorten its life. If
the idle speed limit screws require adjustment, see • Never operate the engine with the air cleaner
your Isuzu Distributor. element(s) removed. This may allow foreign
material to enter the engine and damage it.
NOTICE
NOTICE
The tightening torque in the Standard Torque Chart
(see General Service Information section) should The maximum air intake restriction, in terms of
be applied only to the bolts with a “7” head. (JIS differential pressure measurement, must not
strength classification: 7T) exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
• Apply 60 % torque to bolts that are restriction exceeds the above mentioned value.
not listed.
• Apply 80 % torque when tightened to NOTICE
aluminum alloy. It is important to perform daily checks.
Periodic maintenance prevents unexpected
NOTICE downtime, reduces the number of accidents due to
Establish a periodic maintenance plan according to poor machine performance and helps extend the
the engine application and make sure you perform life of the engine.
the required periodic maintenance at intervals
indicated. Failure to follow these guidelines will NOTICE
impair the engine’s safety and performance
characteristics, shorten the engine’s life and may If the oil pump must be replaced, replace it as an
affect the warranty coverage on your engine. assembly only. Do not replace individual
components.
Consult your Isuzu Distributor for assistance when
checking items marked with a . NOTICE
Do not loosen or remove the four bolts retaining the
NOTICE
fuel injection pump drive gear to the fuel injection
If the water separator is positioned higher than the pump hub. Do not disassemble the fuel injection
fuel level in the fuel tank, water may not drip out pump drive gear from the hub. Correct fuel injection
when the water separator drain cock is opened. If timing will be very difficult or impossible to achieve.
this happens, turn the air vent screw on the top of
the water separator 2 - 3 turns counterclockwise. NOTICE
Be sure to tighten the air vent screw after the water The starter motor can be damaged if operated
has drained out. continuously longer than 10 seconds while
performing the no-load test.

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SAFETY Safety Precautions

NOTICE NOTICE
Do not short-circuit the charging system between After marking the position of the pump drive gear,
alternator terminals IG and L. Damage to the do not rotate the engine crankshaft. Rotating the
alternator will result. crankshaft will cause the fuel injection pump to
become misaligned.
NOTICE
Do not connect a load between alternator terminals
NOTICE
L and E. Damage to the alternator will result. Do not use a high-pressure wash directly on the
alternator. Water will damage the alternator and
NOTICE result in inadequate charging.

Do not remove the positive (+) battery cable from

alternator terminal B while the engine is operating.
NOTICE
Damage to the alternator will result. Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
NOTICE stator coil will be damaged.

Do not turn the battery switch OFF while the engine

is operating. Damage to the alternator will result.
NOTICE
When the battery indicator goes out, it should not
NOTICE come on again. The battery indicator only comes
on during operation if the alternator fails. However,
Do not operate the engine if the alternator is if an LED is used in the battery indicator, the LED
producing unusual sounds. Damage to the will shine faintly during normal operation.
alternator will result.
NOTICE
NOTICE
Using a non-specified V-belt will cause inadequate
If the engine coolant pump must be replaced, charging and shorten the belt life. Use the specified
replace the engine coolant pump as an assembly belt.
only. Do not attempt to repair the engine coolant
pump or replace individual components.
NOTICE
NOTICE Agricultural or other chemicals, especially those
with a high sulfur content, can adhere to the IC
Use a new special O-ring between the engine regulator. This will corrode the conductor and result
coolant pump and the joint. Be sure to use the in battery over-charging (boiling) and charging
special O-ring for each engine model. Although the malfunctions. Consult Isuzu before using the
O-ring dimensions are the same as a commercially equipment in such an environment or the warranty
available O-ring, the material is different. is voided.

NOTICE
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection lines
from the retainers or bending any of the fuel lines
will make it difficult to reinstall the fuel lines.

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Safety Precautions SAFETY

NOTICE NOTICE
Make sure that the combined total resistance of the Reversing the battery cable connections at the
battery cable in both directions between the starter battery or on the engine will destroy the SCR diode
motor and the battery is within the value indicated in the current limiter. This will cause the charging
on the wiring diagram. The starter motor will system to malfunction and may cause damage to
malfunction or break down if the resistance is the electrical harnesses.
higher than the specified value.
NOTICE
NOTICE • Never attempt to modify the engine’s design or
The starter motor is water-proofed according to JIS safety features such as defeating the engine
D 0203, R2 which protects the motor from rain or speed limit control or the diesel fuel injection
general cleaning. Do not use high-pressure wash quantity control.
or submerse the starter motor in water.
• Modifications may impair the engine’s safety and
performance characteristics and shorten the
NOTICE engine’s life. Any alterations to this engine may
Use a specialized battery charger to recharge a void its warranty. Be sure to use "Isuzu genuine
battery with a voltage of 8 V or less. Booster parts".
starting a battery with a voltage of 8 V or less will
generate an abnormally high voltage and destroy NOTICE
electrical equipment.
Identify all parts and their location using an
appropriate method. It is important that all parts are
NOTICE returned to the same position during the
Make sure that the combined total resistance of the reassembly process.
battery cable in both directions between the starter
motor and the battery is within the value indicated NOTICE
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will Do not rotate the crankshaft with the injection pump
malfunction and fail if the resistance is higher than removed.
the specified value.
NOTICE
NOTICE Keep the piston pin parts, piston assemblies, and
Removing the battery cables or the battery while connecting rod assemblies together to be returned
the engine is operating may cause damage to the to the same position during the reassembly
current limiter depending on the electrical process. Label the parts using an appropriate
equipment being used. This situation could cause method.
loss of control of output voltage. The continuous
high voltage of 23 - 24 V (for 5000 min-1 (rpm) NOTICE
dynamo) will damage the current limiter and other Do not allow the honing tool to operate in one
electrical equipment. position for any length of time. Damage to the
cylinder wall will occur. Keep the tool in constant
up-and-down motion.

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SAFETY Safety Precautions

NOTICE NOTICE
Any part which is found defective as a result of • Never permit anyone to operate the
inspection or any part whose measured value does engine or driven machine without
not satisfy the standard or limit must be replaced. proper training.

NOTICE
Any part determined to not meet the service • Read and understand this Service Manual before
standard or limit before the next service, as you operate or service the machine to ensure that
determined from the state of current rate of wear, you follow safe operating practices and
should be replaced even though the part currently maintenance procedures.
meets the service standard limit.
• Machine safety signs and labels are additional
reminders for safe operating and maintenance
NOTICE techniques.
• Never remove or attempt to remove the tamper-
• See your Isuzu Distributor for additional training.
proof devices from the full-load fuel adjusting
screw or the high-speed throttle limit screw on the
fuel injection pump and governor assembly.
These adjustments have been made at the
factory to meet all applicable emissions
regulations and then sealed.
• Never attempt to make any adjustments to these
sealed adjustment screws. If adjustments are
required, they can be made only by a qualified
fuel injection shop that will ensure the injection
pump continues to meet all applicable emissions
regulations and then replace the tamper-proof
seals.
• Tampering with or removing these devices may
void the “Isuzu Mortors Limited Warranty.”

NOTICE
The fuel return line is a one-piece assembly. Use
care not to bend or twist the fuel return line.

NOTICE
Never use a steel wire brush to clean fuel injectors.
Damage to the nozzle and other components is
likely to result.

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TNV IDI Service Manual

Section 3

GENERAL SERVICE
INFORMATION
Page
Component Identification................................................................. 3-4
Location of Labels ........................................................................... 3-5
EPA/ARB Emission Control Regulations - USA Only...................... 3-5
Function of Major Engine Components ........................................... 3-6
Function of Cooling System Components ....................................... 3-8
Diesel Fuel ...................................................................................... 3-9
Diesel Fuel Specifications ......................................................... 3-9
Filling the Fuel Tank ................................................................ 3-13
Priming the Fuel System ......................................................... 3-14
Engine Oil...................................................................................... 3-15
Engine Oil Specifications ........................................................ 3-15
Engine Oil Viscosity................................................................. 3-15
Checking Engine Oil ................................................................ 3-16
Adding Engine Oil.................................................................... 3-16
Engine Oil Capacity (Typical) .................................................. 3-16
Engine Coolant.............................................................................. 3-17
Engine Coolant Specifications................................................. 3-18
Filling Radiator with Engine Coolant........................................ 3-18
Engine Coolant Capacity (Typical) .......................................... 3-19
Specifications ................................................................................ 3-20
Description of Model Number .................................................. 3-20
Engine General Specifications ................................................ 3-20
Principal Engine Specifications ..................................................... 3-21
3CH1-NGZG01, 3CH1-SDZP01.............................................. 3-21
3CJ1-NGZG01......................................................................... 3-22
3CJ1-SDZP01 ......................................................................... 3-23
Engine Service Information ........................................................... 3-24
Tightening Torques for Standard Bolts and Nuts .......................... 3-25
Abbreviations and Symbols ........................................................... 3-27
Unit Conversions ........................................................................... 3-28

3-1
TNV_IDI_ServiceManual_A4.book Page 2 Saturday, July 4, 2015 5:50 PM

GENERAL SERVICE INFORMATION

This Page Intentionally Left Blank

3-2
Component Identification GENERAL SERVICE INFORMATION

COMPONENT IDENTIFICATION
Figure 3-1 shows where major engine components are located.

1 2 3 4 5 6 7 8 17 18 19 20 21 22

16 15 14 13 12 11 10 9 25 24 23
046876-00X00

1 – Air intake port (from air cleaner) 14 – Dipstick (engine oil)

2 – Lifting eye (flywheel end) 15 – Engine oil filter
3 – Fuel priming lever 16 – Governor lever
4 – Fuel injection pump 17 – Alternator
5 – Intake manifold 18 – Lifting eye (engine cooling fan end)
6 – Engine coolant pump 19 – Top filler port (engine oil)
7 – Engine cooling fan 20 – Rocker arm cover
8 – V-belt 21 – Fuel filter
9 – Crankshaft V-pulley 22 – Fuel return to fuel tank
10 – Side filler port (engine oil) 23 – Flywheel
11 – Fuel inlet 24 – Starter motor
12 – Drain plug (engine oil)*1 25 – Exhaust manifold
13 – Mechanical fuel pump (if equipped)
Figure 3-1

*1: Engine oil drain plug location may vary based on oil pan options.

3-3
GENERAL SERVICE INFORMATION Location of Labels

LOCATION OF LABELS EPA/ARB EMISSION CONTROL

Figure 3-2 shows the location of regulatory and REGULATIONS - USA ONLY
safety labels on Isuzu C series engines.
Isuzu C series engines meet Environmental
Protection Agency (EPA) (U. S. Federal) emission
2 1 control standards as well as the California Air
Resources Board (ARB, California) regulations.
Only engines that conform to ARB regulations can
be sold in the State of California.
Refer to the specific EPA/ARB installation (page
4-4) and maintenance (page 4-4) in the Periodic
Maintenance section of this manual.

K0000585A

Figure 3-2
The typical location of the emission control
information label is shown (Figure 3-2, (1)).
Typical location of the engine nameplate is shown
(Figure 3-2, (2)).

3-4
Function of Major Engine Components GENERAL SERVICE INFORMATION

FUNCTION OF MAJOR ENGINE COMPONENTS

Component Function
Air cleaner The air cleaner prevents airborne contaminants from entering the engine.
Since the air cleaner is application specific, it must be carefully selected by
an application engineer. It is not part of the basic engine package as
shipped from the Isuzu factory. Periodic replacement of the air cleaner filter
element is necessary. See the Periodic Maintenance Schedule on page 4-5
for the replacement frequency.
Dynamo The dynamo is driven by a V-belt which is powered by the crankshaft V-
pulley. The dynamo supplies electricity to the engine systems and charges
the battery while the engine is running.
Dipstick (engine oil) The engine oil dipstick is used to determine the amount of engine oil in the
crankcase.
Electric fuel pump The electric fuel pump makes sure there is a constant supply of diesel fuel
to the fuel injection pump. The electric fuel pump is electro-magnetic and
runs on 12 V DC. An electric fuel pump may be installed as standard
equipment based on engine model and specification. If an electric fuel pump
is installed, turn the key switch to the ON position for 10 to 15 seconds to
prime the fuel system.
Engine oil filter The engine oil filter removes contaminants and sediments from the engine
oil. Periodic replacement of the engine oil filter is necessary. See
thePeriodic Maintenance Schedule on page 4-5 for the replacement
frequency.
Fuel filter The fuel filter removes contaminants and sediments from the diesel fuel.
Periodic replacement of the fuel filter is necessary. See the Periodic
Maintenance Schedule on page 4-5 for the replacement frequency.
Please note that the word “diesel” is implied throughout this manual
when the word “fuel” is used.
Water separator The water separator removes contaminants, sediments and water from
diesel fuel going to the fuel filter. This is a required component of the fuel
system. This is standard equipment with every engine. The separator is
installed between the fuel tank and the fuel pump. Periodically drain the
water from the water separator using the drain cock at the bottom of the
separator.
Fuel priming lever If the unit has a mechanical fuel pump, a fuel priming lever on the
mechanical fuel pump primes the fuel system. The fuel system needs to be
primed before you start the engine for the first time, if you run out of fuel, or
if fuel system service is performed. To prime the fuel system, operate the
fuel priming lever until the cup in the fuel filter is full of fuel.
Fuel tank The fuel tank is a reservoir that holds diesel fuel. When fuel leaves the fuel
tank it goes to the fuel filter. Next, fuel is pumped to the fuel filter by the fuel
pump. Next the fuel goes to the fuel injection pump. Since fuel is used to
keep the fuel injection pump cool and lubricated, more fuel than necessary
enters the injection pump. When the injection pump pressure reaches a
preset value, a relief valve allows excess fuel to be returned back to the fuel
tank. The fuel tank is a required engine component.

3-5
TNV_IDI_ServiceManual_A4.book Page 6 Saturday, July 4, 2015 5:50 PM

GENERAL SERVICE INFORMATION Function of Major Engine Components

Component Function
Mechanical fuel pump The mechanical fuel pump is a diaphragm type of pump and is installed on
the fuel injection pump body. The mechanical fuel pump is standard
equipment on some engine models and is driven by a cam on the camshaft
of the fuel injection pump. The mechanical fuel pump is not installed on the
fuel injection pump if the electric fuel pump is installed.
Side and top filler port (engine oil) You can fill the crankcase with engine oil from either the side or top filler
port depending upon which one is most convenient.
Starter motor The starter motor is powered by the battery. When you turn the key switch
in the operator’s console to the START position, the starter motor engages
with the ring gear installed on the flywheel and starts the flywheel in motion.

3-6
TNV_IDI_ServiceManual_A4.book Page 7 Saturday, July 4, 2015 5:50 PM

Function of Cooling System Components GENERAL SERVICE INFORMATION

FUNCTION OF COOLING SYSTEM COMPONENTS

Component Function
Cooling system The C series engine is liquid-cooled by means of a cooling system. The
cooling system consists of a radiator, radiator cap, engine cooling fan,
engine coolant pump, thermostat, and reserve tank.
Note that all cooling system components are required for proper
engine operation. Since some of the components are application
specific, they must be carefully selected by an application engineer.
The application specific items are not part of the basic engine package
as shipped from the Isuzu factory.
• Engine cooling fan The engine cooling fan is driven by a V-belt which is powered by the
crankshaft V-pulley. The purpose of the engine cooling fan is to circulate air
through the radiator.
• Engine coolant pump The engine coolant pump circulates the engine coolant through the cylinder
block and cylinder head and returns the engine coolant to the radiator.
• Radiator The radiator acts as a heat exchanger. As the engine coolant circulates
through the cylinder block it absorbs heat. The heat in the engine coolant is
dissipated in the radiator. As the engine cooling fan circulates air through
the radiator, the heat is transferred to the air.
• Radiator cap The radiator cap controls the cooling system pressure. The cooling system
is pressurized to raise the boiling point of the engine coolant. As the engine
coolant temperature rises, the system pressure and the coolant volume
increases. When the pressure reaches a preset value, the release valve in
the radiator cap opens and the excess engine coolant flows into the reserve
tank. As the engine coolant temperature is reduced, the system pressure
and volume is reduced and the vacuum valve in the radiator cap opens
allowing engine coolant to flow from the reserve tank back into the radiator.
• Reserve tank The reserve tank contains the overflow of engine coolant from the radiator.
If you need to add engine coolant to the system, add it to the reserve tank,
not to the radiator.
• Thermostat A thermostat is placed in the cooling system to prevent engine coolant from
circulating into the radiator until the engine coolant temperature reaches a
preset temperature. When the engine is cold, no engine coolant flows
through the radiator. Once the engine reaches its operating temperature the
thermostat opens. By letting the engine warm up as quickly as possible, the
thermostat reduces engine wear, deposits and emissions.

3-7
GENERAL SERVICE INFORMATION Diesel Fuel

DIESEL FUEL • Carbon residue content not to exceed 0.35 % by

volume. Less than 0.1 % is preferred.
Diesel Fuel Specifications • Total aromatics content should not exceed 35 %
Diesel fuel should comply with the following by volume. Less than 30 % is preferred.
specifications. The table lists several worldwide
• PAH (Polycyclic Aromatic Hydrocarbons) content
specifications for diesel fuels.
should be below 10 % by volume.
Diesel fuel specification Location • Metal content of Na, Mg, Si, and Al should be
ASTM D975 USA equal to or lower than 1 mass ppm. (Test analysis
No. 1D S15 method JPI-5S-44-95)
No. 2D S15
EN590:96 European Union • Lubricity: Wear mark of WS1.4 should be Max.
ISO 8217 DMX International 0.018 in. (460 µm) at HFRR test.
BS 2869-A1 or A2 United Kingdom
■ Bio-diesel fuels
JIS K2204 Grade No. 2 Japan
KSM-2610 Korea General description of bio-diesel
GB252 China 1. Bio-diesel is a renewable, oxygenated fuel
made from agricultural and renewable
■ Additional technical fuel requirements resources such as soybeans or rapeseeds. Bio-
• The fuel cetane number should be equal to 45 or diesel is a fuel comprised of methyl or ethyl
higher. ester-based oxygenates of long chain fatty
acids derived from the transesterification of
• The sulfur content must not exceed 0.5 % by vegetable oils, animal fats, and cooking oils. It
volume. Less than 0.05 % is preferred. Especially contains no petroleum-based diesel fuel but
in U.S.A. and Canada, Ultra Low Sulfur fuel must can be blended at any level with petroleum-
be used. based diesel fuel. In case it is not blended with
• Bio-Diesel fuels. See Bio-diesel fuels on petroleum-based diesel fuel such bio-diesel is
page 3-8. referred to as “B 100”, which means that it
consists of 100 % (pure) bio-diesel. However,
• Never mix kerosene, used engine oil, or residual most common biodiesel is blended with
fuels with the diesel fuel. conventional (petroleum-based) diesel fuel. The
percentage of the blend can be identified by its
• Water and sediment in the fuel should not exceed name. The most common blends are “B 7”
0.05 % by volume. (consisting of 7 % bio- diesel and 93 %
• Keep the fuel tank and fuel-handling equipment conventional petroleum-based diesel fuel) and
clean at all times. “B 20” (a blend of 20 % bio-diesel and 80 %
conventional diesel). Raw pressed vegetable
• Poor quality fuel can reduce engine performance oils are not considered to be biodiesel.
and/or cause engine damage.
2. Advantages of bio-diesel:
• Fuel additives are not recommended. Some fuel • Bio-diesel produces less visible smoke and a
additives may cause poor engine performance. lower amount of particulate matter.
Consult your Isuzu representative for more
• Bio-diesel is biodegradable and nontoxic.
information.
• Bio-diesel is safer than conventional diesel fuel
• Ash content not to exceed 0.01 % by volume. because of its higher flash point.

3-8
Diesel Fuel GENERAL SERVICE INFORMATION
Following the increased interest in the reduction Approved fuel
of emissions and the reduction of the use of In case of using bio-diesel (only concentrations up
petroleum distillate based fuels; many to B 20) such fuel should comply with the below
governments and regulating bodies encourage recommended standards. However, raw pressed
the use of biodiesel. vegetable oils are not considered to be biodiesel
3. Disadvantages of bio-diesel: and are not acceptable for use as fuel in any
concentration in Isuzu C series engines.
Concentrations that are higher than 7 % of bio-
diesel (higher than B 7) can have an adverse 1. EN14214 (European standard) and/or ASTM D-
affect on the engine’s performance, its integrity 6751 (American standard).
and/ or durability. The risk of problems occurring 2. All applicable engines can be operated with bio-
in the engine increases as the level of bio-diesel diesel fuel up to B 20 (20 % bio-fuel blend) as a
blend increases. The following negative affects maximum concentration.
are exemplary and typical for the usage of high (For your information: In Japan, the legally
concentrated biodiesel blends: allowed maximum concentration for on-road
• Bio-diesel can accelerate the oxidation of applications is B 5.)
Aluminum, Brass, Bronze, Copper and Zinc. Conditions for the operation with bio-diesel
• Bio-diesel damages, and finally seeps through (B 8 through B 20)
certain seals, gaskets, hoses, glues and When operating your applicable Isuzu C series
plastics. engine with bio-diesel blends concentrated above B
• Certain natural rubbers, nitride and butyl 8, we seriously recommend observing the following
rubbers will become harder and more brittle as operation, service and maintenance conditions:
degradation proceeds when used with bio-
1. The original service interval of the below stated
diesel.
services as indicated in the respective Isuzu C
• Bio-diesel typically creates deposits in the series engine standard operation manual, the
engines. application manual and the service manual
• Due to its natural characteristic, bio-diesel will should be halved (please refer to your own
decrease the engine output by approximately 2 manuals for the each service interval):
percent (in case of B 20) comparing to • Replacement interval of engine oil filter, engine
conventional (petroleum-based) diesel fuel. oil and the fuel filter.
• The fuel consumption ratio will increase by • Cleaning interval of the water separator
approximately 3 percent (in case of B 20)
• Drain interval of the fuel tank.
comparing to conventional diesel fuel.
2. It is required to inspect, clean and adjust the
Approved engines fuel injector every 1000 operating hours.
Isuzu C series engine can be operated with 3. Replacement of the following parts before using
biodiesel with concentrations up to B 20. In case of the recommended bio-diesel:
using biodiesel fuel up to B 7 concentrations, no
• Fuel hose
special preparations etc. have to be made and the
original operating conditions and service intervals • Fuel feed pump (diaphragm type)
as stated in the operating manuals apply. In case of • If not already installed, a water separator
running the engine with bio-diesel concentrations needs to be built in
above B 8 up to B 20, the required operating • O-ring of fuel filter
conditions (see below Conditions for the operation
with bio-diesel (B 8 through B 20)) have to be • O-ring of water separator
observed. Please refer to the attached list of exchange
parts for details.

3-9
TNV_IDI_ServiceManual_A4.book Page 10 Saturday, July 4, 2015 5:50 PM

GENERAL SERVICE INFORMATION Diesel Fuel

4. Please use only bio-diesel fuel that is

appropriate to the intended operation
environment of the engines. This especially
applies if the operating ambient temperature
falls below 0 degree centigrade.
5. Operation with bio-diesel requires daily
maintenance as follows:
• Please daily check the engine oil level. If the oil
level rises above the oil level of the previous
day, the engine oil needs to be immediately
replaced.
• Please daily check the water level of the water
separator. If the water level rises above the
“max” indicator, an immediate drain of the
water separator is required.
6. Bio-diesel blends up to B 20 can only be used
for a limited time of up to 3 months of the date
of biodiesel manufacture. Therefore biodiesel
needs to be used at latest within 2 months from
the time of filling the tank or within 3 months
from the time of production by the fuel supplier,
whichever comes first.
7. Before a long-term storage without operating
the engine, the biodiesel needs to be drained
out completely and the engine has to be run for
5 hours with conventional diesel fuel as
indicated in your operation manual.

3-10
TNV_IDI_ServiceManual_A4.book Page 11 Saturday, July 4, 2015 5:50 PM

Diesel Fuel GENERAL SERVICE INFORMATION

■ KIT parts list for B 20
3CH1, 3CJ1
5-8640-2407-0
No. (1)
Length 2000
Fuel oil tank - / - Fuel oil tank Part No. 5-8640-2241-0
Part name FO-T CMP
Number 2
No. (3)
Length 450
Fuel feed pump - Fuel oil filter Part No. 5-8640-2242-0
Part name FO-T CMP
Number 1
No. (6)
Length 270
Fuel oil filter - Fuel injection pump Part No. 5-8640-2243-0
Part name FO-T CMP
Number 1
No. (11)
Length 450
Fuel injection pump - Fuel oil filter Part No. 5-8640-2244-0
Part name FO-T CMP
Number 1
Part No.
Cap, fuel injection nozzle Part name No need
Number
No.
Length
Fuel injection nozzle -Fuel injection nozzle Part No. No need
Part name
Number
No. (16)
Length 150
Fuel injection nozzle - Fuel injection pump Part No. 5-8640-2245-0
Part name FO-T CMP
Number 1
Fuel oil filter Need to change only O-ring.
P44: 5-8640-2246-0 --> A
Need to change only O-ring.
Water separator
P44: 5-8640-2246-0 --> B

5-8640-2409-0
Electric feed pump: 5-8640-0024-0
Fuel feed pump
Cover assy, feed pump: 5-8640-1927-0

A
B

A 5-8640-2246-0 (P44)
B 5-8640-2246-0 (P44)
033051-00X 033050-00X

3-11
GENERAL SERVICE INFORMATION Diesel Fuel

Filling the Fuel Tank NOTICE

DANGER • Only use diesel fuels recommended by Isuzu for
the best engine performance, to prevent engine
Fire and Explosion Hazard damage and to comply with EPA/ARB warranty
• Diesel fuel is flammable and requirements.
explosive under certain
conditions. • Only use clean diesel fuel.
• Never remove the primary strainer (if equipped)
from the fuel tank filler port. If removed, dirt and
• Only fill the fuel tank with diesel fuel. Filling debris could get into the fuel system causing it to
the fuel tank with gasoline may result in a fire clog.
and will damage the engine.
• Never refuel with the engine running.
Note that a typical fuel tank is shown. The fuel tank
• Wipe up all spills immediately. on the equipment being serviced may be different.
• Keep sparks, open flames or any other form of 1. Clean the area around the fuel cap
ignition (match, cigarette, static electric (Figure 3-3, (1)).
source) well away when refueling.
2. Remove the fuel cap (Figure 3-3, (1)) from the
• Never overfill the fuel tank. fuel tank (Figure 3-3, (2)).
• Fill the fuel tank. Store any containers 3. Observe the fuel level sight gauge
containing fuel in a well-ventilated area, away (Figure 3-3, (3)) and stop fueling when gauge
from any combustibles or sources of ignition. shows fuel tank is full. Never overfill the fuel
• Be sure to place the diesel fuel container on tank.
the ground when transferring the diesel fuel 4. Replace the fuel cap and hand-tighten. Over
from the pump to the container. Hold the hose tightening the fuel cap will damage it.
nozzle firmly against the side of the container
while filling it. This prevents static electricity 1
buildup which could cause sparks and ignite
fuel vapors.
• Never place diesel fuel or other flammable
2
material such as oil, hay or dried grass close
to the engine during engine operation or
shortly after shutdown.
• Before you operate the engine, check for fuel 3
leaks. Replace rubberized fuel hoses every
two years or every 2000 hours of engine K0000002A

operation, whichever comes first, even if the

Figure 3-3
engine has been out of service. Rubberized
fuel lines tend to dry out and become brittle
after two years or 2000 hours of engine
operation, whichever comes first.
• Failure to comply will result in death or
serious injury.

3-12
Diesel Fuel GENERAL SERVICE INFORMATION
Priming the Fuel System 1. Operate the fuel priming lever (Figure 3-4, (1))
several times until the fuel filter cup
DANGER (Figure 3-4, (2)) is filled with fuel.
Fire and Explosion Hazard 2. Never use the starter motor to prime the fuel
system. This may cause the starter motor to
• Diesel fuel is flammable and overheat and damage the coils, pinion and/or
explosive under certain ring gear.
conditions.

• If the unit has an electric fuel pump, when you 2

prime the fuel system, turn the key switch to
the ON position for 10 to 15 seconds to allow
the electric fuel pump to prime the system.
• If the unit has a mechanical fuel pump, when
you prime the fuel system, operate the fuel
priming lever of the mechanical fuel pump
several times until the fuel filter cup is filled 1
K0000649A
with fuel.
• Failure to comply will result in death or Figure 3-4
serious injury.

The fuel system needs to be primed under certain

conditions:
• Before starting the engine for the first time
• After running out of fuel and fuel has been added
to the fuel tank
• After fuel system maintenance such as changing
the fuel filter and draining the water separator, or
replacing a fuel system component
To prime the fuel system if an electric fuel pump is
installed:
1. Turn the key to the ON position for 10 to 15
seconds. This will allow the electric fuel pump
to prime the fuel system.
2. Never use the starter motor to prime the fuel
system. This may cause the starter motor to
overheat and damage the coils, pinion and/or
ring gear.
To prime the fuel system if a mechanical fuel pump
is installed:

3-13
GENERAL SERVICE INFORMATION Engine Oil

ENGINE OIL Note:

• Be sure the engine oil, engine oil storage
NOTICE containers, and engine oil filling equipment are
• Only use the engine oil specified. Other engine free of sediments and water.
oils may affect warranty coverage, cause internal • Change the engine oil after the first 50 hours of
engine components to seize and/or shorten operation and then every 250 hours thereafter.
engine life.
• Select the oil viscosity based on the ambient
• Prevent dirt and debris from contaminating the temperature where the engine is being operated.
engine oil. Carefully clean the oil cap/dipstick and See the SAE service grade viscosity chart
the surrounding area before you remove the cap. (Figure 3-5).
• Never mix different types of engine oil. This may • Isuzu does not recommend the use of engine oil
adversely affect the lubricating properties of the “additives”.
engine oil.
■ Additional technical engine oil
• Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal requirements:
damage. The engine oil must be changed when the Total
Base Number (TBN) has been reduced to 1.0
(mgKOH/g) test method; JIS K-201-5.2-2 (HCI),
ASTM D4739 (HCI).
Engine Oil Specifications
Use an engine oil that meets or exceeds the Engine Oil Viscosity
following guidelines and classifications: Select the appropriate engine oil viscosity based on
the ambient temperature and use the SAE service
■ Service categories
grade viscosity chart in Figure 3-5.
• API service categories CD, CF, CF-4 and CI-4
• ACEA service categories E-3, E-4, and E-5
SAE 10W-30
• JASO service category DH-1
SAE 5W-30
■ Definitions SAE 15W-40
• API classification (American Petroleum Institute) SAE 20

SAE 30
• ACEA classification (Association des
Constructeurs Européens d'Automobilies)
• JASO (Japanese Automobile Standards -30°C -20°C -10°C 0 10°C 20°C 30°C 40°C
K0000005A05
Organization)
Figure 3-5

3-14
Engine Oil GENERAL SERVICE INFORMATION
Checking Engine Oil Adding Engine Oil
1. Make sure engine is level. 1. Make sure engine is level.
2. Remove dipstick (Figure 3-6, (1)) and wipe with 2. Remove oil cap (Figure 3-6, (4)).
clean cloth. 3. Add indicated amount of engine oil at the top or
3. Fully reinsert dipstick. side engine oil filler port (Figure 3-6, (5)).
4. Remove dipstick. The oil level should be 4. Wait three minutes and check oil level.
between upper (Figure 3-6, (2)) and lower 5. Add more oil if necessary.
(Figure 3-6, (3)) lines on the dipstick.
6. Replace oil cap (Figure 3-6, (4)) and
5. Fully reinsert dipstick. hand-tighten. Over-tightening may damage the
cap.
4

Engine Oil Capacity (Typical)

Note: These are the engine oil capacities
associated with a “deep standard” oil pan.
4
Oil capacity will vary dependant upon which
optional oil pan is used. Refer to the
operation manual provided by the driven
machine manufacturer for the actual engine
oil capacity of your machine.
5
The following are the engine oil capacities for
various Isuzu C series engines:
1
Dipstick
Engine model
upper limit/lower limit
3CH1-NGZG01
3.6/1.9 qt (3.4/1.8 ℓ)
3CH1-SDZP01
3CJ1-NGZG01 3.0/1.6 qt (2.8/1.5 ℓ)
3CJ1-SDZP01 3.1/1.7 qt (2.9/1.6 ℓ)
2
3
K0000587C

Figure 3-6

3-15
TNV_IDI_ServiceManual_A4.book Page 16 Saturday, July 4, 2015 5:50 PM

GENERAL SERVICE INFORMATION Engine Coolant

ENGINE COOLANT NOTICE

DANGER • Only use the engine coolant specified. Other
engine coolants may affect warranty coverage,
Scald Hazard cause an internal buildup of rust and scale and/or
• Never remove the radiator cap if shorten engine life.
the engine is hot. Steam and hot
• Prevent dirt and debris from contaminating the
engine coolant will spurt out and
engine coolant. Carefully clean the radiator cap
seriously burn you. Allow the
and the surrounding area before you remove the
engine to cool down before you
cap.
attempt to remove the radiator
cap. • Never mix different types of engine coolants. This
• Tighten the radiator cap securely after you may adversely affect the properties of the engine
check the radiator. Steam can spurt out coolant.
during engine operation if the cap is loose.
• Always check the level of the engine coolant
by observing the reserve tank.
• Failure to comply will result in death or
serious injury.

WARNING
Burn Hazard
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.

• Failure to comply could result in death or

serious injury.

CAUTION
Coolant Hazard
• Wear eye protection
and rubber gloves
when you handle long
life or extended life
engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water.
• Failure to comply may result in minor or
moderate injury.

3-16
Engine Coolant GENERAL SERVICE INFORMATION
Engine Coolant Specifications Filling Radiator with Engine Coolant
Use a Long Life Coolant (LLC) or an Extended Life Fill the radiator and reserve tank as follows. This
Coolant (ELC) that meets or exceeds the following procedure is for filling the radiator for the first time
guidelines and specifications: or refilling it after it is flushed. Note that a typical
radiator is illustrated.
■ Additional technical coolant
specifications:
2
• ASTM D6210, D4985 (US)
5
• JIS K-2234 (Japan)
• SAE J814C, J1941, J1034 or J2036 3
(International)
6 FULL

■ Alternative engine coolant LOW

4
If an Extended or Long Life Coolant is not available,
you may use an ethylene glycol or propylene glycol
based conventional coolant (green).
Note: 1
K0000029A

• Always use a mix of coolant and water.

Figure 3-7
Never use water only.
1. Check to be sure the radiator drain plug is
• Mix coolant and water per the mixing instructions
installed and tightened or the drain cock
on the coolant container.
(Figure 3-7, (1)) is closed. Also make sure the
• Water quality is important to coolant coolant drain plug (Figure 3-8, (1)) in the
performance. Isuzu recommends that soft, cylinder block is closed.
distilled, or demineralized water be used to mix
with coolants.
• Never mix extended or long life coolants and OIL

conventional (green) coolants.

• Never mix different types and/or colors of
extended life coolants.
• Replace the coolant every 1000 engine hours or
once a year.

1 K0002923

Figure 3-8
2. Remove the radiator cap (Figure 3-7, (2)) by
turning it counterclockwise about 1/3 of a turn.

3-17
GENERAL SERVICE INFORMATION Engine Coolant

3. Pour the engine coolant slowly into the radiator Engine Coolant Capacity (Typical)
until it is even with the lip of the engine coolant
filler port. Make sure that air bubbles do not Note: Capacities listed are for engine only without
develop as you fill the radiator. a radiator. Refer to the operation manual
provided by the driven machine
4. Reinstall the radiator cap (Figure 3-7, (2)). manufacturer for actual engine coolant
Align the tabs on the back of the radiator cap capacity on your machine.
with the notches on the engine coolant filler
port. Press down and turn the cap clockwise The following are the engine coolant capacities for
about 1/3 of a turn. various Isuzu C series engines.
5. Remove the cap of the reserve tank
Engine model Engine coolant capacity
(Figure 3-7, (3)), and fill it to the LOW (COLD)
mark (Figure 3-7, (4)) with engine coolant. 3CH1-NGZG01
1.0 qt (0.9 ℓ)
Reinstall the cap. 3CH1-SDZP01

6. Check the hose (Figure 3-7, (5)) that connects 3CJ1-NGZG01 1.0 qt (0.9 ℓ)
the reserve tank (Figure 3-7, (3)) to the 3CJ1-SDZP01 1.1 qt (1.0 ℓ)
radiator. Be sure it is securely connected and
there are no cracks or damage. If the hose is
damaged, engine coolant will leak out instead
of going into the reserve tank.
7. Run the engine until it is at operating
temperature. Check the level of engine coolant
in the reserve tank. When the engine is running
and the engine coolant is at normal
temperature, the coolant level in the tank should
be at or near the FULL (HOT) mark
(Figure 3-7, (6)). If the engine coolant is not at
the FULL (HOT) mark (Figure 3-7, (6)), add
additional engine coolant to the reserve tank to
bring the level to the FULL (HOT) mark.

3-18
Specifications GENERAL SERVICE INFORMATION

SPECIFICATIONS
Description of Model Number
3 C H 1

Identified Designation

Cylinder bore (mm)

Engine series

No. of cylinders

When ordering parts or making an inquiry about the engine you are working on, be sure to include the
complete model and serial numbers as shown on the engine nameplate. See Location of Labels on
page 3-4.

Engine General Specifications

Type Vertical in-line, water cooled, 4-cycle diesel engine
Combustion system Swirl chamber (ball type)
Starting system Electric starting
Cooling system Radiator
Lubricating system Forced lubrication with trochoid pump
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end

Note:
• The information described in Principal Engine Specificationsis for a “standard” engine. To obtain the
information for the engine installed in your driven machine, please refer to the manual provided by the
driven machine manufacturer.
• Engine rating conditions are as follows (SAE J1349, ISO 3046/1):
• Atmospheric Condition: Room temperature 77 °F (25 °C), atmospheric pressure 29.53 in Hg (100 kPa,
750 mm Hg), Relative humidity 30 %
• Fuel temperature at fuel injector pump inlet: 104 °F (40 °C)
• With cooling fan, air cleaner, muffler: Isuzu standard
• After engine break-in period; output allowable deviation: ± 3 %
• 1 PS = 0.7355 kW
• 1 hp SAE (Society of Automotive Engineers) = 0.7457 kW

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GENERAL SERVICE INFORMATION Principal Engine Specifications

PRINCIPAL ENGINE SPECIFICATIONS

3CH1-NGZG01, 3CH1-SDZP01
Engine model 3CH1-NGZG01 3CH1-SDZP01
Type Vertical in-line diesel engine
Combustion system Ball-type swirl chamber (IDI)
Aspiration Naturally aspiration
No. of cylinders 3
Bore × stroke 80 × 84 mm
Displacement 1.266 ℓ
-1
1800 min 3000 min-1
Rated output (Gross) 10.7 kW 17.8 kW
14.6 PS 24.2 PS
-1
High idling 1925 min 3210 ± 25 min-1
Engine weight (Dry) 117 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.24 - 0.35 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.1 kW)
Starting system Alternator (12 V - 40 A)
Recommended battery capacity: 12 V 433CCA
Dimensions (L × W × H) 567 × 427 × 532 523 × 427 × 532
3.4/1.8 ℓ
Engine oil pan capacity
Dipstick upper limit/lower limit)
Engine coolant capacity 0.9 ℓ (Engine only)
Standard cooling fan ø335 pusher
Crank V-pulley dia./
ø110/ø100 mm
fan V-pulley dia.
Top clearance 0.778 ± 0.069 mm

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Principal Engine Specifications GENERAL SERVICE INFORMATION

3CJ1-NGZG01
Engine model 3CJ1-NGZG01
Type Vertical in-line diesel engine
Combustion system Ball-type swirl chamber (IDI)
Aspiration Naturally aspiration
No. of cylinders 3
Bore × stroke 74 × 77 mm
Displacement 0.993 ℓ
3000 min-1
Rated output (Gross) 14.2 kW
19.3 PS
High idling 3210 ± 25 min-1
Engine weight (Dry) 98 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.29 - 0.44 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.0 kW)
Starting system Alternator (12 V - 40 A)
Recommended battery capacity: 12 V 433CCA
Dimensions (L × W × H) 504 × 441 × 543
2.8/1.5 ℓ
Engine oil pan capacity
Dipstick upper limit/lower limit)
Engine coolant capacity 0.9 ℓ (Engine only)
Standard cooling fan ø310 pusher
Crank V-pulley dia./
ø110/ø100 mm
fan V-pulley dia.
Top clearance 0.778 ± 0.069 mm

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GENERAL SERVICE INFORMATION Principal Engine Specifications

3CJ1-SDZP01
Engine model 3CJ1-SDZP01
Type Vertical in-line diesel engine
Combustion system Ball-type swirl chamber (IDI)
Aspiration Naturally aspiration
No. of cylinders 3
Bore × stroke 74 × 77 mm
Displacement 0.993 ℓ
3000 min-1
Rated output (Gross) 14.9 kW
20.3 PS
High idling 3175 min-1
Engine weight (Dry) 110 kg
PTO position Flywheel end
Direction of rotation Counterclockwise viewed from flywheel end
Cooling system Liquid-cooled with radiator
Lubricating system Forced lubrication with trochoid pump
Normal oil pressure at
0.29 - 0.44 MPa
rated engine speed
Normal oil pressure at
0.06 MPa
low idle speed
Electric starting (Starter motor: DC 12 V - 1.2 kW)
Starting system Alternator (12 V - 40 A)
Recommended battery capacity: 12 V 433CCA
Dimensions (L × W × H) 556 × 422 × 568
3.4/1.8 ℓ
Engine oil pan capacity
Dipstick upper limit/lower limit)
Engine coolant capacity 1.0 ℓ (Engine only)
Standard cooling fan ø310 pusher
Crank V-pulley dia./
ø100/ø90 mm
fan V-pulley dia.
Top clearance 0.708 ± 0.070 mm

3-22
Engine Service Information GENERAL SERVICE INFORMATION

ENGINE SERVICE INFORMATION

Inspection item Standard Limit
0.006 - 0.010 in.
Intake/exhaust valve gap –
(0.15 - 0.25 mm)
Fuel injection timing See Checking and Adjusting Fuel Injection Timing on page 6-17
1784 - 1929 psi
3CJ1-SDZP01 (12.3 - 13.3 MPa; –
125 - 136 kgf/cm²)
Fuel injection pressure
3CH1-NGZG01 1711 - 1842 psi
3CH1-SDZP01 (11.8 - 12.8 MPa; –
3CJ1-NGZG01 120 - 130 kgf/cm²)
470 ± 15 psi 370 ± 15 psi
3CJ1-NGZG01
(3.24 ± 0.1 MPa; (2.55 ± 0.1 MPa;
3CJ1-SDZP01
Compression pressure at 250 min- 33 ± 1 kgf/cm²) 26 ± 1 kgf/cm²)
1
(rpm) 498 ± 15 psi 399 ± 15 psi
3CH1-NGZG01
(3.43 ± 0.1 MPa; (2.75 ± 0.1 MPa;
3CH1-SDZP01
35 ± 1 kgf/cm²) 28 ± 1 kgf/cm²)
41 - 55 psi
3CJ1-SDZP01 (0.28 - 0.38 MPa; –
2.86 - 3.87 kgf/cm2)
At rated output
Lubricating oil 3CH1-NGZG01 42 - 64 psi
pressure 3CH1-SDZP01 (0.29 - 0.44 MPa; –
3CJ1-NGZG01 2.96 - 4.49 kgf/cm2)
8.5 psi (0.06 MPa; 0.6 kgf/cm2)
When idling –
or greater
Full opening lift
Valve opening temperature
temperature
Thermostat 0.32 in. (8 mm) or
157 - 163 °F
Above
(70 - 73 °C)
185 °F (85 °C)
225 - 235 °F
Temperature coolant switch –
(107 - 113 °C)

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GENERAL SERVICE INFORMATION Tightening Torques for Standard Bolts and Nuts

TIGHTENING TORQUES FOR STANDARD BOLTS AND NUTS

Use the correct amount of torque when you tighten fasteners on the machine. Applying excessive torque
may damage the fastener or component and not enough torque may cause a leak or component failure.

NOTICE
The tightening torque in the Standard Torque Chart in General Service Information should be applied only
to the bolts with a “7” head. (JIS strength classification: 7T)
• Apply 60 % torque to bolts that are not listed.
• Apply 80 % torque when tightened to aluminum alloy.

Nominal thread
Item × pitch Tightening torque Remarks
diameter
87 - 104 in-lb
M6 × 1.0 mm (9.8 - 11.8 N·m;
1.0 - 1.2 kgf·m)
200 - 251 in-lb
M8 × 1.25 mm (22.6 - 28.4 N·m;
2.3 - 2.9 kgf·m)
33 - 40 ft-lb Use 80 % of the value at
M10 × 1.5 mm (44.1 - 53.9 N·m; left when the tightening
Hexagon bolt (7T) 4.5 - 5.5 kgf·m) part is aluminum.
and nut 58 - 72 ft-lb Use 60 % of the value at
M12 × 1.75 mm (78.4 - 98.0 N·m; left for 4T bolts and lock
8.0 - 10 kgf·m) nuts.
94 - 108 ft-lb
M14 × 1.5 mm (127.5 - 147.1 N·m;
13 - 15 kgf·m)
159 - 174 ft-lb
M16 × 1.5 mm (215.7 - 235.4 N·m;
22 - 24 kgf·m)
87 in-lb
1/8
(9.8 N·m; 1.0 kgf·m)
173 in-lb
1/4
(19.6 N·m; 2.0 kgf·m)
PT plug –
22 ft-lb
3/8
(29.4 N·m; 3.0 kgf·m)
43 ft-lb
1/2
(58.8 N·m; 6.0 kgf·m)

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Tightening Torques for Standard Bolts and Nuts GENERAL SERVICE INFORMATION

Nominal thread
Item × pitch Tightening torque Remarks
diameter
112 - 148 in-lb
M8 (12.7 - 16.7 N·m;
1.3 - 1.7 kgf·m)
173 - 225 in-lb
M10 (19.6 - 18.734 N·m;
2.0 - 3.5 kgf·m)
18 - 25 ft-lb
Pipe Joint Bolt M12 (24.5 - 34.3 N·m; –
2.5 - 3.5 kgf·m)
29 - 36 ft-lb
M14 (39.2 - 49.0 N·m;
4.0 - 5.0 kgf·m)
36 - 43 ft-lb
M16 (49.0 - 58.8 N·m;
5.0 - 6.0 kgf·m)
Note: Torque values shown in this manual are for clean, non-lubricated fasteners unless otherwise
specified.

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GENERAL SERVICE INFORMATION Abbreviations and Symbols

ABBREVIATIONS AND SYMBOLS

■ Abbreviations L liter
L/hr liter per hour
A ampere lb pound
AC alternating current lbf pond force
Association des Constructeurs mL milliliter
ACEA
Européens d’Automobilies mm millimeter
Ah ampere-hour MPa megapascal
approx. approximately mV millivolt
API American Petroleum Institute N newton
ARB Air Resources Board N·m newton meter
ATDC after top dead center No. number
BTDC before top dead center O.D. outside diameter
°C degree Celsius oz ounce
CARB California Air Resources Board PS horsepower (metric)
CCA cold cranking amp psi pound per square inch
cm centimeter qt quart (U.S.)
cm³ cubic centimeter rpm revolutions per minute
cm³/min cubic centimeter per minute SAE Society of Automotive Engineers
cu in. cubic inch sec. second
DC direct current t short ton 2000 lb
DI direct injection TBN total base number
DVA direct volt adapter TDC top dead center
EPA Environmental Protection Agency V volt
ESG electronic speed governor VAC volt alternating current
°F degree Fahrenheit VDC volt direct current
fl oz fluid ounce (U.S.) W watt
fl oz/min fluid ounce (U.S.) per minute
ft foot ■ Symbols
ft-lb foot pound
ft-lbf/min foot pound force per minute ° angular degree
g gram + plus
gal/hr gallon (U.S.) per hour - minus
gal gallon (U.S.) ± plus or minus
GL gear lubricant  ohm
hp horsepower (U.S.)  micro
hrs hours % percent
I.D. inside diameter ~ approximate
IDI indirect injection
in. inch
in.-lb inch pound
Japanese Automobile Standards
JASO
Organization
kg kilogram
kilogram force per square
kgf/cm²
centimeter
kgf·m kilogram force meter
km kilometers
kPa kilopascal
kW kilowatt

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Unit Conversions GENERAL SERVICE INFORMATION

UNIT CONVERSIONS ■ Units of torque

ft-lb × 1.3558 = N·m
■ Unit prefixes ft-lb × 0.1383 = kgf·m
in.-lb × 0.1130 = N·m
Prefix Symbol Power
in.-lb × 0.0115 = kgf·m
mega M × 1,000,000
kgf·m × 7.2330 = ft-lb
kilo k × 1,000
kgf·m × 86.8000 = in.-lb
centi c × 0.01
kgf·m × 9.8070 = N·m
milli m × 0.001
N·m × 0.7376 = ft-lb
micro  × 0.000001
N·m × 8.8510 = in.-lb
■ Units of length N·m × 0.1020 = kgf·m

mile × 1.6090 = km ■ Units of pressure

ft × 0.3050 =m
psi × 0.0689 = bar
in. × 2.5400 = cm
psi × 6.8950 = kPa
in. × 25.4000 = mm
psi × 0.0703 = kg/cm²
km × 0.6210 = mile
bar × 14.5030 = psi
m × 3.2810 = ft
bar × 100.0000 = kPa
cm × 0.3940 = in.
= in Hg
mm × 0.0394 = in. bar × 29.5300
(60 °F)
■ Units of volume kPa × 0.1450 = psi
kPa × 0.0100 = bar
gal (U.S.) × 3.78540 =ℓ kPa × 0.0102 = kg/cm²
qt (U.S.) × 0.94635 =ℓ kg/cm² × 98.0700 = psi
cu in. × 0.01639 =ℓ kg/cm² × 0.9807 = bar
cu in. × 16.38700 = mℓ kg/cm² × 14.2200 = kPa
fl oz (U.S.) × 0.02957 =ℓ in. Hg (60°) × 0.0333 = bar
fl oz (U.S.) × 29.57000 = mℓ in. Hg (60°) × 3.3770 = kPa
cm³ × 1.00000 = mℓ in. Hg (60°) × 0.0344 = kg/cm²
cm³ × 0.03382 = fl oz (U.S.)
■ Units of power
■ Units of mass
hp (metric or
× 0.9863201 = hp SAE
lb × 0.45360 = kg PS)
oz × 28.35000 =g hp (metric or
× 0.7354988 = kW
kg × 2.20500 = lb PS)
g × 0.03527 = oz = hp (metric
hp SAE × 1.0138697
or PS)
■ Units of force hp SAE × 0.7456999 = kW
= hp (metric
lbf × 4.4480 =N kW × 1.3596216
or PS)
lbf × 0.4536 = kgf
kW × 1.3410221 = hp SAE
N × 0.2248 = lbf
N × 0.1020 = kgf ■ Units of temperature
kgf × 2.2050 = lbf
kgf × 9.8070 =N °F = (1.8 × °C) + 32
°C = 0.556 × (°F - 32)

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GENERAL SERVICE INFORMATION Unit Conversions

This Page Intentionally Left Blank

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TNV IDI Service Manual

Section 4

PERIODIC
MAINTENANCE
Page
Before You Begin Servicing ............................................................ 4-3
Introduction...................................................................................... 4-4
The Importance of Periodic Maintenance.................................. 4-4
Performing Periodic Maintenance ............................................. 4-4
Isuzu Replacement Parts .......................................................... 4-4
Required EPA/ARB Maintenance - USA Only........................... 4-4
EPA/ARB Installation Requirements - USA Only ...................... 4-4
Periodic Maintenance Schedule ...................................................... 4-5
Periodic Maintenance Procedures .................................................. 4-7
After Initial 50 Hours of Operation ............................................. 4-7
Every 50 Hours of Operation ................................................... 4-10
Every 250 Hours of Operation ................................................. 4-13
Every 500 Hours of Operation ................................................. 4-17
Every 1000 Hours of Operation ............................................... 4-20
Every 1500 Hours of Operation ............................................... 4-22
Every 2000 Hours of Operation ............................................... 4-23

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PERIODIC MAINTENANCE

This Page Intentionally Left Blank

4-2
Before You Begin Servicing PERIODIC MAINTENANCE

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

4-3
PERIODIC MAINTENANCE Introduction

INTRODUCTION Isuzu Replacement Parts

This section of the Service Manual describes the Isuzu recommends that you use "Isuzu genuine
procedures for proper care and maintenance of the parts" when replacement parts are needed.
engine. Genuine replacement parts help ensure long
engine life.
The Importance of Periodic
Maintenance Required EPA/ARB Maintenance -
USA Only
Engine deterioration and wear occurs in proportion
to length of time the engine has been in service and To maintain optimum engine performance and
the conditions the engine is subject to during compliance with the Environmental Protection
operation. Periodic maintenance prevents Agency (EPA) Regulations Non-road Engines and
unexpected downtime, reduces the number of the California Air Resources Board (ARB,
accidents due to poor machine performance and California), it is essential that you follow the
helps extend the life of the engine. Periodic Maintenance Schedule on page 4-5 and
Periodic Maintenance Procedures on page 4-7.
Performing Periodic Maintenance
EPA/ARB Installation Requirements -
WARNING USA Only
Exhaust hazard The following are the installation requirements for
• Never operate the engine in an the EPA/ARB. Unless these requirements are met,
enclosed area such as a garage, the exhaust gas emissions will not be within the
tunnel, underground room, limits specified by the EPA and ARB.
manhole or ship’s hold without
Maximum Exhaust Gas Restriction shall be:
proper ventilation.
• Never block windows, vents, or other means • 1.70 psi (11.76 kPa; 1200 mm Aq) or less
of ventilation if the engine is operating in an Maximum air intake restriction shall be 0.90 psi
enclosed area. All internal combustion (6.23 kPa; 635 mmAq) or less. Clean or replace the
engines create carbon monoxide gas during air cleaner element if the air intake restriction
operation. Accumulation of this gas within an exceeds the above mentioned value.
enclosure could cause illness or even death.
• Make sure that all connections are tightened
to specifications after repair is made to the
exhaust system.
• Failure to comply could result in death or
serious injury.

Perform periodic maintenance procedures in an

open, level area free from traffic. If possible,
perform the procedures indoors to prevent
environmental conditions, such as rain, wind, or
snow, from damaging the machine.

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Periodic Maintenance Schedule PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Daily and periodic maintenance is important to keep the engine in good operating condition. The following
is a summary of maintenance items by periodic maintenance intervals. Periodic maintenance intervals vary
depending on engine application, loads, diesel fuel and engine oil used and are hard to establish
definitively. The following should be treated only as a general guideline.

NOTICE
Establish a periodic maintenance plan according to the engine application and make sure you perform the
required periodic maintenance at intervals indicated. Failure to follow these guidelines will impair the
engine’s safety and performance characteristics, shorten the engine’s life and may affect the warranty
coverage on your engine.
Consult your Isuzu Distributor for assistance when checking items marked with a .

: Check : Replace ●: Contact your Isuzu Distributor

Periodic maintenance interval

System Check item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Check and refill engine coolant 
Check and clean radiator fins 


Check and adjust cooling fan V-belt 2nd and
1st time
after
Cooling
 or
system
every
1 year
Drain, flush and refill cooling system with
which-
new coolant
ever
comes
first
Adjust intake/exhaust valve clearance 
Cylinder
head Lap intake/exhaust valve seats (if

required)
Electrical Check indicators 
equipment Check battery 
Check engine oil level 

Engine oil Drain and fill engine oil 


2nd and
Replace engine oil filter 1st time
after
Engine
Check and adjust governor lever and
speed  
engine speed control
control

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PERIODIC MAINTENANCE Periodic Maintenance Schedule

: Check : Replace ●: Contact your Isuzu Distributor

Periodic maintenance interval

System Check item Daily Every Every Every Every Every Every
50 250 500 1000 1500 2000
hours hours hours hours hours hours
Emission Inspect, clean and test fuel injectors, if

control necessary
warranty Inspect crankcase breather system 
Check and refill fuel tank level 
Drain fuel tank 
Drain water separator 
Fuel
Check water separator 
Clean water separator 
Replace fuel filter 
 or
Replace fuel system and cooling system
Hoses every 2
hoses
years
Intake and
Clean or replace air cleaner element  
exhaust
Complete
Overall visual check daily 
engine

Note: These procedures are considered normal maintenance and are performed at the owner’s expense.

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Periodic Maintenance Procedures PERIODIC MAINTENANCE

PERIODIC MAINTENANCE NOTICE

PROCEDURES • Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
After Initial 50 Hours of Operation engine components to seize and/or shorten
engine life.
Perform the following maintenance after the initial
• Prevent dirt and debris from contaminating the
50 hours of operation.
engine oil. Carefully clean the oil cap/dipstick and
• Replace engine oil and engine oil filter the surrounding area before you remove the cap.

• Check and adjust cooling fan V-belt • Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
■ Replace engine oil and engine oil filter engine oil.

WARNING • Never overfill. Overfilling may result in white

exhaust smoke, engine overspeed or internal
Burn Hazard damage.
• If you must drain the engine oil
while it is still hot, stay clear of NOTICE
the hot engine oil to avoid being
burned. • Always be environmentally
responsible.

• Always wear eye protection.

• Failure to comply could result in death or
serious injury.
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
WARNING hazardous materials such as engine oil, diesel
To refuel the engine oil, refuel slowly after fuel and engine coolant. Consult the local
removing the dipstick and both caps. If you authorities or reclamation facility.
refuel rapidly, the oil intrusion to the intake
occurs through the PCV valve of the valve • Never dispose of hazardous materials
cover. It will result in an oil hammer at engine irresponsibly by dumping them into a sewer, on
start, which may cause damage to the engine. the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.

4-7
PERIODIC MAINTENANCE Periodic Maintenance Procedures

The engine oil on a new engine becomes Remove the engine oil filter as follows:
contaminated from the initial break-in of internal 1. Turn the engine oil filter (Figure 4-2, (2))
parts. It is very important that the initial oil and filter counterclockwise (Figure 4-2, (4)) using a filter
change is performed as scheduled. wrench.
Note: The oil drain plug may be in another location
if an optional oil pan is used.
Drain the engine oil as follows:
1. Make sure the engine is level.
3
2. Start the engine and bring it up to operating
temperature. 4
3. Stop the engine.
4. Remove the oil filler cap (Figure 4-1, (1)) to
vent the engine crankcase and allow the engine
oil to drain more easily. 2
5. Position a container under the engine to collect
waste oil.
1
K0000651B
1
Figure 4-2
2. Clean the engine oil filter mounting face.
3. Lightly coat the gasket on the new oil filter with
clean engine oil. Install the new engine oil filter
1 manually by turning it clockwise
(Figure 4-2, (3)) until it contacts the mounting
surface. Tighten to 14 - 17 ft-lb (19.6 - 23.5
N·m, 2.0 - 2.4 kgf·m or one additional turn using
the filter wrench.

Applicable engine oil filter Part No.

K0000587B
Engine model Part No.
3CH1, 3CJ1 5-8640-0632-0
Figure 4-1
6. Remove the oil drain plug (Figure 4-2, (1)). 4. Add new engine oil to the engine as specified in
Allow oil to drain. Adding Engine Oil on page 3-15.
7. After all oil has been drained from the engine,
reinstall the oil drain plug (Figure 4-2, (1)) and
tighten to 39.8 - 47.0 ft-lb (53.9 - 63.7 N·m, 5.5 -
6.5 kgf·m).
8. Dispose of used oil properly.

4-8
Periodic Maintenance Procedures PERIODIC MAINTENANCE
■ Check and adjust cooling fan V-belt
The V-belt will slip if it does not have the proper
tension. This will prevent the alternator from 3
generating sufficient power. Also, the engine will
overheat due to the engine coolant pump pulley
slipping.
Check and adjust the V-belt tension (deflection) as
follows:
1
1. Press the V-belt down with your thumb with a 2
force of approximately 22 ft-lb (98 N·m, 10 K0000653B
kgf·m) to check the deflection.
Figure 4-4
There are three positions to check for V-belt
tension (Figure 4-3, (A), (B) and (C)). You can 3. Tighten the V-belt to the proper tension. There
check the tension at whichever position is the must be clearance (Figure 4-5, (1)) between
most accessible. The proper deflection of a used the V-belt and the bottom of the pulley groove. If
V-belt at each position is: there is no clearance (Figure 4-5, (2)) between
the V-belt and the bottom of the pulley groove,
replace the V-belt.
B

2
A
1

C K0000584

K0000652B Figure 4-5

Figure 4-3 4. Check the V-belt for cracks, oil or wear. If any of
these conditions exist, replace the V-belt.
Used V-belt tension
• “New V-belt” refers to a V-belt which has been
A B C used less than 5 minutes on a running engine.
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in. • “Used V-belt” refers to a V-belt which has been
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
used on a running engine for 5 minutes or
more.
2. If necessary, adjust the V-belt tension. Loosen
the adjusting bolt (Figure 4-4, (1)) and the 5. Inspect the condition of the used V-belt. There
other related bolts and/or nuts, then move the must be clearance (Figure 4-5, (1)) between
alternator (Figure 4-4, (2)) with a pry bar the V-belt and the bottom of the pulley groove. If
(Figure 4-4, (3)) to tighten the V-belt to the there is no clearance (Figure 4-5, (2)) between
desired tension. Then tighten the adjusting the V-belt and the bottom of the pulley groove,
bolts and/or nuts. replace the V-belt.

4-9
TNV_IDI_ServiceManual_A4.book Page 10 Saturday, July 4, 2015 5:50 PM

PERIODIC MAINTENANCE Periodic Maintenance Procedures

6. Install the new V-belt. Refer to the table for

proper tension. Every 50 Hours of Operation
New V-belt tension After you complete the initial 50 hour maintenance
A B C procedures, perform the following procedures every
5/16 - 7/16 in. 3/16 - 5/16 in. 1/4 - 7/16 in. 50 hours thereafter.
(8 - 12 mm) (5 - 8 mm) (7 - 11 mm)
• Drain water separator
7. After adjusting, run the engine for 5 minutes or • Check battery
more. Check the tension again using the
specifications for a used V-belt. ■ Drain water separator
Used V-belt tension DANGER
A B C
Fire and Explosion Hazard
3/8 - 1/2 in. 1/4 - 3/8 in. 5/16 - 1/2 in.
(10 - 14 mm) (7 - 10 mm) (9 - 13 mm)
• Diesel fuel is flammable and
explosive under certain
conditions.

• When you remove any fuel system component

to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.

NOTICE
If the water separator is positioned higher than the
fuel level in the fuel tank, water may not drip out
when the water separator drain cock is opened. If
this happens, turn the air vent screw on the top of
the water separator 2-3 turns counterclockwise.
Be sure to tighten the air vent screw after the water
has drained out.

4-10
Periodic Maintenance Procedures PERIODIC MAINTENANCE
2. Close (Figure 4-6, (2)) the fuel valve
NOTICE (Figure 4-6, (3)).
• Always be environmentally 3. Turn the retaining ring (Figure 4-6, (4)) to the
responsible. left (Figure 4-6, (9)).
4. Carefully remove the cup (Figure 4-6, (1)).
Remove the retaining spring (Figure 4-6, (6))
and float (Figure 4-6, (7)) from the cup. Pour
• Follow the guidelines of the EPA or other the fuel into an approved container and dispose
governmental agencies for the proper disposal of properly. Hold the bottom of the cup with a shop
hazardous materials such as engine oil, diesel towel to prevent the fuel from dripping. Wipe up
fuel and engine coolant. Consult the local any spills immediately.
authorities or reclamation facility. 5. Clean the inside of the cup.
• Never dispose of hazardous materials 6. Inspect the condition of the mesh filter
irresponsibly by dumping them into a sewer, on (Figure 4-6, (10)). Clean the mesh filter if
the ground, or into ground water or waterways. necessary.

• Failure to follow these procedures may seriously 7. Inspect the condition of the O-ring
harm the environment. (Figure 4-6, (11)). Replace the O-ring if
necessary.
8. Put the float (Figure 4-6, (7)) and retaining
Drain the water separator whenever there are spring (Figure 4-6, (6)) inside the cup.
contaminants, such as water, collected in the 9. Reinstall the cup to the mounting flange
bottom of the cup. Never wait until the scheduled (Figure 4-6, (8)) and turn the retaining ring
periodic maintenance if contaminants are (Figure 4-6, (4)) to the right (Figure 4-6, (5)).
discovered. Hand-tighten only.
The cup of the separator is made from 10. Open the fuel valve (Figure 4-6, (3)).
semi-transparent material. In the cup is a 11. Be sure to prime the fuel system. See Priming
red-colored float ring. The float ring will rise to the the Fuel System on page 3-13.
surface of the water to show how much needs to be
drained. Also, some optional water separators are 12. Check for fuel leaks.
equipped with a sensor to detect the amount of
contaminants. This sensor sends a signal to an NOTICE
indicator to alert the operator. If the water separator is positioned higher than
the fuel level in the fuel tank, water may not drip
Drain the water separator as follows:
out when the water separator drain cock is
1. Position an approved container under the water opened. If this happens, turn the air vent screw
separator (Figure 4-6, (1)) to collect the on the top of the water separator 2 - 3 turns
contaminants. counterclockwise.
Be sure to tighten the air vent screw after the
8
water has drained out.

5 11
9 4 6
3 10
1
7
2 K0000590A

Figure 4-6

4-11
PERIODIC MAINTENANCE Periodic Maintenance Procedures

■ Check battery
NOTICE
DANGER • Always be environmentally
responsible.
Explosion Hazard
• Never check the remaining
battery charge by shorting out the
terminals. This will result in a
spark and may cause an • Follow the guidelines of the EPA or other
explosion or fire. Use a governmental agencies for the proper disposal of
hydrometer to check the hazardous materials such as engine oil, diesel
remaining battery charge. fuel and engine coolant. Consult the local
authorities or reclamation facility.
• If the electrolyte is frozen, slowly warm the
battery before you recharge it. • Never dispose of hazardous materials
• Failure to comply will result in death or irresponsibly by dumping them into a sewer, on
serious injury. the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
WARNING harm the environment.
Burn Hazard
• Batteries contain sulfuric acid.
• When the amount of fluid nears the lower limit
Never allow battery fluid to come
(Figure 4-7, (3)), fill with distilled water
in contact with clothing, skin or
(Figure 4-7, (2)) so it is at the upper limit
eyes. Severe burns could result.
(Figure 4-7, (1)). If operation continues with
Always wear safety goggles and
insufficient battery fluid, the battery life is
protective clothing when
shortened, and the battery may overheat and
servicing the battery. If battery
explode. During the summer, check the fluid level
fluid contacts the eyes and/or
more often than specified.
skin, immediately flush the
affected area with a large amount
of clean water and obtain prompt 2
medical treatment.
• Failure to comply could result in death or
serious injury.

1
3

031783-00X

Figure 4-7

4-12
TNV_IDI_ServiceManual_A4.book Page 13 Saturday, July 4, 2015 5:50 PM

Periodic Maintenance Procedures PERIODIC MAINTENANCE

• If the engine cranking speed is so slow that the
engine does not start, recharge the battery. Every 250 Hours of Operation
• If the engine still will not start after charging, have Perform the following maintenance every 250 hours
your Isuzu Distributor check the battery and the of operation.
engine’s starting system.
• Drain fuel tank
• If operating the machine where the ambient
temperature could drop to 5 °F (-15 °C) or less, • Replace engine oil and engine oil filter
remove the battery from the machine at the end
of the day. Store the battery in a warm place until • Check and clean radiator fins
the next use. This will help start the engine easily • Check and adjust cooling fan V-belt
at low ambient temperatures.
• Check and adjust the governor lever and
engine speed control
• Clean air cleaner element

■ Drain fuel tank

DANGER
Fire and Explosion Hazard
• Diesel fuel is flammable and
explosive under certain
conditions.

• When you remove any fuel system component

to perform maintenance (such as changing
the fuel filter) place an approved container
under the opening to catch the fuel.
• Never use a shop rag to catch the fuel. Vapors
from the rag are flammable and explosive.
• Wipe up any spills immediately.
• Wear eye protection. The fuel system is under
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.

4-13
PERIODIC MAINTENANCE Periodic Maintenance Procedures

■ Replace engine oil and engine oil filter

NOTICE
• Always be environmentally NOTICE
responsible. • Only use the engine oil specified. Other engine
oils may affect warranty coverage, cause internal
engine components to seize and/or shorten
engine life.
• Follow the guidelines of the EPA or other • Prevent dirt and debris from contaminating the
governmental agencies for the proper disposal of engine oil. Carefully clean the oil cap/dipstick and
hazardous materials such as engine oil, diesel the surrounding area before you remove the cap.
fuel and engine coolant. Consult the local
authorities or reclamation facility. • Never mix different types of engine oil. This may
adversely affect the lubricating properties of the
• Never dispose of hazardous materials engine oil.
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways. • Never overfill. Overfilling may result in white
exhaust smoke, engine overspeed or internal
• Failure to follow these procedures may seriously damage.
harm the environment.
NOTICE
Note that a typical fuel tank is illustrated. • Always be environmentally
1. Position an approved container under the diesel responsible.
fuel tank (Figure 4-8, (1)) to collect the
contaminates.

3 • Follow the guidelines of the EPA or other

governmental agencies for the proper disposal of
1 hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
2 irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
K0000065A

• Failure to follow these procedures may seriously

Figure 4-8 harm the environment.
2. Remove the fuel cap (Figure 4-8, (3)).
3. Remove the drain plug (Figure 4-8, (2)) of the Change the engine oil every 250 hours of operation
fuel tank to drain the contaminates (water, dirt, after the initial change at 50 hours. Replace the
etc.) from the bottom of the tank. engine oil filter at the same time. See Replace
4. Drain the tank until clean diesel fuel with no engine oil and engine oil filter on page 4-7.
water or dirt flows out. Reinstall and tighten the
drain plug firmly.
5. Reinstall the fuel cap.
6. Check for fuel leaks.

4-14
Periodic Maintenance Procedures PERIODIC MAINTENANCE
■ Check and clean radiator fins ■ Check and adjust cooling fan V-belt
Check and adjust the cooling fan V-belt every 250
CAUTION hours of operation after the initial 50 hour V-belt
Flying Object Hazard maintenance. See Check and adjust cooling fan V-
• Always wear eye protection when belt on page 4-9.
servicing the engine and when
■ Check and adjust the governor lever and
using compressed air or high-
engine speed control
pressure water. Dust, flying
debris, compressed air, The governor lever and engine speed control
pressurized water or steam may (throttle lever, accelerator pedal etc.), are
injure your eyes. connected together by a cable or linkage. If the
cable becomes stretched, or the linkage wears or
• Failure to comply may result in minor or
loosens, the governor lever may not respond to a
moderate injury.
change in the position of the engine speed control.

Dirt and dust adhering to the radiator fins reduce NOTICE

the cooling performance, causing overheating.
Never attempt to adjust the low or high idle speed
Make it a rule to check the radiator fins daily and
limit screw. This may impair the safety and
clean as needed.
performance of the machine and shorten its life. If
Note that a typical radiator is shown in Figure 4-9 the idle speed limit screws require adjustment, see
for illustrative purposes only. your Isuzu Distributor.

• Blow off dirt and dust from fins and radiator with
28 psi (0.19 MPa; 2 kgf/cm2) or less of 1. Check that the governor lever (Figure 4-10, (1))
compressed air (Figure 4-9, (1)). Be careful not makes firm contact with the high idle stop
to damage the fins with the compressed air. (Figure 4-10, (2)) and the low idle speed limit
screw (Figure 4-10, (3)) when the engine
• If there is a large amount of contamination on the
speed control is in the full speed or low idle
fins, apply detergent, thoroughly clean and rinse
speed positions.
with tap water.
2. If the governor lever does not make proper
NOTICE contact with the high idle stop or the low idle
speed limit screw, adjust the throttle cable or
Never use high-pressure water or compressed air linkage as necessary.
at greater than 28 psi (193 kPa; 19 686 mmAq) or a
Note: Do not force the throttle cable or linkage
wire brush to clean the radiator fins. Radiator fins
to move. This may damage the governor
damage easily.
lever, the throttle cable or linkage and
cause irregular operation of the engine
speed control.

NOTICE
1 The engine speed control (throttle lever,
FULL

LOW
accelerator pedal etc.), should be equipped with
stops to prevent the application of excessive
pressure by the governor lever to either the high
idle stop or low idle speed limit screw.

K0000085A

Figure 4-9

4-15
PERIODIC MAINTENANCE Periodic Maintenance Procedures

1. Unlatch and remove the air cleaner cover

2 (Figure 4-11, (1)).
2. Remove the element (Figure 4-11, (2)) (outer
element if equipped with two elements).
3
6 4
2
5
3

1
1
K0000654B02

Figure 4-10
K0000070A

■ Clean air cleaner element

Figure 4-11
CAUTION
Flying Object Hazard
• Always wear eye protection when 2
servicing the engine and when
using compressed air or high-
pressure water. Dust, flying
debris, compressed air, 1
pressurized water or steam may
injure your eyes.
• Failure to comply may result in minor or K0000071A-01X

moderate injury.
Figure 4-12
3. Blow air (Figure 4-11, (3)) through the element
Note that a typical air cleaner is shown in
from the inside out using 42 - 71 psi (0.29 - 0.49
Figure 4-11 and Figure 4-12 for illustrative
MPa; 3.0 - 5.0 kgf/cm2) compressed air to
purposes only.
remove the particulates. Use the lowest
The engine performance is adversely affected possible air pressure to remove the dust without
when the air cleaner element is clogged with dust. damaging the element.
Be sure to clean the air filter element periodically. If the air cleaner is equipped with a double
element, only remove and replace the inner
NOTICE element (Figure 4-12, (1)) if the engine lacks
power or the dust indicator actuates (if
• When the engine is operated in dusty conditions,
equipped).
clean the air cleaner element more frequently.
The inner element should not be removed
• Never operate the engine with the air cleaner
when cleaning or replacing the outer element.
element(s) removed. This may allow foreign
The inner element is used to prevent dust from
material to enter the engine and damage it.
entering the engine while servicing the outer
element.

4-16
Periodic Maintenance Procedures PERIODIC MAINTENANCE
4. Replace the element with a new one if the
element is damaged, excessively dirty or oily. Every 500 Hours of Operation
5. Clean inside of the air cleaner cover.
Perform the following maintenance every 500 hours
6. Install the element into the air cleaner case of operation.
(Figure 4-11, (4)).
Note: If there is a red line (Figure 4-13, (2)) in • Replace air cleaner element
the outer element, reinsert the element • Replace fuel filter
until the overlap position of red line and
end face of the air cleaner case. • Clean water separator
7. Install the air cleaner cover making sure you ■ Replace air cleaner element
match the arrow (Figure 4-11, (5)) on the cover
with the arrow on the case (Figure 4-11, (6)). NOTICE
8. Latch the air cleaner cover to the case. The maximum air intake restriction, in terms of
differential pressure measurement, must not
exceed 0.90 psi (6.23 kPa; 635 mmAq). Clean or
replace the air cleaner element if the air intake
restriction exceeds the above mentioned value.

Replace the air cleaner element (Figure 4-11, (2))

every 500 hours even if it is not damaged or dirty.
When replacing the element, clean the inside of the
air cleaner case (Figure 4-11, (4)).
If the air cleaner is equipped with a double element,
only remove and replace the inner element
(Figure 4-12, (1)) if the engine lacks power or the
dust indicator actuates (if equipped). This is in
addition to replacing the outer element.

4-17
PERIODIC MAINTENANCE Periodic Maintenance Procedures

■ Replace fuel filter

NOTICE
DANGER For maximum engine life, Isuzu recommends that
when shutting the engine down, you allow the
Fire and Explosion Hazard
engine to idle, without load, for five minutes. This
• Diesel fuel is flammable and will allow the engine components that operate at
explosive under certain high temperatures, such as the turbocharger (if
conditions. equipped) and exhaust system, to cool slightly
before the engine itself is shut down.

• When you remove any fuel system component

to perform maintenance (such as changing Replace the fuel filter at specified intervals to
the fuel filter) place an approved container prevent contaminants from adversely affecting the
under the opening to catch the fuel. diesel fuel flow.
• Never use a shop rag to catch the fuel. Vapors 1. Stop the engine and allow it to cool.
from the rag are flammable and explosive. 2. Close the fuel valve of the water separator.
• Wipe up any spills immediately. 3. Turn the retaining ring (Figure 4-13, (1)) to the
• Wear eye protection. The fuel system is under left (Figure 4-13, (2)).
pressure and fuel could spray out when you
remove any fuel system component.
• Failure to comply will result in death or
serious injury.

NOTICE 6
2
• Always be environmentally 5
1 4
responsible.
3

K0000589A

Figure 4-13
• Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of 4. Carefully remove the cup (Figure 4-13, (3)) and
hazardous materials such as engine oil, diesel pour the fuel into an approved container and
fuel and engine coolant. Consult the local dispose of waste properly. Hold the bottom of
authorities or reclamation facility. the cup with a shop towel to prevent the fuel
from dripping. Wipe up any spills immediately.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on 5. Remove the element (Figure 4-13, (4)) by
the ground, or into ground water or waterways. pulling it down.
6. Replace the element with a new one.
• Failure to follow these procedures may seriously
harm the environment. Applicable fuel filter Part No.
Part No.
Engine model
Standard Dust proof
3CH1, 3CJ1 5-8640-0778-0 5-8640-1510-0

7. Wash the inside of the cup with clean fuel.

4-18
Periodic Maintenance Procedures PERIODIC MAINTENANCE
8. Check the condition of the cup O-ring
(Figure 4-13, (6)). Replace if necessary. NOTICE
9. Reinstall the cup to the mounting flange and • Always be environmentally
turn the retaining ring (Figure 4-13, (1)) to the responsible.
right (Figure 4-13, (2)). Hand-tighten only.
10. Open the fuel valve of the water separator.
11. Prime the fuel system. See Priming the Fuel
System on page 3-13. • Follow the guidelines of the EPA or other
governmental agencies for the proper disposal of
12. Check for fuel leaks.
hazardous materials such as engine oil, diesel
■ Clean water separator fuel and engine coolant. Consult the local
authorities or reclamation facility.
DANGER • Never dispose of hazardous materials
Fire and Explosion Hazard irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Diesel fuel is flammable and
explosive under certain • Failure to follow these procedures may seriously
conditions. harm the environment.

• Never use diesel fuel as a cleaning agent. Periodically clean the water separator element and
inside the cup.
• When you remove any fuel system component
to perform maintenance (such as changing 1. Position an approved container under the cup
the fuel filter) place an approved container (Figure 4-14, (1)) of the water separator to
under the opening to catch the fuel. collect the contaminants.
• Never use a shop rag to catch the fuel. Vapors 2
from the rag are flammable and explosive.
9
• Wipe up any spills immediately.
c

• Wear eye protection. The fuel system is under o

pressure and fuel could spray out when you

remove any fuel system component. 5
• Failure to comply will result in death or 10 4 6
3 8
serious injury. 1
7
K0000590B

Figure 4-14
2. Close (Figure 4-14, (2)) the fuel valve
(Figure 4-14, (3)).
3. Turn the retaining ring (Figure 4-14, (4)) to the
left (Figure 4-14, (10)).

4-19
PERIODIC MAINTENANCE Periodic Maintenance Procedures

4. Carefully remove the cup (Figure 4-14, (1)) and

pour the fuel into an approved container and Every 1000 Hours of Operation
dispose of properly. Hold the bottom of the cup
with a shop towel to prevent the fuel from Perform the following maintenance every 1000
dripping. Wipe up any spills immediately. hours of operation.
5. Keep the retaining spring (Figure 4-14, (6)) and • Drain, flush and refill cooling system with new
float (Figure 4-14, (7)) handy for reassembly. coolant
6. Remove the element (Figure 4-14, (8)) by
pulling it down. • Adjust intake/exhaust valve clearance

7. Replace the element with a new one. ■ Drain, flush and refill cooling system
with new coolant
Applicable mesh filter Part No.
Engine model Part No. DANGER
3CH1, 3CJ1 5-8640-0832-0
Scald Hazard
Note: Please confirm the part number with • Never remove the radiator cap if
parts catalog for your engine. the engine is hot. Steam and hot
engine coolant will spurt out and
8. Wash the inside of the cup with clean diesel seriously burn you. Allow the
fuel. engine to cool down before you
9. Check the condition of the cup O-ring. Replace attempt to remove the radiator
if necessary. cap.
10. Put the float (Figure 4-14, (7)) and retaining • Tighten the radiator cap securely after you
spring (Figure 4-14, (6)) inside the cup. check the radiator. Steam can spurt out
11. Reinstall the cup to the mounting flange during engine operation if the cap is loose.
(Figure 4-14, (9)) and turn the retaining ring • Always check the level of the engine coolant
(Figure 4-14, (4)) to the right (Figure 4-14, (5)). by observing the reserve tank.
Hand-tighten only.
• Failure to comply will result in death or
12. Open the fuel valve (Figure 4-14, (3)). serious injury.
13. Prime the fuel system. See Priming the Fuel
System on page 3-13. WARNING
14. Check for fuel leaks. Burn Hazard
• Wait until the engine cools before
you drain the engine coolant. Hot
engine coolant may splash and
burn you.

• Failure to comply could result in death or

serious injury.

4-20
Periodic Maintenance Procedures PERIODIC MAINTENANCE

CAUTION
1
Coolant Hazard
• Wear eye protection
and rubber gloves
when you handle long FULL

LOW

life or extended life

engine coolant. If
contact with the eyes
or skin should occur,
flush eyes and wash
immediately with
clean water. 2 K0000074A

• Failure to comply may result in minor or Figure 4-15

moderate injury.
4. Drain the coolant from the engine block.
NOTICE Remove the coolant drain plug
(Figure 4-16, (1)) from the engine block.
• Always be environmentally
responsible.

OIL

• Follow the guidelines of the EPA or other

governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on 1 K0002923

the ground, or into ground water or waterways.

Figure 4-16
• Failure to follow these procedures may seriously
5. After draining the engine coolant, flush the
harm the environment.
radiator and engine block to remove any rust,
scale and contaminants.
Engine coolant contaminated with rust or scale 6. Reinstall and tighten the drain plug or close the
reduces the cooling effect. Even when extended life drain cock at the radiator. Reinstall and tighten
engine coolant is properly mixed, the engine the engine block drain plug.
coolant gets contaminated as its ingredients 7. Fill radiator and engine with engine coolant.
deteriorate. Drain, flush and refill the cooling See Filling Radiator with Engine Coolant on
system with new coolant every 1000 hours or once page 3-17.
a year, whichever comes first.
1. Allow engine and coolant to cool.
■ Adjust intake/exhaust valve clearance
2. Remove the radiator cap (Figure 4-15, (1)). Proper adjustment is necessary to maintain the
correct timing for opening and closing the valves.
3. Remove the drain plug or open the drain cock Improper adjustment will cause the engine to run
(Figure 4-15, (2)) at the lower position of the noisily, resulting in poor engine performance and
radiator and drain the engine coolant. engine damage. See Measuring and Adjusting
Valve Clearance on page 5-33.

4-21
PERIODIC MAINTENANCE Periodic Maintenance Procedures

■ Inspect crankcase breather system

Every 1500 Hours of Operation
Proper operation of the crankcase breather system
is required to maintain the emission requirements
Perform the following maintenance every 1500 of the engine. The EPA/ARB requires that the
hours of operation. crankcase breather system is inspected every 1500
• Inspect, clean and test fuel injectors, if hours.
necessary The 3CH1, 3CJ1-NGZG01 engine use a crankcase
• Inspect crankcase breather system breather system that has a spring-backed
diaphragm (Figure 4-17, (1)) in the valve cover
■ Inspect, clean and test fuel injectors (Figure 4-17, (2)). When the crankcase pressure
reaches a predetermined value, the diaphragm
WARNING opens a passage that allows crankcase fumes to
be routed to the intake manifold.
High-Pressure Hazard
• Avoid skin contact with the
high-pressure diesel fuel spray 4
caused by a fuel system leak such 3
as a broken fuel injection line.
High-pressure fuel can penetrate 5
your skin and result in serious
injury. If you are exposed to high-
1
pressure fuel spray, obtain
prompt medical treatment.
• Never check for a fuel leak with your hands.
2
Always use a piece of wood or cardboard.
Have your Isuzu Distributor repair the
damage.
• Failure to comply could result in death or
serious injury.

Proper operation of the fuel injectors is required to

obtain the optimum injection pattern for full engine K0004055

performance. The EPA/ARB requires that the fuel

Figure 4-17
injectors are inspected, cleaned and tested every
1500 hours. See Testing of Fuel Injectors on To inspect the diaphragm and spring
page 6-23. (Figure 4-17, (3)):
This procedure is considered normal maintenance 1. Remove the bolts retaining the diaphragm cover
and is performed at the owner’s expense. This (Figure 4-17, (4)).
procedure is not covered by the Isuzu Motors
2. Remove the diaphragm cover, spring,
Limited Warranty.
diaphragm plate (Figure 4-17, (5)) and
diaphragm.
3. Inspect the diaphragm for tears. Inspect the
spring for distortion. Replace components if
necessary.

4-22
Periodic Maintenance Procedures PERIODIC MAINTENANCE
4. Reinstall the diaphragm, diaphragm plate,
spring and diaphragm cover. Tighten the Every 2000 Hours of Operation
diaphragm bolts to the specified torque. See
Tightening Torques for Standard Bolts and Nuts Perform the following maintenance every 2000
on page 3-24. hours of operation.
Failure of the diaphragm and/or spring will cause • Check and replace fuel hoses and engine
the loss of pressure control and allow an excessive coolant hoses
amount of crankcase fumes to be routed to the
intake manifold. This could result in excessive • Lap the intake and exhaust valves
deposits in the intake system, high engine exhaust
smoke levels, excessive engine oil consumption, ■ Check and replace fuel hoses and engine
and/or engine run-on due to the burning of the coolant hoses
engine oil.
NOTICE
• Always be environmentally
responsible.

• Follow the guidelines of the EPA or other

governmental agencies for the proper disposal of
hazardous materials such as engine oil, diesel
fuel and engine coolant. Consult the local
authorities or reclamation facility.
• Never dispose of hazardous materials
irresponsibly by dumping them into a sewer, on
the ground, or into ground water or waterways.
• Failure to follow these procedures may seriously
harm the environment.

Regularly check the fuel system and engine coolant

system hoses. If they are cracked or degraded,
replace them. Replace the hoses at least every two
years. See Check and replace fuel hoses and
engine coolant hoses on page 4-23.

■ Lap the intake and exhaust valves

Adjustment is necessary to maintain proper contact
of the valves and seats. See Inspection of intake
and exhaust valves on page 5-26.

4-23
TNV_IDI_ServiceManual_A4.book Page 24 Saturday, July 4, 2015 5:50 PM

PERIODIC MAINTENANCE Periodic Maintenance Procedures

This Page Intentionally Left Blank

4-24
TNV_IDI_ServiceManual_A4.book Page 1 Saturday, July 4, 2015 5:50 PM

TNV IDI Service Manual

Section 5

ENGINE
Page
Before You Begin Servicing ............................................................ 5-3
Introduction...................................................................................... 5-4
Cylinder Head Specifications .......................................................... 5-4
Adjustment Specifications ......................................................... 5-4
Cylinder Head............................................................................ 5-4
Intake/Exhaust Valve and Guide ............................................... 5-5
Push Rod................................................................................... 5-5
Valve Spring .............................................................................. 5-5
Rocker Arm and Shaft ............................................................... 5-6
Camshaft and Timing Gear Train Specifications ............................. 5-7
Camshaft ................................................................................... 5-7
Idler Gear Shaft and Bushing .................................................... 5-8
Timing Gear Backlash ............................................................... 5-8
Crankshaft and Pistons Specifications ............................................ 5-9
Crankshaft ................................................................................. 5-9
Crankshaft Reconditioning ...................................................... 5-10
Thrust Bearing ......................................................................... 5-10
Piston....................................................................................... 5-11
Piston Ring .............................................................................. 5-12
Connecting Rod....................................................................... 5-13
Tappet ..................................................................................... 5-14
Cylinder Block Specifications ........................................................ 5-14
Cylinder Block.......................................................................... 5-14
Special Torque Chart .................................................................... 5-15
Torque for Bolts and Nuts........................................................ 5-15
Special Service Tools.................................................................... 5-16
Measuring Instruments.................................................................. 5-18

5-1
TNV_IDI_ServiceManual_A4.book Page 2 Saturday, July 4, 2015 5:50 PM

ENGINE
Cylinder Head ................................................................................ 5-20
Cylinder Head Components ..................................................... 5-20
Disassembly of Cylinder Head ................................................. 5-21
Cleaning of Cylinder Head Components .................................. 5-25
Inspection of Cylinder Head Components................................ 5-25
Reassembly of Cylinder Head.................................................. 5-29
Measuring and Adjusting Valve Clearance .............................. 5-33
Cylinder Block ................................................................................ 5-35
Crankshaft and Camshaft Components ................................... 5-35
Disassembly of Cylinder Block Components............................ 5-38
Disassembly of Camshaft and Timing Components ................ 5-39
Disassembly of Crankshaft and Piston Components ............... 5-44
Inspection of Crankshaft and Camshaft Components.............. 5-47
Reconditioning the Crankshaft ................................................. 5-53
Honing and Boring.................................................................... 5-54
Reassembly of Crankshaft and Piston Components................ 5-55
Reassembly of Camshaft and Timing Components ................. 5-61

5-2
Before You Begin Servicing ENGINE

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

5-3
ENGINE Introduction

INTRODUCTION
This section of the Service Manual describes servicing of the engine.

CYLINDER HEAD SPECIFICATIONS

Adjustment Specifications
Model Valve clearance
All models 0.006 - 0.010 in. (0.15 - 0.25 mm)

Cylinder Head
Reference
Inspection item Standard Limit
page
0.0020 in. 0.0059 in.
Combustion surface distortion (flatness)
(0.05 mm) or less (0.15 mm)
See Valve
0.0157 - 0.0236 in. 0.0354 in.
Intake recession on
(0.4 - 0.6 mm) (0.9 mm)
Valve recession page 5-27
0.0157 - 0.0236 in. 0.0315 in.
Exhaust
(0.4 - 0.6 mm) (0.8 mm)
Intake 120° – See Valve
Seat angle face and
Valve seat Exhaust 90° –
valve seat on
Seat correction angle 40°, 150° – page 5-27

5-4
Cylinder Head Specifications ENGINE
Intake/Exhaust Valve and Guide
Reference
Inspection item Standard Limit
page
0.2362 - 0.2367 in. 0.2394 in.
Guide inside diameter
(6.000 - 6.012 mm) (6.08 mm)
Valve stem outside 0.2346 - 0.2352 in. 0.2323 in.
diameter (5.960 - 5.975 mm) (5.90 mm)
Intake
0.0010 - 0.0020 in. 0.0063 in.
Oil clearance
(0.025 - 0.052 mm) (0.15 mm)
0.0004 in. See Inspection
Valve stem bend –
(0.010 mm) of valve
0.2362 - 0.2367 in. 0.2394 in. springs on
Guide inside diameter page 5-28
(6.000 - 6.012 mm) (6.08 mm)
Valve stem outside 0.2341 - 0.2346 in. 0.2323 in.
diameter (5.945 - 5.960 mm) (5.90 mm)
Exhaust
0.0016 - 0.0026 in. 0.0067 in.
Oil clearance
(0.040 - 0.067 mm) (0.17 mm)
0.0004 in.
Valve stem bend –
(0.010 mm)
0.3858 - 0.3937 in.
Valve guide projection from cylinder head – See
(9.8 - 10.0 mm)
Reassembly of
0.429 - 0.441 in.
Valve stem seal projection from cylinder head – valve guides
(10.9 - 11.2 mm)
on page 5-29
Valve guide installation method Cold-fitted –

Push Rod
Reference
Inspection item Standard Limit
page
See Push rod
Less than 0.0012 in.
Push rod bend bend on
0.0012 in. (0.03 mm) (0.03 mm)
page 5-25

Valve Spring
Reference
Inspection item Standard Limit
page
1.4882 in. See Inspection
Free length –
(37.8 mm) of valve
0.0512 in. springs on
Squareness – page 5-28
(1.3 mm)

5-5
ENGINE Cylinder Head Specifications

Rocker Arm and Shaft

Reference
Inspection item Standard Limit
page
0.4724 - 0.4732 in. 0.4752 in.
Arm shaft hole diameter
(12.000 - 12.020 mm) (12.07 mm) See Inspection
0.4711 - 0.4718 in. 0.4701 in. of rocker arm
Shaft outside diameter
(11.966 - 11.984 mm) (11.94 mm) assembly on
0.0006 - 0.0021 in. 0.0051 in. page 5-25
Oil clearance
(0.016 - 0.054 mm) (0.13 mm)

5-6
Camshaft and Timing Gear Train Specifications ENGINE

CAMSHAFT AND TIMING GEAR TRAIN SPECIFICATIONS

Camshaft
Reference
Inspection item Standard Limit
page
See Removal
0.0020 - 0.0059 in. 0.0098 in.
End play of camshaft on
(0.05 - 0.15 mm) (0.25 mm)
page 5-42
0 - 0.0008 in. 0.0020 in.
Bend (1/2 the dial gauge reading)
(0 - 0.02 mm) (0.05 mm)
3CH1-NGZG01
1.3596 - 1.3647 in. 1.3500 in.
3CH1-SDZP01
(34.535 - 34.665 mm) (34.29 mm)
Cam lobe height 3CJ1-SDZP01
1.3439 - 1.3490 in. 1.3343 in.
3CJ1-NGZG01
(34.135 - 34.265 mm) (33.89 mm)
1.5748 - 1.5758 in. 1.5807 in.
Bushing inside diameter
(40.000 - 40.025 mm) (40.150 mm)
Camshaft outside 1.5724 - 1.5732 in. 1.5711 in.
Gear end
diameter (39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0033 in. 0.0096 in. See Inspection
Oil clearance
(0.040 - 0.085 mm) (0.245 mm) of camshaft on
1.5748 - 1.5758 in. 1.5787 in. page 5-53
Bushing inside diameter
(40.000 - 40.025 mm) (40.100 mm)
Shaft outside
Intermedia Camshaft outside 1.5713 - 1.5722 in. 1.5699 in.
diameter/bearing
te diameter (39.910 - 39.935 mm) (39.875 mm)
inside diameter
0.0026 - 0.0045 in. 0.0089 in.
Oil clearance
(0.065 - 0.115 mm) (0.225 mm)
1.5748 - 1.5758 in. 1.5787 in.
Bushing inside diameter
(40.000 - 40.025 mm) (40.100 mm)
Flywheel Camshaft outside 1.5724 - 1.5732 in. 1.5711 in.
end diameter (39.940 - 39.960 mm) (39.905 mm)
0.0016 - 0.0033 in. 0.0077 in.
Oil clearance
(0.040 - 0.085 mm) (0.195 mm)

5-7
ENGINE Camshaft and Timing Gear Train Specifications

Idler Gear Shaft and Bushing

Reference
Inspection item Standard Limit
page
1.1795 - 1.1803 in. 1.1779 in.
3CJ1-SDZP01
(29.959 - 29.980 mm) (29.918 mm)
Shaft outside diameter 3CH1-NGZG01
1.4547 - 1.4557 in. 1.4528 in.
3CH1-SDZP01
(36.950 - 36.975 mm) (36.900 mm)
3CJ1-NGZP01
1.1811 - 1.1821 in. 1.1837 in.
3CJ1-SDZP01 See Inspection
(30.000 - 30.025 mm) (30.066 mm)
of idler gear
Bushing inside diameter 3CH1-NGZG01
1.4567 - 1.4577 in. 1.4596 in. and shaft on
3CH1-SDZP01 page 5-54
(37.000 - 37.025 mm) (37.075 mm)
3CJ1-NGZP01
0.00079 - 0.00260 in. 0.0060 in.
3CJ1-SDZP01
(0.02 - 0.066 mm) (0.152 mm)
Oil clearance 3CH1-NGZG01
0.0010 - 0.0030 in. 0.0069 in.
3CH1-SDZP01
(0.025 - 0.075 mm) (0.175 mm)
3CJ1-NGZP01

Timing Gear Backlash

Reference
Inspection item Standard Limit
page
See Checking
Crank gear, cam gear, idler gear, fuel injection pump gear 0.0024 - 0.0047 in. 0.0055 in. timing gear
and PTO gear (0.06 - 0.12 mm) (0.14 mm) backlash on
page 5-39

5-8
Crankshaft and Pistons Specifications ENGINE

CRANKSHAFT AND PISTONS SPECIFICATIONS

Crankshaft
Note: Check appropriate parts catalog for undersized replacement main bearing inserts.

Reference
Inspection item Standard Limit
page
0.0008 in.
Bend (1/2 the dial gauge reading) –
(0.02 mm)
0.0004 in.(0.01 mm) 0.0008 in.
Roundness
or less (0.02 mm)
3CJ1-NGZG01 1.4942 - 1.4946 in. 1.4725 in.
Journal outside 3CJ1-SDZP01 (37.952 - 37.962 mm) (37.402 mm)
diameter 3CH1-NGZG01 1.6517 - 1.6520 in. 1.6497 in.
3CH1-SDZP01 (41.952 - 41.962 mm) (41.902 mm)
See Inspection
3CJ1-NGZG01 1.4954 - 1.4965 in.
– of crankshaft
Bearing inside 3CJ1-SDZP01 (37.982 - 38.010 mm)
on page 5-52
Connecting diameter 3CH1-NGZG01 1.6528 - 1.6536 in.
–
rod journals 3CH1-SDZP01 (41.982 - 42.002 mm)
Bearing insert 0.0592 - 0.0594 in.
All models –
thickness (1.503 - 1.509 mm)
3CJ1-NGZG01 0.0008 - 0.0023 in. 0.0043 in.
3CJ1-SDZP01 (0.020 - 0.058 mm) (0.110 mm)
Oil clearance
3CH1-NGZG01 0.0008 - 0.0020 in. 0.0043 in.
3CH1-SDZP01 (0.020 - 0.050 mm) (0.110 mm)
1.7311 - 1.7315 in. 1.7293 in.
3CJ1-SDZP01
(43.970 - 43.980 mm) (43.923 mm)
Journal outside
diameter 3CH1-NGZG01
1.8485 - 1.8489 in. 1.8465 in.
3CH1-SDZP01
(46.952 - 46.962 mm) (46.902 mm)
3CJ1-NGZG01
1.7324 - 1.7331 in.
3CJ1-SDZP01 –
(44.002 - 44.020 mm)
Bearing inside
diameter 3CH1-NGZG01
1.8497 - 1.8505 in.
3CH1-SDZP01 –
(46.982 - 47.002 mm) See Inspection
Main bearing 3CJ1-NGZG01
of crankshaft
journal 0.0787 - 0.0789 in.
3CJ1-SDZP01 – on page 5-52
(2.000 - 2.004 mm)
Bearing insert
thickness 3CH1-NGZG01
0.0791 - 0.0793 in.
3CH1-SDZP01 –
(2.009 - 2.014 mm)
3CJ1-NGZG01
0.0008 - 0.0020 in. 0.0047 in.
3CJ1-SDZP01
(0.022 - 0.050 mm) (0.120 mm)
Oil clearance 3CH1-NGZG01
0.0008 - 0.0020 in. 0.0047 in.
3CH1-SDZP01
(0.020 - 0.050 mm) (0.120 mm)
3CJ1-NGZG01

5-9
ENGINE Crankshaft and Pistons Specifications

Crankshaft Reconditioning
Reference
Item Finishing precision
page
3CJ1-NGZG01 1.4843 - 1.4847 in.
Connecting rod journal undersize 3CJ1-SDZP01 (37.702 - 37.712 mm)
finished size 3CH1-NGZG01 1.6418 - 1.6422 in.
3CH1-SDZP01 (41.702 - 41.712 mm)
1.7213 - 1.7217 in. See
3CJ1-SDZP01
(46.702 - 46.712 mm) Reconditionin
Main bearing journal undersize
finished size 3CH1-NGZG01 g the
1.8387 - 1.8391 in.
3CH1-SDZP01 Crankshaft on
(43.720 - 43.730 mm)
3CJ1-NGZG01 page 5-53
0.138 - 0.150 in.
Journal radius
(3.5 - 3.8 mm)
All models
Journal face finish 0.8 S (super polish)
Thrust face finish 1.6

Thrust Bearing
Reference
Inspection item Standard Limit
page
0.0052 - 0.0090 in. 0.0110 in.
Crankshaft end play See Removal
(0.133 - 0.228 mm) (0.28 mm)
of crankshaft
0.0760 - 0.0780 in. 0.0728 in. on page 5-45
Bearing thickness
(1.930 - 1.980 mm) (1.850 mm)

5-10
Crankshaft and Pistons Specifications ENGINE
Piston
Reference
Inspection item Standard Limit
page
3CJ1-NGZG01 2.9122 - 2.9126 in. 2.9100 in.
Piston outside diameter 3CJ1-SDZP01 (73.969 - 73.979 mm) (73.915 mm)
(measure at 90° to the piston pin.) 3CH1-NGZG01 3.1481 - 3.1485 in. 3.1461 in.
3CH1-SDZP01 (79.962 - 79.972 mm) (79.910 mm)
Piston diameter measurement location 0.8661 - 0.9843 in.
All models –
(upward from the bottom of the piston) (22.0 - 25.0 mm) See
3CJ1-NGZG01 0.0012 - 0.0020 in. Inspection
– of pistons,
3CJ1-SDZP01 (0.031 - 0.051 mm)
Piston-to-cylinder clearance piston rings
3CH1-NGZG01 0.0015 - 0.0023 in. and wrist
–
3CH1-SDZP01 (0.038 - 0.058 mm) pin on
Hole inside 0.8661 - 0.8665 in. 0.8677 in. page 5-49
diameter (22.000 - 22.009 mm) (22.0039 mm)
Pin outside All 0.8659 - 0.8661 in. 0.8648 in.
Wrist pin
diameter models (21.995 - 22.000 mm) (21.965 mm)
Oil 0.0000 - 0.0006 in. 0.0029 in.
clearance (0.000 - 0.014 mm) (0.074 mm)

5-11
ENGINE Crankshaft and Pistons Specifications

Piston Ring
Reference
Inspection item Standard Limit
page
0.0803 - 0.0811 in.
Ring groove width –
(2.040 - 2.060 mm)
0.0764 - 0.0772 in. 0.0571 in.
Ring width
(1.940 - 1.960 mm) (1.450 mm)
Top ring
0.0031 - 0.0047 in.
Side clearance –
(0.080 - 0.120 mm)
0.0059 - 0.0118 in. 0.0154 in.
End clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0622 - 0.0628 in. 0.0667 in.
Ring groove width
(1.580 - 1.595 mm) (1.695 mm)
0.0563 - 0.0571 in. 0.0555 in. See Inspection
Ring width of pistons,
3CH1-NGZG01 (1.430 - 1.450 mm) (1.410 mm)
Second ring piston rings
3CH1-SDZP01 0.0020 - 0.0035 in. 0.0112 in.
Side clearance and wrist pin
(0.050 - 0.090 mm) (0.285 mm) on page 5-49
0.0071 - 0.0130 in. 0.0165 in.
End clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1191 in. 0.1232 in.
Ring groove width
(3.010 - 3.025 mm) (3.130 mm)
0.1169 - 0.1177 in. 0.1161 in.
Ring width
(2.970 - 2.990 mm) (2.950 mm)
Oil ring
0.0008 - 0.0022 in. 0.0071 in.
Side clearance
(0.020 - 0.055 mm) (0.180 mm)
0.0079 - 0.0177 in. 0.0213 in.
End clearance
(0.200 - 0.450 mm) (0.540 mm)

5-12
Crankshaft and Pistons Specifications ENGINE
(Piston ring cont.)

Reference
Inspection item Standard Limit
page
0.0610 - 0.0618 in.
Ring groove width –
(1.550 - 1.570 mm)
0.0579 - 0.0587 in. 0.0571 in.
Ring width
(1.470 - 1.490 mm) (1.450 mm)
Top ring
0.0024 - 0.0039 in.
Side clearance –
(0.060 - 0.100 mm)
0.0059 - 0.0118 in. 0.0154 in.
End clearance
(0.150 - 0.300 mm) (0.390 mm)
0.0606 - 0.0614 in. 0.0654 in.
Ring groove width
(1.540 - 1.560 mm) (1.660 mm)
0.0579 - 0.0587 in. 0.0571 in. See Inspection
Ring width of pistons,
3CJ1-NGZG01 (1.470 - 1.490 mm) (1.950 mm)
Second ring piston rings
3CJ1-SDZP01 0.0020 - 0.0035 in. 0.0083 in.
Side clearance and wrist pin
(0.050 - 0.090 mm) (0.210 mm) on page 5-49
0.0071 - 0.0130 in. 0.0165 in.
End clearance
(0.180 - 0.33 mm) (0.42 mm)
0.1185 - 0.1191 in. 0.1232 in.
Ring groove width
(3.010 - 3.025 mm) (3.130 mm)
0.1170 - 0.1177 in. 0.1161 in.
Ring width
(2.970 - 2.990 mm) (2.950 mm)
Oil ring
0.0008 - 0.0022 in. 0.0071 in.
Side clearance
(0.020 - 0.055 mm) (0.180 mm)
0.0059 - 0.0138 in. 0.0173 in.
End clearance
(0.150 - 0.350 mm) (0.440 mm)

Connecting Rod
■ Connecting rod small end
Reference
Inspection item Standard Limit
page
0.8671 - 0.8676 in. 0.8688 in.
Wrist pin bushing inside diameter
(22.025 - 22.038 mm) (22.068 mm) See Inspection
0.8659 - 0.8661 in. 0.8647 in. of connecting
Wrist pin outside diameter
(21.995 - 22.000 mm) (21.963 mm) rod on
0.0010 - 0.0017 in. 0.0041 in. page 5-50
Oil clearance
(0.025 - 0.043 mm) (0.105 mm)

5-13
ENGINE Cylinder Block Specifications

■ Connecting rod big end

Reference
Inspection item Standard Limit
page
0.0079 - 0.0157 in. See Inspection
Side clearance –
(0.20 - 0.40 mm) of connecting
rod on
Bearing inside diameter and oil clearance See Crankshaft on page 5-9 page 5-50

■ Connecting rod distortion

Reference
Inspection item Standard Limit
page
See Inspection
Less than
0.003 in. of connecting
Twist and bend per 3.937 in. (100 mm) 0.001 in.
(0.08 mm) rod on
(0.03 mm)
page 5-50

Tappet
Reference
Inspection item Standard Limit
page
0.8268 - 0.8276 in. 0.8284 in.
Tappet bore (block) inside diameter
(21.000 - 21.021 mm) (21.041 mm)
See Inspection
0.8244 - 0.8252 in. 0.8231 in.
Tappet stem outside diameter of tappets on
(20.939 - 20.960 mm) (20.907 mm)
page 5-51
0.0016 - 0.0032 in. 0.0053 in.
Oil clearance
(0.040 - 0.082 mm) (0.134 mm)

CYLINDER BLOCK SPECIFICATIONS

Cylinder Block
Reference
Inspection item Standard Limit
page
3CJ1-NGZG01 2.9138 - 2.9142 in. 2.9213 in.
3CJ1-SDZP01 (74.010 - 74.020 mm) (74.200 mm)
Cylinder inside diameter See Inspection
3CH1-NGZG01 3.1500 - 3.1504 in. 3.1575 in. of cylinder
3CH1-SDZP01 (80.010 - 80.020 mm) (80.200 mm) block on
Roundness 0.0004 in. (0.01 mm) 0.0012 in. page 5-48
Cylinder bore
Taper or less (0.03 mm)

5-14
Special Torque Chart ENGINE

SPECIAL TORQUE CHART

Torque for Bolts and Nuts
Lubricating oil
Thread diameter Tightening application Reference
Component
and pitch torque (thread portion page
and seat surface)
43 - 46 ft-lb See Reassembly
Cylinder head bolts M9 × 1.25 mm (59 - 63 N·m; Applied of cylinder head
6.0 - 6.4 kgf·m) on page 5-30
17 - 20 ft-lb See Installation
Connecting rod bolts M7 × 1.0 mm (22.6 - 27.5 N·m; Applied of pistons on
2.3 - 2.8 kgf·m) page 5-59
59 - 64 ft-lb See Installation
Flywheel bolts M10 × 1.25 mm (80.4 - 86.4 N·m; Applied of crankshaft on
8.2 - 8.8 kgf·m) page 5-58
56 - 60 ft-lb See Installation
Main bearing cap bolts M10 × 1.25 mm (75.5 - 81.5 N·m; Applied of crankshaft on
7.7 - 8.3 kgf·m) page 5-58
61 - 69 ft-lb
Cast
(83.4 - 93.1 N·m;
FC250 See Installation
8.5 - 9.5 kgf·m)
Crankshaft pulley bolts M12 × 1.25 mm Applied of crankshaft on
83 - 90 ft-lb page 5-58
Forged
(113 - 123 N·m;
PS48C
11.5 - 12.5 kgf·m)
See Reassembly
11 - 15 ft-lb of intake
Glow plug M10 × 1.25 (14.7 - 19.6 N·m; Not Applied manifold/valve
1.5 - 2.0 kgf·m) cover on
page 5-32
Main bearing cap bolts 32 - 35 ft-lb
3CJ1- TORX E12
and ladder frame (43 - 47 N·m; Applied
SDZP01 M9 × 1.25
mounting bolts 4.4 - 4.8 kgf·m)

Note: See Tightening Torques for Standard Bolts and Nuts on page 3-24 for standard hardware torque
values.

5-15
TNV_IDI_ServiceManual_A4.book Page 16 Saturday, July 4, 2015 5:50 PM

ENGINE Special Service Tools

SPECIAL SERVICE TOOLS

Note: Tools not having Isuzu genuine part numbers must be acquired locally.

No. Tool name Applicable model and tool size Illustration

L1 L2 d1 d2
L2 d2
Valve guide tool 0.787 in. 2.953 in. 0.217 in. 0.374 in.
1 (for removing (20 mm) (75 mm) (5.5 mm) (9.5 mm) L1
valve guides) Locally manufactured
d1
010932-00X

L1 L2 d1 d2
L2
Valve guide tool 0.394 in. 2.362 in. 0.433 in. 0.669 in.
2 (for installing (10 mm) (60 mm) (11 mm) (17 mm) L1
valve guides) Locally manufactured Allowance L1:
0 to -0.0118 in. d1
d2
(0 to -0.3 mm) 001421-00X

L1 L2 d1 d2
Wrist pin 0.984 in. 3.346 in. 0.866 in. 0.984 in.
L2
bushing tool (25 mm) (85 mm) (22 mm) (25 mm) d2
(for removing/ L1
3 Locally manufactured Allowance d1: Allowance d2:
installing of
wrist pin -0.0118 to -0.0118 to
bushings) -0.0236 in. -0.0236 in. d1
(-0.3 to -0.6 (-0.3 to -0.6 010933-00X

mm) mm)

Valve spring
compressor
Part No.
4 (for removing/
5-8640-2419-0
installing valve
springs) 010931-00X

5-16
TNV_IDI_ServiceManual_A4.book Page 17 Saturday, July 4, 2015 5:50 PM

Special Service Tools ENGINE

No. Tool name Applicable model and tool size Illustration

d1 d2 d3 L1 L2 L3
L2
0.157 in.
0.591 in. 0.827 in. 0.472 in. 0.433 in. 2.559 in.
(4 mm) or L1
(15 mm) (21 mm) (12 mm) (11 mm) (65 mm)
more
Allowance: d1
d1: ±0.00787 in. (±0.2 mm) d2 001421-00X

L1: ±0.00393 in. (±0.1 mm)

Stem seal tool Locally manufactured
5 (for installing
stem seals)

L2
d3 L3
d1 L1
d2

001422-00X

L1 L2 d1 d2
L2
Camshaft 0.709 in. 2.756 in. 1.772 in. 1.890 in.
bushing tool (18 mm) (70 mm) (45 mm) (48 mm) L1
6 (for removing Locally manufactured Allowance d1: Allowance d2:
camshaft -0.0118 to -0.0118 to d1
bushing) -0.0236 in. -0.0236 in. d2 001421-00X
(-0.3 to -0.6 (-0.3 to -0.6
mm) mm)

Part No. Cylinder bore

2.756 - 2.992 in.
Flex-hone 5-8640-1009-0
(70 - 76 mm)
7 (for preparing
cylinder walls)

010930-00X

Piston ring
Part No. 5-8640-2420-0
compressor
8 The piston insertion tool is applicable for
(for installing
2.362 - 4.921 in. (60 - 125 mm) diameter pistons
pistons)

007236-00X

Piston ring tool

(for removing/
9 Available locally
installing of
piston rings)
001411-00X

5-17
TNV_IDI_ServiceManual_A4.book Page 18 Saturday, July 4, 2015 5:50 PM

ENGINE Measuring Instruments

MEASURING INSTRUMENTS
No. Instrument name Application Illustration

1 Dial indicator Locally available Measure shaft bend and end play

001429-00X

Measurements of narrow or deep portions that

2 Test indicator Locally available
cannot be measured by dial gauge
001430-00X

3 Magnetic stand Locally available For holding the dial gauge when measuring.

001431-00X

For measuring the outside diameters of

4 Micrometer Locally available
crankshaft, pistons, piston pins, etc.
001432-00X

For measuring the inside diameters of cylinder

5 Cylinder bore gauge Locally available
liners, bearing bores, etc.
001433-00X

For measuring outside diameters, depth,

6 Calipers Locally available
thickness and width
001434-00X

7 Depth micrometer Locally available For measuring of valve recession

001435-00X

For measuring valve spring inclination and

8 Square Locally available
straightness of parts

001436-00X

5-18
TNV_IDI_ServiceManual_A4.book Page 19 Saturday, July 4, 2015 5:50 PM

Measuring Instruments ENGINE

No. Instrument name Application Illustration

9 V-block Locally available For measuring shaft bend

001437-00X

For tightening nuts and bolts to the specified

10 Torque wrench Locally available
torque
001438-00X

For measuring piston ring gaps, piston ring

11 Feeler gauge Locally available
clearance, and valve adjustment clearance

001426-00X

5-19
TNV_IDI_ServiceManual_A4.book Page 20 Saturday, July 4, 2015 5:50 PM

ENGINE Cylinder Head

CYLINDER HEAD
Cylinder Head Components

30
2
29
28
27
3

26
5

6 7
24 8
25
23
9
11
22 10
12
13
14
21 15
16

17

18
20
19

K0002130

Figure 5-1

5-20
Cylinder Head ENGINE
1 – Baffle plate Disassembly of Cylinder Head
2 – Oil fill cap
3 – Valve cover/intake manifold Prepare a clean, flat working surface on a
4 – Gasket workbench large enough to accommodate the
5 – Rocker arm shaft cylinder head assembly. Discard all gaskets,
6 – Rocker arm shaft support O-rings and seals. Use new gaskets, O-rings and
7 – Adjuster lock nut seals on reassembly of cylinder head.
8 – Valve adjuster screw
9 – Rocker arm
10 – Circlip
NOTICE
11 – Valve cap Mark all valve train components so they can be
12 – Keeper installed in their original locations.
13 – Valve spring retainer
14 – Valve spring
15 – Valve stem seal Note: Record all measurements taken during
16 – Valve guide disassembly.
17 – Cylinder head
18 – Exhaust valve 1. Drain coolant from engine into a suitable
19 – Intake valve container. See Drain, flush and refill cooling
20 – Cylinder head gasket system with new coolant on page 4-20.
21 – Push rod (2 per cylinder)
22 – Glow plug NOTICE
23 – Glow plug wiring harness
24 – Cylinder head bolt Identify all parts and their location using an
appropriate method. It is important that all parts
are returned to the same position during the
reassembly process.

2. Remove the coolant pump. See Disassembly of

Engine Coolant Pump on page 7-6.
3. Remove the high-pressure fuel lines and fuel
injectors from the cylinder head. See Removal
of Fuel Injectors on page 6-23.

5-21
ENGINE Cylinder Head

■ Removal of intake manifold/valve cover

1. Remove the intake manifold bolts 2
(Figure 5-2, (1)) and valve cover bolts
(Figure 5-2, (2)).
2. Remove the valve cover/intake manifold 1
(Figure 5-2, (3)). Discard gasket
(Figure 5-2, (4)).

3
K0002146

4
Figure 5-3

■ Removal of rocker arm assembly

1. Remove the bolts (Figure 5-4, (1)) and nuts
5 (Figure 5-4, (2)) that retain the rocker arm shaft
6 supports.
7 2. Remove the rocker arm shaft assembly from
the cylinder head.
8
Note: Identify the push rods so they can be
reinstalled in their original locations.
K0002131

3. Remove the push rods and identify for

Figure 5-2 reinstallation.
3. Remove the exhaust manifold bolts
(Figure 5-2, (5)) and nuts (Figure 5-2, (6)). 2
Remove the exhaust manifold (Figure 5-2, (7))
and the exhaust manifold gasket
(Figure 5-2, (8)).

■ Removal of glow plugs

1 2
1. Disconnect the glow plug harness
(Figure 5-3, (2)) from the glow plugs
(Figure 5-3, (1)).
2. Remove the glow plugs from the cylinder head.

K0002147

Figure 5-4

5-22
Cylinder Head ENGINE
■ Disassembly of rocker arm assembly ■ Removal of cylinder head
1. Remove the rocker arm shaft alignment set 1. Loosen the cylinder head bolts following the
screw (Figure 5-5, (6)) from support sequence shown in Figure 5-6.
(Figure 5-5, (5)).
2
8 8 14 5
2 2 12 9 3
1 1
3 4 10 11 1
4 7 6 13 7

6 K0002148-01
5
1 – Cooling fan end
2 – Camshaft side
9
Figure 5-6
2. Remove the cylinder head bolts
(Figure 5-7, (1)).
3. Lift the cylinder head away from the cylinder
8 block. Discard the cylinder head gasket
K0002160
(Figure 5-7, (2)). Position the cylinder head on
Figure 5-5 the work bench to prevent damage to the
combustion surface.
Note: The set screw is located in the center
support.
1
2. Remove two circlips (Figure 5-5, (8)).
Note: The rocker arm shaft fits tightly in the
rocker arm supports. Clamp the support
in a padded vise. Twist and pull out on
the rocker arm shaft to remove. Reverse
this process when installing the rocker
arm shaft into the supports.
3. Slide the rocker arm shaft (Figure 5-5, (7)) out 2
of the rocker arm supports (Figure 5-5, (5)),
springs (Figure 5-5, (4)), and rocker arms
(Figure 5-5, (1)).
Note: Mark the rocker arms so they can be
reinstalled with the original matching
valve and pushrod.
4. Remove the valve adjusting screw K0002150

(Figure 5-5, (3)) and lock nut (Figure 5-5, (2)) Figure 5-7
from the rocker arms. Mark parts so they can
be reinstalled on the same rocker arm.

5-23
ENGINE Cylinder Head

■ Removal of intake/exhaust valves 8. Turn the cylinder head so the exhaust port side
1. Put the cylinder head on the work bench with faces down. Remove the intake and exhaust
the combustion side down (Figure 5-8). valves (Figure 5-9, (6)) from the cylinder head.
9. Remove the valve stem seals (Figure 5-9, (5)).

■ Removal of valve guides

Note: Removal of valve guides should be
postponed until inspection and
measurement procedures have been
performed. See Inspection of valve guides
K0000191 on page 5-26.
Figure 5-8 If the valve guides are not within specifications, use
2. Remove the valve stem cap (Figure 5-9, (1)) a drift pin and hammer to drive the valve guides
and keep with the valve it was installed on. (Figure 5-10, (1)) out of the cylinder head.

3. Using the valve spring compressor tool,

compress one of the valve springs (Figure 5-8). 1

4. Remove the valve keepers (Figure 5-9, (2)).

5. Slowly release the tension on the valve spring.
6. Remove the spring retainer (Figure 5-9, (3))
and valve spring (Figure 5-9, (4)).

1
2

3 K0002152

4 Figure 5-10
5

K0002151

Figure 5-9
7. Repeat procedure with all remaining valves.
Note: If the valves are to be reused, identify
them so they can be reinstalled in their
original location.

5-24
Cylinder Head ENGINE
Cleaning of Cylinder Head ■ Inspection of push rods
Components Push rod bend
Determine if the bend of the push rods is within the
WARNING specified limit.
Fume/Burn Hazard
1. Place the push rods on a flat inspection block or
• Always read and layout bed.
follow safety related
precautions found on 2. Roll the push rods until a gap can be observed
containers of between a portion of the push rod and the
hazardous substances surface of the block or layout bed.
like parts cleaners, 3. Use a feeler gauge to measure the gap
primers, sealants and (Figure 5-11). See Push Rod on page 5-5 for
sealant removers. the service limit.
• Failure to comply could result in death or
serious injury.

Thoroughly clean all components using a

non-metallic brush and an appropriate solvent.
Each part must be free of carbon, metal filings and
other debris.

Inspection of Cylinder Head

Components K0000204

Visually inspect the parts. Replace any parts that Figure 5-11
are obviously discolored, heavily pitted or otherwise
■ Inspection of rocker arm assembly
damaged. Discard any parts that do not meet its
specified limits. Rocker arm shaft hole diameter
Use a telescoping gauge and micrometer to
NOTICE measure the inside diameter of all the rocker arm
• Any part which is found defective as a result of support brackets and the rocker arms
inspection or any part whose measured value (Figure 5-12). Record the measurements. See
does not satisfy the standard or limit must be Rocker Arm and Shaft on page 5-6 for the service
replaced. limit.

• Any part determined to not meet the service Inspect contact areas (Figure 5-12, (1)) for
standard or limit before the next service, as excessive wear or damage.
determined from the state of current rate of wear,
should be replaced even though the part currently
meets the service standard limit.
• Mark all valve train components so they can be
installed in their original locations.

1
Note: Record all measurements taken during 1
inspection.

K0001916

Figure 5-12

5-25
ENGINE Cylinder Head

Rocker arm shaft outside diameter ■ Inspection of cylinder head

Use a micrometer to measure rocker arm shaft
Cylinder head distortion
diameter. Measure at each rocker arm location in
two directions 90° apart (Figure 5-13). Record the Put the cylinder head flat and inverted (combustion
measurements. See Rocker Arm and Shaft on side up) on the bench. Use a straightedge and
page 5-6 for the service limit. feeler gauge to measure cylinder head distortion
(Figure 5-15). Measure diagonally and along each
side. Record the measurements. See Cylinder
Head on page 5-4 for the service limit.

K0000192
K0001952

Figure 5-15
Figure 5-13
If distortion exceeds the service limit, resurface or
■ Inspection of valve guides replace the cylinder head. Remove only enough
Visually inspect the valve guides for distortions, material to make the cylinder head flat, but do not
scoring or other damage. remove more than 0.008 in. (0.20 mm).
Note: Measure valve guides while they are ■ Inspection of intake and exhaust valves
installed in cylinder head.
Visually inspect the intake and exhaust valves.
Use a telescoping gauge and micrometer to Replace any valves that are obviously discolored,
measure the inside diameter of the valve guide. heavily pitted or otherwise damaged.
Measure in three places and 90° apart
(Figure 5-14). Record the measurements. See Valve stem diameter
Intake/Exhaust Valve and Guide on page 5-5 for Use a micrometer to measure the valve stem
the service limit. Replace valve guides if not within diameter. Measure the valve stem near the
specification. combustion end and near the opposite end
(Figure 5-16, (1)). Record the measurements. See
Intake/Exhaust Valve and Guide on page 5-5 for
the service limit.
K0001869
1
Figure 5-14

K0000197

Figure 5-16

5-26
Cylinder Head ENGINE
Valve stem bend
Place the valve stem on a flat inspection block or
layout bed. Roll the valve until a gap can be
observed between a portion of the valve stem and
the surface of the block or bed. Use a feeler gauge
to measure the gap (Figure 5-17). Record the
measurements. See Intake/Exhaust Valve and
Guide on page 5-5 for the service limit.

K0001755

Figure 5-19

Valve face and valve seat

Always check the clearance between the valve and
valve guide before grinding or lapping the valve
seats. See Intake/Exhaust Valve and Guide on
K0000199 page 5-5 for the service limit. If the clearance
exceeds the limit, replace the valve and/or valve
Figure 5-17 guide to bring the clearance within the limit.
Valve recession Roughness or burrs will cause poor seating of a
Note: The valve guides must be installed to valve. Visually inspect the seating surfaces of each
perform this check. valve and valve seat to determine if lapping or
grinding is needed.
Insert the valves into their original locations and
press them down until they are fully seated. Use a Visually inspect all valve faces and valve seats for
depth micrometer (Figure 5-18) to measure the pitting, distortion, cracking, or evidence of
difference between the cylinder head gasket overheating. Usually the valves and valve seats can
surface and the combustion surface of each be lapped or ground to return them to serviceable
exhaust and intake valve (Figure 5-19). Record the condition. Severely worn or damaged components
measurements. See Cylinder Head on page 5-4 for will require replacement.
the service limit.
Coat the valve seat with a thin coat of bluing
compound. Install valve and rotate to distribute
bluing onto the valve face. The contact pattern
should be approximately centered on the valve face
(Figure 5-20, (1)) and even in width.

K0000193

Figure 5-18

5-27
ENGINE Cylinder Head

■ Inspection of valve springs

Inspect the valve springs. If damage or corrosion is
seen, or if measurements exceed the specified
limits, replace the springs. Record the
measurements.

Fractures
Check for fractures on the inside and outside
portions of the springs. If the valve spring is
1
fractured, replace the valve spring.

Corrosion
K0001691B Check for corrosion of spring material caused by
Figure 5-20 oxidation.

Also visually inspect the valve seat for even Squareness

contact. Use a flat surface and a square to check each
spring for squareness (Figure 5-22). See Valve
Light cutting can be performed by the use of a Spring on page 5-5 for the service limit.
hand-operated cutter (Figure 5-21, (3)).

1
150° 40°

3
2

K0001862
K0000201

Figure 5-21
Figure 5-22
Valve seat diameter can be adjusted by
Free length
top-grinding with a 150° stone to make the seat
diameter smaller, and bottom-grinding using a 40° Use a caliper to measure the length of the spring
stone to make the seat diameter larger. Once the (Figure 5-23). See Valve Spring on page 5-5 for
seat location has been corrected, grind and lap the the service limit.
seat angle (Figure 5-21, (1)) to specification. See
Cylinder Head on page 5-4 for the service limit.
Grind the valve face and/or valve seat only enough
to return them to serviceable condition. Grinding is
needed if the valve and the valve seat do not
2
3
1

contact correctly. Check the valve recession after

4
0

5
9

grinding.
6
8
7

If the valve or seat require grinding, lap the valve

after grinding. Lap the valve face to the valve seat
using a mixture of valve lapping compound and K0000200

engine oil.
Figure 5-23
Be sure to thoroughly wash all parts to remove all
grinding powder or compound.

5-28
Cylinder Head ENGINE
Reassembly of Cylinder Head ■ Reassembly of intake and exhaust valves
Use new gaskets, O-rings and seals on reassembly NOTICE
of cylinder head.
Always install new valve stem seals.
NOTICE The exhaust valve stem seals are different than the
Liberally oil all components during assembly to intake valve stem seals and can be identified by the
prevent premature wear or damage. color the seal spring (Figure 5-26, (4)). Ensure
they are installed in the correct locations.

■ Reassembly of valve guides

Marking
1. The valve guides are installed into the cylinder Engine model
Intake Exhaust
head with an extremely tight press-fit. Before
installing the valve guides, place the valve White Black
3CH1, 3CJ1
guides in a freezer for at least twenty minutes. (seal spring) (seal spring)
This will cause the valve guides to contract,
making it easier to install the valve guides in 1. Oil the lip of the valve stem seal
place. (Figure 5-26, (2)). Using the valve stem seal
installation tool (Figure 5-26, (1)), install a new
2. Immediately after removing the valve guides valve stem seal on each of the valve guides
from the freezer, insert the valve guides (Figure 5-26, (3)).
(Figure 5-24, (1)) in their proper positions.

K0002152

Figure 5-24 K0001873B

3. Finish installing the valve guides Figure 5-26

(Figure 5-25, (1)) to the proper height
2. Measure the distance (Figure 5-27, (1)) from
(Figure 5-25, (3)) using the valve guide
the cylinder head to valve stem seal to ensure
installation tool (Figure 5-25, (2)). See valve
proper clearance (Figure 5-27, (2)) between
guide projection specification on page 5-5.
the valve guide and seal. See valve stem seal
projection specification on page 5-5.
2

1
K0001756A

Figure 5-25

5-29
ENGINE Cylinder Head

■ Reassembly of cylinder head

1. Carefully clean both the combustion surface of
the cylinder head and the top surface of the
cylinder block. Install a new cylinder head
2 gasket (Figure 5-29, (2)) on the cylinder block.
1
2. Position the cylinder head on the cylinder head
gasket.

1
K0001874

Figure 5-27
3. Put the cylinder head assembly on its exhaust
port side.
4. Install all the valves (Figure 5-28, (6)) in their
proper location in the cylinder head.
2
1
2

3
4
5
K0002150

Figure 5-29
3. Lightly oil the threads of the cylinder head bolts
(Figure 5-29, (1)). Tighten the bolts to the
specified torque shown in the chart below.
Tighten in the sequence shown in Figure 5-30.
6 See Torque for Bolts and Nuts on page 5-15.

K0002151 First step 1/2 of final torque

Second step Final torque
Figure 5-28
5. Put the cylinder head on the workbench with
2
the combustion side down to install the valve
springs. Reinstall the valve spring 13
7
3
1
6
10
12
(Figure 5-28, (4)) and spring retainer 1
(Figure 5-28, (5)). 11
9
5
2
4
8
14

6. Using a valve spring compressor tool, K0002149-01

compress the valve spring. 1 – Cooling fan end

7. Insert the valve keeper (Figure 5-28, (2)) and 2 – Camshaft side
slowly release the tension in the valve spring. Figure 5-30
Reinstall the valve cap (Figure 5-28, (1)).
Repeat steps on all remaining valves. 4. Insert the push rods in their respective
positions.

5-30
Cylinder Head ENGINE
■ Reassembly of rocker arm assembly Note:
• The rocker arm shaft fits tightly in the rocker
2
arm supports. Clamp the support in a padded
vise. Twist and push on the rocker arm shaft to
1 reinstall.
• The set screw is located in the center support.
2. Align the hole in the rocker arm shaft
(Figure 5-32, (7)) and the hole in the rocker
arm support (Figure 5-32, (5)). Reinstall the
alignment set screw (Figure 5-32, (6)).
1 K0001914 3. Place the rocker arm shaft assembly onto the
cylinder head.
Figure 5-31
4. If removed, reinstall the valve adjusting screws
NOTICE (Figure 5-32, (3)) and lock nuts
(Figure 5-32, (2)).
Ensure the lubrication holes in the rocker arm shaft 5. Align the push rods with their respective rocker
(Figure 5-31, (1)). are oriented correctly with arms.
respect to the rocker arms (Figure 5-31, (2)).
6. Reinstall and tighten the rocker arm shaft
retaining bolts to the specified torque.
1. Lubricate the rocker arm shaft. Slide the rocker 7. Tighten the rocker arm shaft alignment screw.
arm supports (Figure 5-32, (5)), springs
8. Adjust the valve clearance. See Measuring and
(Figure 5-32, (4)) and rocker arms
Adjusting Valve Clearance on page 5-33.
(Figure 5-32, (1)) onto the shaft.

8
2
1
3
4 7
6
5

8
K0002160

Figure 5-32

5-31
ENGINE Cylinder Head

■ Reassembly of intake manifold/valve

1
cover
1. Reinstall the glow plugs (Figure 5-33, (1)) and
tighten to specification. Reinstall the electrical
harness (Figure 5-33, (2)). 2

3
2
4

5
6
7

K0002131

Figure 5-34
K0002146
5. Reinstall the exhaust manifold using a new
Figure 5-33 gasket. Tighten the bolts and nuts
(Figure 5-34, (5 and 6)) securely.
2. Lightly grease a new valve cover gasket
(Figure 5-34, (4)). Place the gasket in the 6. Reinstall the fuel injectors. See Installation of
groove of the intake manifold/valve cover the Fuel Injectors on page 6-28.
(Figure 5-34, (3)). 7. Reinstall the high pressure and return fuel
3. Place the valve cover on the cylinder head. injection lines. See Installation of the Fuel
Injectors on page 6-28.
4. Reinstall and tighten bolts
(Figure 5-34, (1 and 2)) securely. 8. Reinstall the coolant pump. See Reassembly of
Engine Coolant Pump on page 7-8.
9. Reinstall the alternator. See Installation of
Alternator on page 10-14.

5-32
TNV_IDI_ServiceManual_A4.book Page 33 Saturday, July 4, 2015 5:50 PM

Cylinder Head ENGINE

Measuring and Adjusting Valve • If there is no valve clearance, and the piston is at
TDC of the compression stroke, extreme wear or
Clearance
damage to the cylinder head or valves may be
Measure and adjust while the engine is cold. possible.
Note: • If adjusting each cylinder individually, the cylinder
to be adjusted first does not have to be the No. 1
• The No. 1 piston position is on the flywheel end of
cylinder. Select and adjust the cylinder where the
the engine, opposite end of the radiator. The firing
piston is nearest to the top dead center after
order is 1-3-2 for 3-cylinder engines.
turning. Adjust the remaining cylinders in the
• 3-cylinder engines fire every 240° of crankshaft order of firing by turning the crankshaft each time.
rotation.
• To decrease the number of rotations required to
• Valve clearance of both the intake and exhaust check all cylinders of a 3-cylinder engine, other
valves can be checked with the piston for that cylinders can also be checked as indicated in the
cylinder at top dead center (TDC) of the chart below.
compression stroke. When a piston is at TDC of
Example: Engine, with the No. 1 piston at TDC on
the compression stroke, both rocker arms will be
the compression stroke (both valves closed), the
loose and the cylinder TDC mark on the flywheel
valves indicated on the top line of the chart can be
will be visible in the timing port of the flywheel
adjusted without rotating the crankshaft. To adjust
housing.
the remaining two valves, rotate the crankshaft until
the No. 1 piston is at TDC on the exhaust stroke
(exhaust valve only open).

Cylinder No. 1 2 3
Valve Intake Exhaust Intake Exhaust Intake Exhaust
No. 1 cylinder at TDC
• • • •
compression
No. 1 cylinder at TDC exhaust • •

5-33
ENGINE Cylinder Head

1. Remove the intake manifold/valve cover. See 6. Insert a feeler gauge of the correct thickness
Removal of intake manifold/valve cover on (Figure 5-37, (1)) between rocker arm and
page 5-22. valve cap. Turn the valve adjustment screw to
2. Rotate the crankshaft clockwise as seen from adjust the valve clearance so there is a slight
the coolant pump end, to bring No. 1 piston to “drag” on the feeler gauge when sliding it
TDC of the compression stroke while watching between the rocker arm and valve cap. Hold the
the rocker arm motion and timing grid on the adjusting screw while tightening the valve
flywheel. (Position so both the intake and adjusting screw lock nut (Figure 5-36, (1)).
exhaust valves are closed.) Recheck the clearance (see Adjustment
Specifications on page 5-4).
3. Insert a feeler gauge (Figure 5-35, (1))
between rocker arm and valve cap and record Note: There is a tendency for the clearance to
the measured valve clearance. (Use the data decrease slightly when the lock nut is
for estimating wear.) tightened. It is suggested that the initial
clearance adjustment be made slightly
1 on the “loose” side before tightening the
lock nut.

K0001782A

Figure 5-35
4. If adjustment is required, proceed to the next K0001782A

step. Figure 5-37

5. Loosen the valve adjusting screw lock nut
(Figure 5-36, (1)) and valve adjusting screw 7. Apply oil to the contact surface between
(Figure 5-36, (2)) on the rocker arm. Check the adjusting screw and push rod.
valve for inclination of the valve cap, entrance of 8. Rotate the crankshaft and measure the next
dirt, or wear. cylinder. Continue until all valves are adjusted.

K0001783A

Figure 5-36

5-34
TNV_IDI_ServiceManual_A4.book Page 35 Saturday, July 4, 2015 5:50 PM

Cylinder Block ENGINE

CYLINDER BLOCK
Crankshaft and Camshaft Components
■ 3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01

1
3

5
6
2 4
39
9 5
41 40
10
11
12 7
13 8

16
38 15
37 14
36 34
35 33

31 32
30 17
29 18
28 19 20
21
22
27

23

24

25

26

K0002180

Figure 5-38

5-35
TNV_IDI_ServiceManual_A4.book Page 36 Saturday, July 4, 2015 5:50 PM

ENGINE Cylinder Block

1 – Cylinder block
2 – Camshaft bushing
3 – Gear case
4 – Dowel (2 used)
5 – O-ring
6 – Gear case cover
7 – Front crankshaft seal
8 – Fuel injection pump gear cover
9 – Tappets
10 – Camshaft
11 – Camshaft gear key
12 – Camshaft end plate
13 – Camshaft gear
14 – Idler gear shaft
15 – Idler gear bushing
16 – Idler gear
17 – Oil pickup O-ring
18 – Oil pickup
19 – Crankshaft
20 – Crankshaft gear key
21 – Crankshaft gear
22 – Crankshaft pulley
23 – Main bearing inserts
24 – Main bearing cap
25 – Crankcase extension
26 – Oil pan
27 – Thrust bearings
28 – Flywheel
29 – Connecting rod cap
30 – Connecting rod bearing inserts
31 – Connecting rod
32 – Wrist pin bushing
33 – Circlip
34 – Wrist pin
35 – Piston
36 – Oil ring
37 – Second compression ring
38 – Top compression ring
39 – Dowel (2 used)
40 – Crankshaft rear seal
41 – Flywheel housing

5-36
TNV_IDI_ServiceManual_A4.book Page 37 Saturday, July 4, 2015 5:50 PM

Cylinder Block ENGINE

■ 3CJ1-SDZP01

36

2 3 5
6
7
8

15
14
16
13
17 12
9
19
18 20

21 22

23
24
25 27 10
28
29 11
26 31 30

32

33
35
34

026973-00X

Figure 5-39

5-37
ENGINE Cylinder Block

1 – Flywheel housing Disassembly of Cylinder Block

2 – Dowel (2 used)
3 – Crankshaft rear seal
Components
4 – Tappets Prepare a clean, flat working surface on a
5 – Camshaft workbench large enough to accommodate the
6 – Camshaft gear key engine components. Discard all used gaskets,
7 – Camshaft end plate O-rings and seals. Use new gaskets, O-rings and
8 – Camshaft gear
seals for reassembly of engine.
9 – Gear case cover
10 – Front crankshaft seal
11 – Fuel injection pump gear cover NOTICE
12 – Idler gear shaft
• Identify all parts and their location using an
13 – Idler gear bushing
14 – Idler gear
appropriate method. It is important that all parts
15 – Top compression ring are returned to the same position during the
16 – Second compression ring reassembly process.
17 – Oil ring
• Mark all valve train components so they can be
18 – Piston
19 – Wrist pin
installed in their original locations.
20 – Circlip
21 – Wrist pin bushing
22 – Connecting rod Note: Record all measurements taken during
23 – Connecting rod bearing inserts disassembly.
24 – Connecting rod cap If the engine will be completely disassembled, the
25 – Flywheel
following preliminary steps should be performed:
26 – Ring gear
27 – Crankshaft 1. Disconnect the battery cables at the battery.
28 – Crankshaft gear key Always disconnect the negative (-) cable first.
29 – Crankshaft gear
30 – Crankshaft pulley 2. Remove the throttle cable, electrical
31 – Thrust bearings connections, intake and exhaust system
32 – Main bearing inserts connections, and fuel supply lines from the
33 – Oil pickup O-ring engine.
34 – Oil pickup 3. Remove the alternator. See Removal of
35 – Oil pan
Alternator on page 10-10.
36 – Cylinder block
4. Drain the engine coolant from the radiator and
cylinder block. See Drain, flush and refill cooling
system with new coolant on page 4-20.
Remove the cooling system components from
the engine.

NOTICE
Be sure to secure the engine solidly to prevent
injury or damage to parts due to the engine falling
during work on the engine.

5-38
Cylinder Block ENGINE
5. Remove the engine from the machine. Mount
the engine to a suitable engine repair stand
having adequate weight capacity.
6. Clean the engine by washing with solvent, air or
steam cleaning. Carefully operate to prevent 3
any foreign matter or fluids from entering the 1
2
engine, fuel system, or electrical components
remaining on the engine.
7. Drain the engine oil into a suitable container.
Remove oil filter.
8. Remove the cylinder head. See Disassembly of
Cylinder Head on page 5-21.
9. Remove the fuel injection pump from the gear K0002181
case only if it must be sent out for repair, or will
interfere with other procedures such as “hot Figure 5-40
tank” cleaning. See Removal of Fuel Injection
Pump on page 6-12. ■ Checking timing gear backlash
10. Remove the starter motor. See Removal of Prior to removing the timing gears, measure the
Starter Motor on page 9-8. gear backlash and determine the gear wear.
Note: Check the backlash between each pair of
Disassembly of Camshaft and Timing mating gears. If not within specification,
Components replace both mating gears. Do not allow the
Discard all gaskets, O-rings and seals. Use new gear being checked to move axially as
gaskets, O-rings and seals on reassembly of excess end play could cause a false reading.
camshaft and timing components. See Timing Gear Backlash on page 5-8 for
service limits.
■ Removal of timing gear case cover
1. Remove the bolt and washer retaining the 1
2
crankshaft pulley.
3
NOTICE C
C
B B
Use care not to damage the threads in the end of
A
the crankshaft when removing the crankshaft A
5
pulley.
4 K0002190-01X

2. Remove the crankshaft pulley with a gear puller. 1 – Fuel injection pump drive gear
2 – Camshaft drive gear
3. Remove the bolts that retain the gear case 3 – Auxiliary drive gear (optional)
cover to the cylinder block and oil pan. 4 – Crankshaft drive gear
4. Remove the gear case cover (Figure 5-40, (1)). 5 – Idler gear
5. Remove the dowel pins (Figure 5-40, (3)) and Figure 5-41
O-ring (Figure 5-40, (2)).

5-39
ENGINE Cylinder Block

■ Measuring idler gear-to-crankshaft gear ■ Removal of timing gears

backlash 1. Remove the bolts from the idler gear shaft
1. Install a dial indicator as shown in Figure 5-42. (Figure 5-43, (1)). Remove the idler gear shaft,
idler gear (Figure 5-43, (3)) and bushing
(Figure 5-43, (2)).

3
2
1

K0002192
K0002182

Figure 5-42
Figure 5-43
2. Rotate the idler gear back and forth to check
idler gear-to-crankshaft gear backlash. Total 2. Do not remove the crankshaft gear unless it is
indicator reading is backlash. Record the damaged and requires replacement. If the gear
measurement. must be removed, remove it with a gear puller.
3. Removal of the camshaft gear requires the
■ Measuring idler gear-to-camshaft gear camshaft be removed with a press. Do not
backlash remove the camshaft gear unless it or the
1. Drive a small wooden wedge between the camshaft is damaged and requires
crankshaft gear and idler gear to prevent the replacement. See Removal of camshaft on
idler gear from rotating. page 5-42.
2. Install a dial indicator to read camshaft gear NOTICE
backlash. Rotate camshaft drive gear against
idler gear to measure backlash. Record the Do not loosen or remove the four bolts retaining
measurement. the fuel injection pump drive gear to the fuel
injection pump hub. Do not disassemble the fuel
3. Check the idler gear-to-fuel injection pump
injection pump drive gear from the hub. Correct
drive gear backlash in the same manner as the
fuel injection timing will be very difficult or
camshaft drive gear. Record the measurement.
impossible to achieve.

5-40
Cylinder Block ENGINE
4. Do not remove the fuel injection pump drive ■ Removal of oil pan
gear unless absolutely necessary due to 1. Invert the engine (oil pan up) on the engine
damage to the gear or pump. Do not loosen or stand.
remove the four bolts (Figure 5-44, (3))
retaining pump drive gear to the hub. Only 2. Remove the oil pan (Figure 5-45, (2)).
remove the nut (Figure 5-44, (1)) and washer 3. Remove the crankcase extension
(Figure 5-44, (2)), leaving the hub attached to (Figure 5-45, (1)) if equipped.
the gear. Remove the pump drive gear and hub
as an assembly using a gear puller.

3
1

2
2
K0002183

Figure 5-44

NOTICE
K0002184
Do not loosen or remove the four bolts retaining
the fuel injection pump drive gear to the fuel Figure 5-45
injection pump hub. Do not disassemble the fuel
4. Remove the oil pickup tube (Figure 5-46, (1))
injection pump drive gear from the hub. Correct
and O-ring (Figure 5-46, (2)).
fuel injection timing will be very difficult or
impossible to achieve.

K0002185

Figure 5-46

5-41
ENGINE Cylinder Block

■ Removal of oil pan (with ladder frame) ■ Removal of camshaft

1. Invert the engine (oil pan up) on the engine 1. Before removing the camshaft, check the
stand. camshaft end play.
2. Remove the oil pan (Figure 5-47, (4)). • Method A: Install a dial indicator
3. Remove the ladder frame (Figure 5-47, (1)). (Figure 5-48, (1)) on the cylinder block. Move
the camshaft and gear (Figure 5-48, (2)) in
and out to measure the end play. Record the
measurement. See Camshaft on page 5-7 for
the service limit.

1
2

3
K0002191

Figure 5-48
• Method B: Use a feeler gauge to measure the
clearance between the thrust plate
(Figure 5-49, (1)) and front camshaft bearing
4 (Figure 5-49, (2)). Record the measurement.
See Thrust Bearing on page 5-10 for the
service limit.
026977-00X

Figure 5-47 1

4. Remove the oil pickup tube (Figure 5-47, (3)) 2

and O-ring (Figure 5-47, (2)).
Note: Torx bolts are used for oil sump mounting
bolts and ladder frame mounting bolts.
Specialized tool (Torx bolt wrench) is
required.
Oil sump bolts: TORX E8
Ladder frame: TORX E12
K0001710B

Figure 5-49

5-42
Cylinder Block ENGINE
2. Remove two bolts (Figure 5-50, (3)) retaining ■ Removal of gear case
the camshaft thrust plate (Figure 5-50, (1)). Note: The camshaft must be removed before the
gear case can be removed. See Removal of
5
camshaft on page 5-42.
1. Remove bolts (Figure 5-51, (4)).
Note: It is not necessary to remove the fuel
injection pump from the gear case to
remove the gear case. If the fuel injection
pump does not need to be repaired,
leave it mounted to the timing gear case.
2 See Removal of Fuel Injection Pump on
page 6-12.

1 2. Remove the gear case (Figure 5-51, (1)) from

3 the cylinder block.
4 K0002186

3. Inspect and measure the camshaft bushing.

Figure 5-50 See Camshaft on page 5-7 for service limits. If
3. Extract the tappets (Figure 5-50, (5)) through damaged or worn beyond service limits, remove
the top of the cylinder block. Mark the tappets the camshaft bushing (Figure 5-51, (3)).
so they can be reinstalled in the same location. 4. Remove O-rings (Figure 5-51, (2)).
4. Slowly pull the camshaft (Figure 5-50, (2))
assembly out of the engine being careful not to
damage the front camshaft bushing. 3
5. Remove the camshaft gear (Figure 5-50, (4)) 1
only if the gear or camshaft require
replacement. Use a knife-edge puller and a 4
press to remove the gear. The gear is a
shrink-fit and will need to be heated to 356° -
392°F (180° - 200 °C) to remove.
2

K0002187

Figure 5-51

5-43
ENGINE Cylinder Block

Disassembly of Crankshaft and NOTICE

Piston Components
Mark the connecting rod caps and connecting
■ Removal of pistons rods so the caps and connecting rods stay
together.
NOTICE
Keep the piston pin parts, piston assemblies, and 2. Remove the bearing cap. Do not remove the
connecting rod assemblies together to be returned bearing inserts at this time.
to the same position during the reassembly 3. Wipe oil from the bearing insert and crankshaft
process. Label the parts using an appropriate journal surfaces.
method.
4. Place a piece of PLASTIGAGE®
(Figure 5-53, (1)) along the full width of the
NOTICE bearing insert.
Engines with high operating hours may have a
ridge near the top of the cylinders that will catch the
piston rings and make it impossible to remove the 1
pistons. Use a suitable ridge reamer to remove
ridges and carbon prior to removing pistons.

Note: Pistons can fall from cylinder block if engine

is inverted. Rotate the engine so the K0001898

connecting rods are horizontal before

removing the connecting rod caps. Figure 5-53

1. Using a feeler gauge, measure the connecting NOTICE

rod side clearance (Figure 5-52). See
Connecting Rod on page 5-13 for the standard Do not rotate crankshaft when using
limit. If the measurement is out of specification, PLASTIGAGE. A false reading may result.
replace the crankshaft, connecting rod, or both.

5. Reinstall the bearing cap and tighten to

specification. See Special Torque Chart on
page 5-15.
6. Remove the bearing cap.

K0001899

K0000219
Figure 5-54
Figure 5-52

5-44
Cylinder Block ENGINE
7. Compare the width of the flattened 15. Remove the wrist pin (Figure 5-55, (6)) and
PLASTIGAGE (Figure 5-54, (1)) to the connecting rod (Figure 5-55, (8)) from the
graduation marks on the package. The mark piston (Figure 5-55, (9)).
that most closely matches the width of the 16. Repeat steps until all pistons are removed and
flattened PLASTIGAGE will indicate the bearing dissembled.
oil clearance. Record the measurements. See
Crankshaft on page 5-9. ■ Removal of crankshaft
8. Repeat with the remaining connecting rods. 1. Remove the flywheel (Figure 5-56, (1)) from
the crankshaft.
NOTICE
2. Remove the bolts (Figure 5-56, (2)) from the
Do not allow the connecting rod to contact the flywheel housing assembly. Remove the
crankshaft journal during piston removal. flywheel housing from the engine.
Damage to the bearing journal may result.
2

9. Use a wooden dowel against the connecting

rod and tap the piston/connecting rod assembly 3
out of the cylinder.
1
10. Mark the cylinder number on the piston and
connecting rod.
11. Remove the bearing inserts (Figure 5-55, (2)).
12. Remove the compression rings 4
(Figure 5-55, (3)) from the piston using a piston
ring expander.
13. Remove the oil ring (Figure 5-55, (4)) from the K0002188

piston using a piston ring expander.

Figure 5-56
3
3. Before removing the main bearing caps,
4 measure the crankshaft end play. Use either of
the following two methods:
5
• Method A: Install a dial gauge
9 6 (Figure 5-57, (1)) on the cylinder block. Move
5 the crankshaft (Figure 5-57, (2)) in and out to
measure the end play. Record the
measurement.
8
7

K0001705A

1
Figure 5-55
14. Remove the circlips (Figure 5-55, (5)) from the 2 K0001961

wrist pin.
Figure 5-57

5-45
ENGINE Cylinder Block

• Method B: Use a feeler gauge to measure the 7. Reinstall the bearing cap and tighten to
clearance (Figure 5-58, (3)) between the specification. See Special Torque Chart on
thrust bearing (Figure 5-58, (1)) and page 5-15.
crankshaft (Figure 5-58, (2)). Record the 8. Remove the bearing cap.
measurement. See Thrust Bearing on
page 5-10 for the service limit.

1 K0001899

2 Figure 5-60
9. Compare the width of the flattened
PLASTIGAGE (Figure 5-60, (1)) to the
graduation marks on the package. The mark
3 that most closely matches the width of the
K0001962
flattened PLASTIGAGE will indicate the bearing
Figure 5-58 oil clearance. Record the measurement. See
Crankshaft on page 5-9 for clearance
4. Remove the bearing cap (3CH1, 3CJ1-NGZG01) specifications.
or remove the ladder frame (3CJ1-SDZP01).
Do not remove the bearing inserts at this time. 10. Repeat with the remaining main bearings.

5. Wipe oil from the bearing insert and crankshaft Note: Be sure to note the markings on the main
journal surfaces. bearing caps, or make marks so they can
be reinstalled in the same order as they
6. Place a piece of PLASTIGAGE® were removed. The “arrows” on the main
(Figure 5-59, (1)) along the full width of the bearing caps point to the flywheel end of
bearing insert. the engine.
11. Remove the crankshaft from the engine.
1 12. Remove the bearing inserts (Figure 5-61, (1))
and thrust bearings (Figure 5-61, (2)).
Note: Do not remove the crankshaft gear
unless the gear or crankshaft are
damaged and require replacement.
K0001898

Figure 5-59

NOTICE
Do not rotate crankshaft when using
PLASTIGAGE. A false reading may result.

5-46
Cylinder Block ENGINE
Inspection of Crankshaft and
Camshaft Components
WARNING
Fume/Burn Hazard
• Always read and
follow safety related
precautions found on
1 containers of
hazardous substances
2 like parts cleaners,
primers, sealants and
sealant removers.
K0002189

• Failure to comply could result in death or

Figure 5-61 serious injury.
13. If necessary, remove the crankshaft gear
(Figure 5-62, (1)) and key (Figure 5-62, (2)). If Thoroughly clean all components using a brush
using a gear puller, be careful not to damage and appropriate solvent. Each part must be free of
the threads in the end of the crankshaft. carbon, gasket material, metal filings and other
debris.

2 Note: Record all measurements taken during

inspection.

■ Replacement of crankshaft oil seals

1 1. Remove the seal (Figure 5-63, (2)) from the
gear case cover (Figure 5-63, (1)).
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212F, Part No. 5-8640-2421-0 to
the outside diameter of a new oil seal
K0002193 (Figure 5-63, (2)).
Figure 5-62 3. Install a new seal in the gear case cover with
the lip facing in away from the crankshaft pulley.
Apply lithium grease to the lip of the seal.

K0002181A

Figure 5-63

5-47
ENGINE Cylinder Block

4. Remove the rear oil seal (Figure 5-64, (1)) from 3. Measure cylinders for roundness, taper, and
the flywheel housing (Figure 5-64, (2)). inspect for evidence of scoring. Consider
honing, re-boring or replacing the cylinder block
2 if the measurements are not within
specification.
• Take measurements at three places
(Figure 5-65) (a, b, and c), and in two directions
(d and e) in each cylinder. Collect and record the
measurements. See Cylinder Block on page 5-14
for specifications.

1 a 20 mm
(0.75 in.)
d
e
b
K0002188A

Figure 5-64 c
20 mm
5. Apply a continuous bead of ThreeBond Liquid (0.75 in.) K0000230B

Gasket No. 1212F, Part No. 5-8640-2421-0 to Figure 5-65

the outside diameter of a new oil seal
(Figure 5-64, (1)). Roundness
6. Install a new seal in the flywheel housing Roundness can be calculated by subtracting the
(Figure 5-64, (2)) with the lip facing in away smaller measured value from the larger measured
from the flywheel. Apply lithium grease to the lip value of (d or e) at each measuring location (a, b,
of the seal. and c).

■ Crankshaft bearing oil clearance Taper

Oil clearance should be checked during Taper can be calculated by subtracting the
disassembly to determine the extent of wear, and minimum measured value from the maximum
during assembly to ensure long engine life. The measured value of locations (a, b, and c).
same procedure is done for both connecting rods Calculate along both the (d) axis and (e) axis and
and main bearings. See Removal of pistons on use the larger of the two calculations as the value
page 5-44 or Removal of crankshaft on page 5-45 to compare to the specifications.
for specific information.

■ Inspection of cylinder block

1. Ensure that oil passages are clear and
unobstructed.
2. Check for discoloration or evidence of cracks. If
a fracture is suspected, use the color check
method or the MAGNAFLUX® method to
determine if the cylinder block is fractured.

5-48
Cylinder Block ENGINE
■ Inspection of pistons, piston rings and 5. Subtract the piston measurement from the
wrist pin greatest measurement acquired during cylinder
inspection (see Inspection of cylinder block on
Note:
page 5-48) to obtain piston-to-cylinder
• On an engine with low hours, the pistons, piston clearance. Record the measurements. See
rings may be reused if they are found to be within Piston on page 5-11 for specifications.
specifications. The pistons and piston rings must 6. Measure the diameter of the wrist pin bore on
be reinstalled in the same cylinders from which both sides of the piston (Figure 5-67). See
they were originally removed. Piston on page 5-11 for specifications. Record
• On an engine with high hours, the pistons rings the measurements.
should be replaced and the cylinder honed (See
Honing and Boring on page 5-54) or replaced.
The piston should be replaced as necessary.
1. Clean piston ring grooves using a piston ring
groove cleaning tool. Follow manufacturer’s
instructions for correct operation.
2. Wash the pistons in an appropriate solvent
using a soft brush.
K0000237
3. Visually inspect each piston for cracks. Pay
particular attention to the ring lands between Figure 5-67
the piston ring grooves.
7. Measure the outside diameter of the wrist pin in
4. Measure the diameter of the piston skirt at 90° three places and at 90° (Figure 5-68). See
to the wrist pin bore as shown (Figure 5-66). Piston on page 5-11 for specifications. Record
Measurements must be taken at a specified the measurements.
distance (Figure 5-66, (1)) from the bottom of
the piston, based on engine model. Record the
measurements. See Piston on page 5-11 for
specifications.

K0001889

Figure 5-68
8. Using a micrometer, measure the thickness of
each piston ring. See Piston Ring on page 5-12
1 for specifications. Record the measurements.
Note:
K0000235
• On an engine with low hours, the pistons,
Figure 5-66 piston rings and cylinders may be reused if they
are found to be within specifications.
• On an engine with high hours, the pistons rings
should be replaced and the cylinder honed
(See Honing and Boring on page 5-54) or
replaced. The piston should be replaced as
necessary.

5-49
ENGINE Cylinder Block

9. Place each compression piston ring in the Note: Always check the piston ring end gap when
groove as shown (Figure 5-69). Use a feeler installing new piston rings. See Piston Ring
gauge to measure the clearance between the on page 5-12 for specifications. Use a piston
piston ring and the piston ring land. Record the ring end gap filing tool to adjust the piston
measurements. See Piston Ring on page 5-12 ring end gap on new piston rings.
for specifications. Replace the piston if not
11. Repeat the above steps for each cylinder and
within specification.
piston assembly.

■ Inspection of connecting rod

1. Measure the wrist pin bushing bore using a
bore gauge (Figure 5-71, (1)). Replace the
bushing if not within specifications. If the
bushing has been removed, measure the inside
diameter of the connecting rod small end
(Figure 5-71, (2)). Record the measurements.
See Connecting Rod on page 5-13 for
specifications.

K0001892

Figure 5-69
10. To measure piston ring end gap, insert each
compression piston ring (Figure 5-70, (1)), one
at a time, into the cylinder. Use a piston with the
piston rings removed to slide the ring into the
cylinder bore until it is approximately 1.18 in.
(30 mm) (Figure 5-70, (2)) from the bottom of 1
the bore. Remove the piston. Measure the end
gap (Figure 5-70, (3)) of each piston ring.
Record the measurements. See Piston Ring on 2
page 5-12 for specifications.
K0001724A

Figure 5-71
2. Measure the connecting rod twist
(Figure 5-72, (1)) and bend (Figure 5-72, (2))
using a connecting rod alignment tool
(Figure 5-73). Record the measurements. See
Connecting Rod on page 5-13 for
1 specifications.

3 K0001964

Figure 5-70

5-50
Cylinder Block ENGINE
■ Inspection of tappets
1. Inspect the tappet contact surfaces for
abnormal wear (Figure 5-74, (1)). Normal wear
2 will be even as shown in (Figure 5-74, (2)).
Slight surface defects can be corrected using
an oilstone.

K0001896

Figure 5-72
1 2 K0002194

Figure 5-74
2. Measure the outside diameter of the tappet
stem (Figure 5-75, (1)). Record the
measurements. See Tappet on page 5-14 for
the service limit.

K0000242

Figure 5-73
3. Place the connecting rod bearing inserts into
the connecting rod and connecting rod cap.
Install the rod cap and tighten the bolts to the
specified torque.
4. Measure the inside diameter. Record the K0002195

measurements. See Crankshaft on page 5-9 for

specifications. Figure 5-75
3. Measure the tappet bores in the cylinder block.
Record the measurements. See Tappet on
page 5-14 for the service limit.

5-51
ENGINE Cylinder Block

■ Inspection of crankshaft
1. Put the crankshaft end journals
(Figure 5-76, (4)) on V-blocks.
2. Place a dial indicator (Figure 5-76, (3)) on a
center main bearing surface.

2
1

R
3
R

1
2 K0001733A

4 4 K0000232A Figure 5-77

Figure 5-76
3. Rotate the crankshaft and observe runout.
Record the measurements. See Crankshaft on
page 5-9 for specifications.
4. Use the color check method or MAGNAFLUX to
inspect the crankshaft for cracks. Replace the
crankshaft if evidence of fractures is found.
5. Measure the outside diameter of each crankpin
(Figure 5-77, (2)) and main bearing journal
(Figure 5-77, (1)). See Crankshaft on page 5-9
for specifications. Take measurements at
several places around each bearing surface. If
not within specification, grind the journals and
install undersize bearings, or replace the
crankshaft. Record the measurements.

5-52
Cylinder Block ENGINE
Reconditioning the Crankshaft ■ Inspection of camshaft
If any of the crankshaft journals do not meet the 1. Use V-blocks and a dial indicator to check
specifications, it may be possible to grind any or all camshaft bend (Figure 5-79). Place the
of them to an undersize. The connecting rod indicator on the center bearing journal.
bearings, main bearings, and thrust bearing inserts
are available as 0.010 in. (0.25 mm) undersize. If
the journals are ground undersize, the following
finishing standards (Figure 5-78) must be adhered
to:

1
Ry

Ry K0002196

R Figure 5-79
R

R 2. Rotate the camshaft and observe the runout.

Record the measurements. See Camshaft on
K0000234A
page 5-7 for specifications.

Figure 5-78 3. Measure the height of each lobe

(Figure 5-80, (1)). Record the measurements.
Item Finishing precision
See Camshaft on page 5-7 for specifications.

Connecting 3CJ1-NGZG01 1.4843 - 1.4847 in.

rod journal 3CJ1-SDZP01 (37.702 - 37.712 mm)
undersize 3CH1-NGZG01 1.6478 - 1.6422 in. 1
finished size 3CH1-SDZP01 (41.702 - 41.712 mm)
3CH1-NGZG01
Main bearing 1.8387 - 1.8391 in.
3CH1-SDZP01
journal (46.702 - 46.712 mm)
3CJ1-NGZG01
undersize
finished size 1.7213 - 1.7217 in. K0001712A

3CJ1-SDZP01
(43.720 - 43.730 mm) Figure 5-80
0.138 - 0.150 in.
Journal radius (R) 4. Measure the diameter of the gear end
(3.5 - 3.8 mm)
(Figure 5-81, (1)), intermediate
Journal face finish (Ry) 0.8 S (super polish)
(Figure 5-81, (2)), and flywheel end
Thrust face finish (1) 1.6 (Figure 5-81, (3)) bearing journals. Record the
measurements. See Camshaft on page 5-7 for
specifications.

2
1

K0001713A

Figure 5-81

5-53
ENGINE Cylinder Block

■ Inspection of camshaft bushing and Honing and Boring

bores
Pistons must move freely in the cylinders while
1. Measure the I.D. of the front bushing and the maintaining adequate compression and oil sealing.
remaining bores in the cylinder block. Record If the cylinder walls are scuffed, scored,
the measurements. See Camshaft on page 5-7 out-of-round, or tapered beyond specifications,
for specifications. rebore and hone to restore cylinders to usable
2. If the camshaft bushing is not within condition. Slight imperfections can be corrected by
specification, replace using the appropriate honing alone.
service tool. If the remaining bores are not 1. Boring - Significant cylinder damage may be
within specification, the cylinder block will corrected by boring the cylinder to an oversize
require replacement as there are no bearing dimension. Refer to the appropriate parts
inserts used. catalog for available oversize pistons and piston
rings.
■ Inspection of idler gear and shaft
• Boring a cylinder should always be done in a
1. Measure the outside diameter properly equipped machine shop.
(Figure 5-82, (1)) of the idler gear shaft
• A bored cylinder should always be finished with
(Figure 5-82, (2)). Record the measurements.
a hone to properly prepare the cylinder surface
See Idler Gear Shaft and Bushing on page 5-8
so the new piston rings will seat properly.
for specifications.
• After the cylinder has been bored and honed,
2. Measure the inside diameter (Figure 5-82, (3))
install the appropriate oversize pistons and
of the idler gear bushing (Figure 5-82, (4)).
piston rings.
Record the measurements. See Idler Gear
Shaft and Bushing on page 5-8 for 2. Honing - Minor cylinder imperfections may be
specifications. corrected by using a rigid cylinder hone
(Figure 5-84, (1)). Be sure not to exceed the
4 maximum cylinder bore specification.
Deglazing - A used cylinder that did not require
boring or honing, should always be deglazed with
1 3 a ball hone (Figure 5-84, (2)) before installing
new piston rings. This will properly prepare the
cylinder surface to allow new piston rings to seat
2 properly.
Note: When honing a cylinder, with either a
K0001714A
ridged hone or a ball hone
Figure 5-82 (Figure 5-83, (1)), move the rotating
hone up and down in the cylinder bore to
accomplish a 30° to 40° crosshatch
pattern (Figure 5-83). This will provide
the ideal surface for the proper seating of
new piston rings.

5-54
Cylinder Block ENGINE
• When honing is completed, wash the cylinder
NOTICE block with hot water and soap. The cylinder wall
Do not allow the honing tool to operate in one is adequately cleaned when a white rag wiped
position for any length of time. Damage to the in cylinder comes out clean. Use brushes to
cylinder wall will occur. Keep the tool in constant clean all passages and crevices. Rinse with hot
up-and-down motion. water and dry with compressed air. Apply clean
engine oil to all steel surfaces to prevent
rusting.
1 Reassembly of Crankshaft and
Piston Components
Note:
• Proceed slowly. Make no forced assemblies
unless a pressing operation is called for. All parts
must be perfectly clean and lightly lubricated
when assembled.
• Use new gaskets, seals and O-rings during
assembly.
K0000248A

• Liberally apply clean engine oil to all internal

Figure 5-83
parts during assembly.
• Use a 50:50 mixture of diesel fuel and engine
• All fasteners should be tightened to a given
oil as a honing fluid.
torque. If a special torque is not provided in the
• Use a 300-grit hone at 300 - 1200 min-1 (rpm) Special Torque Chart on page 5-15, tighten to
(Figure 5-84). standard torque specifications. See Tightening
Torques for Standard Bolts and Nuts on
1 page 3-24.
2

K0000249B

Figure 5-84

NOTICE
Solvents will not adequately remove honing
residue, resulting in premature piston and ring
wear. Always wash cylinders using hot, soapy
water.

5-55
ENGINE Cylinder Block

■ Reassembly of pistons Note: The actual appearance of the match

1. Select the parts needed to assemble the piston marks will vary but they will always be in
and connecting rod for one cylinder. the same locations.

2. If removed, install a new wrist pin bushing

(Figure 5-85, (7)) using a press and the
appropriate service tool. Be sure to align the oil
holes.

V80
ML
4 1

9 6
5
046877-00X00

2
8
7

2 R
V80

046878-00X00

K0001705A 3
Figure 5-85
3. Reinstall one circlip (Figure 5-85, (5)) into the 80 80
piston. Ensure the circlip is securely seated in
the groove. K0002089

NOTICE Figure 5-86

The piston and connecting rod must be 4. Place the connecting rod into the piston. The
assembled with the correct orientation. When match marks (Figure 5-87, (4)) on the
correctly assembled, the piston identification connecting rod and cap must be on the
mark (Figure 5-86, (1)) stamped into the top of opposite side as the piston identification mark
the piston will be on the opposite side of the (Figure 5-87, (2)) on the top of the piston.
connecting rod as the match marks
(Figure 5-86, (3)) stamped into the connecting
rod and connecting rod cap. When reinstalled in
the cylinder, the embossed mark
(Figure 5-86, (2)) cast into the beam of
connecting rod will face the flywheel end of the
engine.

5-56
Cylinder Block ENGINE

6 1 3

9 6
5
2 5

8
7

3 2

1
4

K0001705A
K0000227A

Figure 5-88
1 – Fuel injection pump side of engine
2 – Piston identification mark Note: Reinstall the top and second piston rings
3 – Embossed mark on connecting rod with the stamped “makers mark”
4 – Connecting rod and cap match marks
(Figure 5-89, (1)) facing the top of the
5 – Flywheel end of engine
piston. The “makers mark” may vary in
6 – Camshaft side of engine
appearance but will always be located on
Figure 5-87 the top surface of the piston ring
adjacent to the piston ring gap. The oil
5. Lubricate and install the wrist pin
ring and oil ring expander can be
(Figure 5-88, (6)) through the piston and
installed either side up.
connecting rod.
6. Reinstall the second circlip (Figure 5-88, (5)) 1
and ensure it is securely seated in the groove.
Note: If installing new piston rings the end gap
must be checked and adjusted as
necessary. See Inspection of pistons, K0000225A

piston rings and wrist pin on page 5-49.

Figure 5-89
Use a piston ring end gap filing tool to
adjust the piston ring end gap on new
piston rings. NOTICE
Always use a piston ring expander when
installing piston rings. Never attempt to install
piston rings by hand.

5-57
ENGINE Cylinder Block

7. Reinstall the oil ring expander

1
(Figure 5-90, (4)). Install the oil ring
(Figure 5-90, (3)) with the end gap at 180° from
the expander end gap.
8. Reinstall the second compression ring 2
(Figure 5-90, (2)). This ring is identified by its
dark color and tapered face profile. 3
9. Reinstall the top compression ring
(Figure 5-90, (1)). This ring is identified by its
silver color and barrel-shaped face profile.

NOTICE
The oil ring expander (Figure 5-90, (4)) end gap
must be located 180° from the oil ring
(Figure 5-90, (3)) end gap.

K0000226A

1 – Top compression ring end gap

1 2 – Second compression ring end gap
3 – Oil ring end gap
Figure 5-91
2
■ Installation of crankshaft
1. If removed, reinstall the key and timing gear on
3
crankshaft.
2. Install new bearing inserts (Figure 5-92, (1))
4 and thrust bearing (Figure 5-92, (2)) in the
K0001722B
cylinder block and main bearing caps. Be sure
the oil holes in the upper bearing shells align
Figure 5-90 with the oil ports in the cylinder block. Apply a
liberal coat of clean engine oil to the bearings
10. Stagger the piston ring end gaps at 120°
and crankshaft journals.
intervals (Figure 5-91, (1, 2, and 3)). Do not
position the top piston ring end gap in line with
the wrist pin.

K0002189

Figure 5-92

5-58
Cylinder Block ENGINE
3. Install the crankshaft in the engine. ■ Installation of pistons

NOTICE NOTICE
The main bearing caps are numbered and have Do not allow the connecting rod to contact the
arrows for proper positioning. The No. 1 cap is at crankshaft journal during piston installation.
the flywheel end. The arrows point toward the Damage to the crankshaft bearing journal may
flywheel end of the engine. result.

4. Reinstall the main bearing caps. 1. Lubricate piston, piston rings, and cylinder with
5. Apply a light coat of clean engine oil to the clean engine oil or assembly lubricant.
bearing cap bolts and tighten the bolts to the 2. Rotate the crankshaft so the crankpin for the
specified torque in two stages (1/2 then full piston being installed is near bottom dead
torque). See Special Torque Chart on center.
page 5-15.
6. Rotate the crankshaft to ensure it turns freely. 1

7. Apply ThreeBond Liquid Gasket No. 1212F,

Part No. 5-8640-2421-0 to the mounting flange
of the flywheel housing (Figure 5-93, (2)). 2
8. Align the flywheel housing with the two dowel
pins (Figure 5-93, (3)). 3
9. Reinstall flywheel housing and seal assembly.
10. Reinstall the flywheel (Figure 5-93, (1)) and
tighten the bolts to the specified torque. See
Special Torque Chart on page 5-15.

3
K0000226A

1
1 – Top compression ring end gap
2 – Second compression ring end gap
3 – Oil ring end gap
Figure 5-94
4
NOTICE
Ensure piston ring gaps are located correctly
K0002188 (Figure 5-94).
Figure 5-93
3. Using a piston ring compressor, compress the
piston rings.

5-59
ENGINE Cylinder Block

5. Reinstall the bearing inserts (Figure 5-96, (1))

NOTICE in the connecting rod and cap.
The piston and connecting rod must be 6. Apply a liberal coat of clean engine oil to the
reinstalled with the correct orientation. When bearing inserts and crankshaft journal.
installed correctly, the identification mark
7. Apply a light coat of clean engine oil to the rod
(Figure 5-95, (2)) stamped into the top of the
cap bolts. Reinstall the connecting rod cap
piston will be on the same side of the engine as
(Figure 5-96, (2)). Tighten the connecting rod
the fuel injection pump (Figure 5-95, (1)) and the
bolts to the specified torque in two stages (1/2
embossed mark (Figure 5-95, (3)) cast into the
then full torque). See Special Torque Chart on
connecting rod beam will face the flywheel end of
page 5-15.
the engine (Figure 5-95, (5)).

4. Carefully reinstall the piston and rod assembly.

Be sure the match marks (Figure 5-95, (4))
stamped into the connecting rod and cap are
facing the fuel injection pump side of the
cylinder block, and the piston identification
mark (Figure 5-95, (2)) stamped into the piston
top is facing the camshaft side 1
(Figure 5-95, (6)). The embossed mark cast
into the connecting rod beam (Figure 5-95, (3))
2
will be facing the flywheel end of the engine
(Figure 5-95, (5)).

6 1
K0001965

Figure 5-96
8. Reinstall the remaining pistons in their
respective cylinders.

2 5

K0000227A

1 – Fuel injection pump side of engine

2 – Piston identification mark
3 – Embossed mark on connecting rod
4 – Rod and cap match marks
5 – Flywheel end of engine
6 – Camshaft side of engine
Figure 5-95

5-60
Cylinder Block ENGINE
Reassembly of Camshaft and Timing 2. Lubricate the camshaft (Figure 5-98, (2)) with
clean engine oil or assembly lube. Slowly insert
Components
the camshaft through the front of the engine.
■ Installation of gear case 3. Reinstall and tighten the cap screws
(Figure 5-98, (3)).
1. If removed, install a new camshaft bushing
(Figure 5-97, (3)) using the appropriate service
tool.
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212F, Part No. 5-8640-2421-0 to
the mounting area of the gear case. Be sure to
circle each bolt hole. 2
3. Reinstall dowels and new O-rings
(Figure 5-97, (2)).
1
3
4 K0002186

3 Figure 5-98
1 4. Lubricate the camshaft lobes and tappets with
clean oil or assembly lube. Reinstall the tappets
4
in their respective locations in the cylinder
block. Push the tappets fully into the tappet
bores until they make solid contact with the
2 camshaft.
5. If removed, reinstall the fuel injection pump.
K0002187 Adjust the fuel injection timing after installation.
See Checking and Adjusting Fuel Injection
Figure 5-97
Timing on page 6-17.
4. Reinstall the gear case (Figure 5-97, (1)).
Tighten the bolts (Figure 5-97, (4)) to the ■ Installation of timing gears
specified torque. 1. Set No. 1 piston to top dead center.
2. Rotate the camshaft until mark
■ Installation of camshaft
(Figure 5-100, (C)) is approximately at the
Note: The gear housing must be installed prior to 9 o’clock position.
reinstalling the camshaft. See Installation of
3. Lubricate the idler gear (Figure 5-99, (3)),
gear case on page 5-61.
bushing (Figure 5-99, (2)) and idler gear shaft
1. If removed, reinstall the camshaft end plate (Figure 5-99, (1)) with clean engine oil or
(Figure 5-98, (1)), key, and camshaft gear assembly lube.
(Figure 5-98, (4)) onto the camshaft using a
press.
• Heat the gear to 356 - 392 °F (180 - 200 °C) and
press onto the end of the camshaft.

5-61
ENGINE Cylinder Block

■ Installation of gear case cover (3CJ1-

SDZP01)
1. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212F, Isuzu Part No. 5-8640-2421-
0 to the mounting area of the gear case cover
3 (Figure 5-101, (1)). Be sure to circle the bolt
2 holes.
1

K0002182

Figure 5-99 3
1
4. Align the timing gears as shown in 2
Figure 5-100.
5. Reinstall the idler gear and idler gear shaft. Be
sure the oil hole in the bushing is facing toward
the top of the engine.
6. Ensure all three timing marks
(Figure 5-100, (A, B, and C)) are aligned.
K0002181

1
2 Figure 5-101
2. Reinstall the dowels (Figure 5-101, (3)) and a
3
C
new O-ring (Figure 5-101, (2)).
C
B B

A NOTICE
A
5 Be sure to align the flats on the oil pump with the
4
flats on the crankshaft gear.
K0002190-01X

1 – Fuel injection pump gear

2 – Camshaft gear 3. Reinstall the timing gear case cover.
3 – Optional accessory drive gear
4 – Crankshaft gear
4. Reinstall and tighten the gear case cover bolts.
5 – Idler gear 5. Reinstall the crankshaft pulley.
Figure 5-100 6. Reinstall the washer and bolt. Tighten to the
specified torque. See Special Torque Chart on
7. When all gears are properly aligned, tighten the page 5-15 for specifications.
idler gear retaining bolts to specified torque.
See Special Torque Chart on page 5-15 for
specifications.

5-62
Cylinder Block ENGINE
■ Installation of oil pan ■ Final assembly of engine
1. Reinstall the oil pickup tube (Figure 5-102, (1)) 1. Reinstall the starter motor.
and a new O-ring (Figure 5-102, (2)). 2. Reinstall the cylinder head. See Reassembly of
cylinder head on page 5-30.
3. Reinstall the engine in the machine.
4. Reconnect the fuel and coolant lines.
5. Reinstall the alternator.
6. Reconnect and adjust the throttle cable.
7. Reconnect all electrical connections.
8. Fill the engine with oil and coolant.
2 9. Reconnect the battery cables, negative (-) cable
last.
1

K0002185

Figure 5-102
2. Apply a continuous bead of ThreeBond Liquid
Gasket No. 1212F, Part No. 5-8640-2421-0 to
the mounting surface of the oil pan
(Figure 5-103, (2)) and crankcase extension (if
equipped) (Figure 5-103, (1)). Be sure to circle
each bolt hole.
3. If equipped, reinstall the crankcase extension
(Figure 5-103, (1)). Reinstall the oil pan and
tighten the bolts securely.

K0002184

Figure 5-103

5-63
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ENGINE Cylinder Block

This Page Intentionally Left Blank

5-64
TNV_IDI_ServiceManual_A4.book Page 1 Saturday, July 4, 2015 5:50 PM

TNV IDI Service Manual

Section 6

FUEL SYSTEM
Page
Before You Begin Servicing ............................................................ 6-3
Introduction...................................................................................... 6-4
Fuel Injection Pump
(ML: 3CH1·3CJ1-NGZG01, MC: 3CJ1-SDZP01) ...................... 6-4
Stop Solenoid ............................................................................ 6-5
Fuel System Specifications ............................................................. 6-6
Special Torque Chart................................................................. 6-6
Test and Adjustment Specifications .......................................... 6-6
Special Service Tools...................................................................... 6-7
Measuring Instruments.................................................................... 6-7
Fuel System Diagram...................................................................... 6-8
Fuel System Components ............................................................... 6-9
Fuel Injection Lines ....................................................................... 6-10
Removal of High-Pressure Fuel Injection Lines ...................... 6-10
Installation of High-Pressure Fuel Injection Lines ................... 6-10
Removal of Fuel Return Line................................................... 6-11
Installation of Fuel Return Line................................................ 6-11
Fuel Injection Pump....................................................................... 6-12
Removal of Fuel Injection Pump.............................................. 6-12
Installation of Fuel Injection Pump........................................... 6-15
Checking and Adjusting Fuel Injection Timing .............................. 6-17
Checking Fuel Injection Timing ............................................... 6-17
Adjusting Fuel Injection Timing................................................ 6-20
Fuel Injectors................................................................................. 6-23
Removal of Fuel Injectors........................................................ 6-23
Testing of Fuel Injectors .......................................................... 6-23

6-1
TNV_IDI_ServiceManual_A4.book Page 2 Saturday, July 4, 2015 5:50 PM

FUEL SYSTEM
Disassembly and Inspection of Fuel Injectors .......................... 6-26
Adjusting Fuel Injector Pressure .............................................. 6-27
Reassembly of Fuel Injectors ................................................... 6-28
Installation of the Fuel Injectors................................................ 6-28

6-2
Before You Begin Servicing FUEL SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

6-3
FUEL SYSTEM Introduction

INTRODUCTION
This section of the Service Manual describes the procedures necessary to remove, install, and time the
ML·MC fuel injection pump and its associated system components. This fuel injection pump is
representative of the fuel injection pumps used on Isuzu C series engines.

4
3
1

5 6 K0002238

Figure 6-1

Fuel Injection Pump (ML: 3CH1·3CJ1- The ML·MC fuel injection pump is an in-line type
pump which consists of a fuel supply plunger
NGZG01, MC: 3CJ1-SDZP01)
(Figure 6-1, (1)) for each cylinder, a camshaft
Note: If the ML·MC fuel injection pump itself (Figure 6-1, (2)), and a pump housing
requires servicing, it must be taken to your (Figure 6-1, (3)). A delivery valve (Figure 6-1, (4))
Isuzu Distributor. connects to a high-pressure fuel line for each
cylinder. The fuel injection pump housing contains
The following describes the features of the ML·MC
a governor (Figure 6-1, (5)).
fuel injection pump.
Fuel from the fuel tank to the fuel injection pump is
The fuel injection pump is a very important
delivered by a low-pressure electric fuel pump. On
component of the engine. It is capable of making
a few special models, a mechanical fuel pump is
very precise fuel delivery adjustments according to
used instead of an electric pump. The mechanical
the varied loads applied to the engine.
fuel pump is mounted to the fuel injection pump
All of the fuel injection pump components are very housing in place of the cover plate
precisely machined. It is extremely important to (Figure 6-1, (6)).
follow good service practices and maintain
Fuel to be injected into the cylinders is pressurized
cleanliness when servicing the fuel injection pump.
by the up and down motion of each
camshaft-driven plunger, and is then supplied by
the high-pressure fuel lines to the respective fuel
injector.

6-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Introduction FUEL SYSTEM

NOTICE Stop Solenoid

The ML·MC fuel injection pumps are equipped with
• Never remove or attempt to remove the tamper-
a stop solenoid that controls the fuel flow inside the
proof devices from the full-load fuel adjusting
fuel injection pump.
screw or the high-speed throttle limit screw on the
fuel injection pump and governor assembly. With the starter switch in the OFF position, no
These adjustments have been made at the current flows to the stop solenoid and the solenoid
factory to meet all applicable emissions plunger is extended holding the fuel injection pump
regulations and then sealed. fuel rack in the “closed” position and not allowing
fuel to flow through the injection pump and to the
• Never attempt to make any adjustments to these
engine.
sealed adjustment screws. If adjustments are
required, they can be made only by a qualified When the starter switch is turned to ON position,
fuel injection shop that will ensure the injection the “pull coil” (36.5 Amp draw/white wire) inside the
pump continues to meet all applicable emissions solenoid is activated and pulls the solenoid plunger
regulations and then replace the tamper-proof into the solenoid. This releases the fuel injection
seals. pump fuel rack, allowing fuel to flow through the
injection pump and allowing the engine to start and
• Tampering with or removing these devices may
run.
void the “Isuzu Motors Limited Warranty.”
Normally, the solenoid “pull coil” current is shut off
with a 1 second timer. If the “pull coil” is energized
The fuel injector is essentially a spring-loaded so that the starter can turn, it will burn.
valve. When fuel pressure from the fuel injection
pump reaches a pre-determined level, the pintle And the “hold coil” (0.5 Amp draw/red wire) inside
(valve) is forced off its seat and fuel is atomized as the solenoid is activated. The “hold coil” holds the
it passes between the pintle and seat. The timing solenoid plunger in the RUN position, allowing fuel
and quantity of the fuel injected into the cylinder is to continue flowing and the engine to continue
controlled by the fuel injection pump and governor running.
assembly.
To stop the engine, the key switch is turned to the
OFF position. Current no longer flows to the stop
solenoid “hold coil,” and the solenoid plunger
extends and moves the injection pump fuel rack to
the “closed” position, and shutting off the fuel flow
and stopping the engine.
Failure of the stop solenoid could result in the
engine not starting, the engine stopping suddenly
or the engine continuing to run with the key switch
returned to the ON or RUN position, or the engine
failing to stop when the key switch is turned to the
OFF position. Use a VOA multimeter or continuity
light to check for a good ground and 12 V at the
stop solenoid in the correct sequence.

6-5
FUEL SYSTEM Fuel System Specifications

FUEL SYSTEM SPECIFICATIONS

Special Torque Chart
Lubricating oil application
Component Tightening torque
(thread portion and seat surface)
36.1 - 43.5 ft·lb
Fuel injector (49 - 59 N·m, Not applied
5.0 - 6.0 kgf·m)
44 - 51 ft·lb
Fuel pump drive gear nut (59 - 69 N·m; Not applied
6 - 7 kgf·m)
22 - 25 ft·lb
High-pressure fuel injection line nuts (29 - 34 N·m; Not applied
3.0 - 3.5 kgf·m)
18 - 24 ft·lb
Fuel return line nuts (24 - 33 N·m; Not applied
2.5 - 3.3 kgf·m)
17 - 21 ft·lb
Fuel injection pump mounting nuts (23 - 28 N·m; Not applied
2.3 - 2.9 kgf·m)
21.4 - 36.1 ft·lb
Fuel injector nozzle case nut (29 - 49 N·m; Not applied
3.0 - 5.0 kgf·m)

Test and Adjustment Specifications

Fuel injector pressure Fuel injection timing
1784 - 1929 psi
See Checking and Adjusting Fuel Injection Timing on
(12.3 - 13.3 MPa;
page 6-17
125 - 136 kgf/cm2)

Note: Fuel injector pressures given are for used parts. New injectors (5 hours operation or less) will read
approximately 72.5 psi (0.5 MPa; 5 kgf/cm2) higher.

6-6
TNV_IDI_ServiceManual_A4.book Page 7 Saturday, July 4, 2015 5:50 PM

Special Service Tools FUEL SYSTEM

SPECIAL SERVICE TOOLS

Note: Tools not having Isuzu genuine part numbers must be acquired locally.

No. Tool name Application Illustration

Torque wrench For tightening nuts and bolts to the specified

1
(locally available) torque
001438-00X

MEASURING INSTRUMENTS
No. Instrument name Application Illustration

For observing injection spray pattern of fuel

Fuel injector tester
1 injection nozzle and measuring injection
OFF
P-

(locally available)
OFF
E-
ON AG
-G

pressure
K0000581

“Spill-timing” tool
2 Used to set fuel injection timing
(local fabricated)*1

K0002415

*1: Make from a short piece of the end of a high-pressure fuel line, a high-pressure fuel line nut, and a short piece of clear plastic
tubing (a thin nozzle from an aerosol spray can works well). Drill out the end of the fuel line to accept the nozzle. Use a small
amount of silicone sealant to seal the nozzle into the fuel line.

6-7
TNV_IDI_ServiceManual_A4.book Page 8 Saturday, July 4, 2015 5:50 PM

FUEL SYSTEM Fuel System Diagram

FUEL SYSTEM DIAGRAM

10

12
7
11

3
6

5 2
4 K0001058A

1 – Diesel fuel supply 6 – Fuel filter

2 – Water separator 7 – Fuel injection pump
3 – Mechanical fuel pump (used in place of the 8 – High-pressure fuel injection lines
electric fuel pump on some models) 9 – Fuel injectors
4 – Electric fuel pump (used on models without 10 – Fuel return from fuel injectors
mechanical fuel pump) 11 – Air bleed orifice
5 – Low-pressure fuel supply lines 12 – Fuel return to tank
Figure 6-2

6-8
TNV_IDI_ServiceManual_A4.book Page 9 Saturday, July 4, 2015 5:50 PM

Fuel System Components FUEL SYSTEM

FUEL SYSTEM COMPONENTS

19

18 1

17 2

16
7
15 4

6
7
5
11

14

10

9
8

13
12
K0002208

1 – High-pressure fuel injection lines 11 – Fuel injection pump

2 – Fuel return line nut 12 – Lube oil line
3 – Fuel return line 13 – Mechanical fuel supply pump
4 – Fuel injector (optional on some models)
5 – Gasket 14 – Fuel return fitting
6 – Protector 15 – Low pressure fuel inlet fitting
7 – Fuel return hose 16 – Water separator
8 – Fuel injection pump drive gear nut 17 – Electric fuel supply pump
9 – Lock washer 18 – Fuel filter
10 – Fuel injection pump drive gear assembly*1 19 – Fuel filter mount
Figure 6-3

*1: Do not remove or loosen the four bolts that fasten the injection pump drive gear to the injection pump drive gear hub.

6-9
FUEL SYSTEM Fuel Injection Lines

FUEL INJECTION LINES 6. Finish loosening all the fuel line nuts and
remove the high-pressure fuel lines as an
Removal of High-Pressure Fuel assembly being careful not to bend any of the
fuel lines. Be sure to protect the fuel system
Injection Lines from contamination by plugging or covering all
open connections.
NOTICE
7. Plug or cap all openings to minimize leakage
Remove or install the high-pressure fuel injection and prevent contamination.
lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection lines Installation of High-Pressure Fuel
from the retainers or bending any of the fuel lines Injection Lines
will make it difficult to reinstall the fuel lines.
NOTICE
Note: To prevent “rounding” the fuel line nuts Remove or install the high-pressure fuel injection
always use a “line” or “flare nut” wrench. lines as an assembly whenever possible.
Disassembling the high-pressure fuel injection lines
1. Close any fuel valves in the fuel supply line.
from the retainers or bending any of the fuel lines
2. Clean the area to keep contaminants from will make it difficult to reinstall the fuel lines.
entering the fuel system.
3. Place a drain pan under the fuel injection pump
to catch any spillage. Note: To prevent “rounding” the fuel line nuts
always use a “line” or “flare nut” wrench.
4. Loosen the fuel line nuts at the fuel injection
pump. 1. Start all the fuel line nuts by hand. Then use a
5. Next, loosen the fuel line nuts at the fuel wrench to just “snug” all the fuel line nuts.
injectors. Use one wrench to hold the fuel return 2. Tighten the fuel line nuts on the fuel injection
line nut and fuel return line from rotating. Use a pump to the specified torque. See Special
second wrench to loosen the fuel line nut Torque Chart on page 6-6.
(Figure 6-4). Repeat with the remaining fuel 3. When tightening the fuel line nuts on the fuel
injectors. injectors, use one wrench to hold the fuel return
line nut and fuel return line from rotating. Use a
second wrench to tighten the fuel line nuts
(Figure 6-5). See Special Torque Chart on
page 6-6.

K0002237

Figure 6-4

K0002237

Figure 6-5

6-10
Fuel Injection Lines FUEL SYSTEM
Removal of Fuel Return Line Installation of Fuel Return Line
1. Clean the area to keep contaminants from 1. Install a new copper gasket on each fuel
entering the fuel system. injector.
2. Remove the high-pressure fuel injection lines
as an assembly. See Removal of High-Pressure NOTICE
Fuel Injection Lines on page 6-10. The fuel return line is a one-piece assembly. Use
care not to bend or twist the fuel return line.
NOTICE
The fuel return line is a one-piece assembly. Use
2. Carefully reinstall the fuel return line assembly.
care not to bend or twist the fuel return line.
3. Reinstall and hand-tighten the fuel return line
nuts.
4. Tighten the fuel return line nuts to the specified
1 torque. See Special Torque Chart on page 6-6.
2 5. Reinstall the fuel return hose.
6. Reinstall the high-pressure fuel injection line
assembly. See Installation of High-Pressure
3
Fuel Injection Lines on page 6-10.

K0002467

Figure 6-6
3. Remove all fuel return line nuts
(Figure 6-6, (2)) from the injectors
(Figure 6-6, (4)).
4. Remove the fuel return hose from the fuel
return fitting on the fuel injection pump.
5. Carefully remove the fuel return line assembly
(Figure 6-6, (3)).
6. Remove and discard the copper gasket
(Figure 6-6, (1)) from each fuel injector.
7. Plug or cap all openings to minimize leakage
and prevent contamination.

6-11
FUEL SYSTEM Fuel Injection Pump

FUEL INJECTION PUMP

Removal of Fuel Injection Pump
1. Loosen the cooling fan V-belt.
2. Remove the engine cooling fan guard (if
equipped), engine cooling fan (Figure 6-7, (2)),
2
spacer (Figure 6-7, (3)) if equipped, V-pulley
(Figure 6-7, (4)) and cooling fan V-belt
1
(Figure 6-7, (1)).

3
3 2

K0002210

1 Figure 6-8
8. Remove the fuel supply line (Figure 6-8, (2))
from the fitting on the fuel injection pump.
4 9. Plug or cap all openings to minimize leakage
K0000163A
and prevent contamination.
Figure 6-7 10. Remove the throttle cable from the fuel injection
3. Close any fuel valves in the fuel supply line. pump.

4. Place a drain pan under the fuel injection pump 11. Separate the stop solenoid wiring connector
to catch any spillage. (Figure 6-8, (3)).

5. Clean the area to keep contaminants from 12. Remove the lube oil line (Figure 6-9, (1)) from
entering the fuel system. the fuel injection pump and cylinder block.

6. Remove the high-pressure fuel injection lines NOTICE

as an assembly. See Removal of High-Pressure
Fuel Injection Lines on page 6-10. Take care to not damage or bend the lube oil line.
7. Disconnect the fuel return lines from the fitting
on the fuel injection pump (Figure 6-8, (1)).
Plug the open ends of the lines to minimize
leakage and prevent contamination.
1

K0002239

Figure 6-9

6-12
Fuel Injection Pump FUEL SYSTEM
13. Remove the fuel injection pump drive gear
access cover (Figure 6-10, (1)) from the gear NOTICE
case cover (Figure 6-10, (2)). Do not loosen or remove the four bolts retaining
Note: The cover is secured with an adhesive the fuel injection pump drive gear to the fuel
sealant. Use a gasket scraper to injection pump hub. Do not disassemble the fuel
separate the cover from the gear case injection pump drive gear from the hub. Correct
cover. fuel injection timing will be very difficult or
impossible to achieve.

2 15. Do not loosen or remove the four bolts

(Figure 6-12, (3)) holding the pump drive gear
to the hub. Only remove the single drive gear
nut (Figure 6-12, (1)) and washer
(Figure 6-12, (2)), leaving the hub attached to
the gear.

1 K0002211

Figure 6-10
14. To aid in reassembly, make reference marks
(Figure 6-11, (1)) on the drive gear and idler
gear.
3
NOTICE
After marking the position of the pump drive gear, 1
do not rotate the engine crankshaft. Rotating the
crankshaft will cause the fuel injection pump to
become misaligned. 2
K0002183

Figure 6-12
16. Hold the gear train stationary using a large
socket wrench on the crankshaft pulley bolt.
Loosen the fuel injection pump drive gear
retaining nut (Figure 6-12, (1)) and turn it out to
the end of the fuel injection pump shaft.
17. Remove the injection pump drive gear and hub
from the injection pump drive shaft as an
assembly using an appropriate gear puller
1 (Figure 6-13).

K0002096

Figure 6-11

6-13
FUEL SYSTEM Fuel Injection Pump

19. Locate the mark (Figure 6-15, (1)) stamped

into the upper outside mounting boss of the fuel
injection pump. Highlight this mark and make a
corresponding mark on the gear case or front
plate (3CH1, 3CJ1-NGZG01).

K0002209

Figure 6-13
Note: The injection pump drive gear can be 1
removed from the gear case; however, it
is best to let it remain in the gear case.
18. Once the fuel injection pump drive gear and K0002416

hub assembly have “popped” loose from the

Figure 6-15
tapered fuel injection pump drive shaft, carefully
remove the drive gear nut (Figure 6-14, (1)) 20. Remove the three nuts fastening the fuel
and lock washer (Figure 6-14, (2)). injection pump to the gear case for 3CH1 and
3CJ1-NGZG01 engines. Remove the fuel
injection pump. Remove the four bolts fastening
the fuel injection pump to the cylinder block for
3CJ1-SDZP01 engines. Leave the fuel injection
pump drive gear in the gear case and meshed
with the idler gear.

NOTICE
Do not rotate the crankshaft with the injection
1 pump removed.

21. If the fuel injection pump requires servicing, it

2
K0002183A must be sent to your Isuzu Distributor for repair
and calibration, or replaced with a new fuel
Figure 6-14
injection pump.

6-14
Fuel Injection Pump FUEL SYSTEM
2. If installing the fuel injection pump on an engine
NOTICE with the front gear case cover removed, the fuel
• Never remove or attempt to remove the injection pump drive gear can be aligned with
tamper-proof devices from the full-load fuel the idler gear by aligning the stamped marks
adjusting screw or the high-speed throttle limit (Figure 6-17, (A, B, C)) on the fuel injection
screw on the fuel injection pump and governor pump drive gear, idler gear, and crankshaft
assembly. These adjustments have been drive gear. Ensure all three timing marks
made at the factory to meet all applicable (A, B, C) are aligned.
emissions regulations and then sealed.
1
• Never attempt to make any adjustments to 2
these sealed adjustment screws. If
adjustments are required, they can be made 3
only by a qualified fuel injection shop that will C
C
B B
ensure the injection pump continues to meet all
A
applicable emissions regulations and then A
replace the tamper-proof seals. 5

• Tampering with or removing these devices may 4 K0002190-01X

void the “Isuzu Motors Limited Warranty.”

1 – Fuel injection pump drive gear
2 – Camshaft drive gear
3 – Optional accessory drive gear
Installation of Fuel Injection Pump 4 – Crankshaft drive gear
1. Ensure the fuel injection pump drive gear is 5 – Idler gear
aligned with the idler gear using the reference Figure 6-17
marks made earlier (Figure 6-16, (1)).
3. Install a new O-ring on the fuel injection pump
mounting flange. Apply some grease to the
O-ring to hold it in place during the installation
of the fuel injection pump.
Note: Ensure the tapered surface of the fuel
injection pump shaft is clean and dry.
4. Align the key on the fuel injection pump shaft
with the keyway in the fuel injection pump drive
gear hub. Reinstall the fuel injection pump into
1 the fuel injection pump drive gear and gear
housing. Install the pump retaining nuts
finger-tight.
K0002096
5. Reinstall the fuel injection pump drive gear lock
washer (Figure 6-18, (2)) and nut
Figure 6-16 (Figure 6-18, (1)). Do not lubricate threads of
the nut or shaft. Hold the crankshaft pulley bolt
with a socket wrench and tighten the drive gear
nut to the specified torque. See Special Torque
Chart on page 6-6.

6-15
FUEL SYSTEM Fuel Injection Pump

10. If installing a new or recalibrated fuel injection

pump, check the fuel injection timing before
completing the installation of the fuel injection
pump. See Checking and Adjusting Fuel
Injection Timing on page 6-17.
Note: While it is not required to check the
injection timing when reinstalling the
original fuel injection pump, it is
recommended that it be done.
1
11. Reinstall the lube oil line (Figure 6-20, (1)).

2
K0002183A

Figure 6-18
6. Align the reference marks (Figure 6-19, (1))
made during disassembly on both the fuel
injection pump mounting flange and gear case.
If installing a replacement fuel injection pump,
align the manufacturer-applied mark on the
pump mounting flange with the mark made on 1
the timing gear cover.

K0002239

Figure 6-20
12. Apply ThreeBond Liquid Gasket No. 1212F,
Part No. 5-8640-2421-0, or equivalent sealant
to the sealing surface of the fuel injection pump
1 drive gear access cover. Reinstall the cover on
the front of the gear case and tighten the bolts.
13. Reinstall the fuel injection high-pressure lines.
See Installation of High-Pressure Fuel Injection
K0002416
Lines on page 6-10.
Figure 6-19
NOTICE
7. Tighten the fuel injection pump retaining nuts or
bolts to specification. See Special Torque Chart When installing a new or repaired fuel injection
on page 6-6. pump, add 5 - 7 oz (150 - 200 cc) of new, clean
engine oil to the fuel injection pump at the fill plug
8. Reconnect the fuel supply and return lines to located in the upper outside section of the
the fuel injection pump. governor housing.
9. Reconnect the throttle linkage and stop
solenoid connector.

6-16
Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
14. Reinstall the coolant pump V-pulley CHECKING AND ADJUSTING
(Figure 6-21, (4)), spacer (Figure 6-21, (3)) (if
equipped) and engine cooling fan FUEL INJECTION TIMING
(Figure 6-21, (2)). Note: The following procedure is performed on the
No. 1 cylinder. While checking and adjusting
the timing on only No. 1 cylinder is usually
sufficient, the same procedure can be
performed on any or all cylinders.
3 2
Checking Fuel Injection Timing
Note: Some fuel may drain from the fuel injection
pump during this process. Make provisions
1 to contain and dispose of any such spillage.
1. Ensure the fuel injection pump is primed with
fuel. See Priming the Fuel System on
page 3-13.
4
K0000163A
2. Clean the area around the fuel injection pump.
Note: The stop solenoid must be removed to
Figure 6-21
allow fuel to flow through the fuel
15. Reinstall the cooling fan V-belt injection pump.
(Figure 6-21, (1)). Adjust as described in
3. Remove two screws (Figure 6-22, (1)).
Check and adjust cooling fan V-belt on
Remove the stop solenoid (Figure 6-22, (2))
page 4-15.
and O-ring (Figure 6-22, (3)).
16. Reinstall the cooling fan guard (if equipped).
17. Prime the fuel system. See Priming the Fuel
System on page 3-13.
18. Operate the engine and check for fuel and lube
oil leaks.
2

3
1

K0002468

Figure 6-22
4. Set the throttle to the HIGH-IDLE position.

6-17
FUEL SYSTEM Checking and Adjusting Fuel Injection Timing

5. Using a wrench on the crankshaft pulley bolt, 7. The flywheel shown in (Figure 6-24) is for an
rotate the crankshaft in a clockwise direction Isuzu “Standard Specification” IDI engine.
while looking through the flywheel inspection Flywheels used on some “OEM Specific” IDI
port (Figure 6-23, (1)). Rotate the crankshaft engines may be marked differently. You should
until the injection timing marks on the flywheel contact that specific OEM for information on the
are visible for No. 1 cylinder. identification of the timing marks.
Note: The TDC (Top Dead Center) mark can
be identified by the cylinder numbers
stamped near the TDC mark
(Figure 6-24, (5)) on the flywheel.
8. If you are uncertain as to the timing degree
designation of the timing marks on the flywheel
timing grid, you can determine the timing
degree designation by measuring the timing
grid.
1 K0002070 • First measure the distance between two of the
“longer” marks on the timing grid. (They are 5°
Figure 6-23 apart.) Then measure the distance from the
6. Typical flywheel markings are as shown in TDC mark to the first “longer” mark on the
(Figure 6-24). timing grid. Divide that measurement by the
distance between the two “longer” marks. The
Note: A typical flywheel will have multiple resulting answer will tell you how many
timing grids depending on the number of degrees there are between the TDC mark and
cylinders. Any grid and its corresponding the first “longer” mark.
cylinder can be used to check the fuel
injection timing. • Example: If the distance between the two
“longer” marks is approximately 2.0 cm and the
distance from the TDC mark is approximately
4.0 cm, the answer is approximately 2. This
3 indicates there is 10° (2 × 5°) between the TDC
2 mark and the first “longer” mark on the timing
4 grid. That means the first “longer” mark on the
1 timing grid indicates 10° BTDC, the second
14

“longer” mark indicates 15° BTDC and the third

5 timing mark indicates 20°. If the answer is 3,
that indicates there is 15° (3 × 15°) between the
TDC mark and the first “longer” mark and that
K0002071
the first “longer” mark indicates 15° BTDC with
the second and third “longer” marks indicating
1 – 15° BTDC (Before Top Dead Center)
20° BTDC and 25° BTDC respectively.
2 – 20° BTDC
3 – 25° BTDC 9. Highlight the timing reference mark on the
4 – Direction of rotation flywheel housing (Figure 6-25, (2)) or engine
5 – TDC (Top Dead Center) back plate (Figure 6-26, (2)). Highlight the TDC
Figure 6-24 (Top Dead Center) mark (Figure 6-25, (1)),
(Figure 6-26, (1)) on the flywheel.

6-18
Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
11. Remove all high-pressure fuel injection lines.
See Removal of High-Pressure Fuel Injection
Lines on page 6-10.
1
2 12. Turn on all fuel supply valves.
Note: As the injection pump injects fuel to a

1
cylinder only once every two engine
revolutions, it may be necessary to rotate
the crankshaft twice to see fuel being
pumped from the timing tool or delivery
valve of the cylinder you are using to
check injection timing.
K0002065A
13. Install the “spill-timing” tool (Figure 6-28, (1))
Figure 6-25 onto the delivery valve for the cylinder being
checked. See Measuring Instruments on
page 6-7.
Note: If a timing tool is not available, timing can
be checked by watching the fuel in the
2 delivery valve itself.
1

K0002142

Figure 6-26
10. Highlight the target timing mark
(Figure 6-26, (1)), (Figure 6-27, (1)) on the
flywheel timing grid.
The fuel injection timing varies depending on
each specification. For details, refer to the K0000592A

machine manual. Figure 6-28

Note: The following references to the direction
of rotation are made facing the cooling
1 fan end of the engine and are adjusted
2 by turning the crankshaft.
14. Slowly rotate the crankshaft clockwise using a
wrench on the crankshaft pulley bolt until fuel is
pumped from the nozzle of the “spill-timing” tool
or delivery valve.
15. Slowly rotate the crankshaft clockwise
approximately two more revolutions until the
timing grid on the flywheel (for the cylinder
K0002066
being checked) is at approximately 30° BTDC.
Figure 6-27

6-19
FUEL SYSTEM Checking and Adjusting Fuel Injection Timing

Note: The fuel injection pump injects fuel to a Adjusting Fuel Injection Timing
cylinder only once every two engine
revolutions. ■ 3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-
16. “Flick” the nozzle of the timing tool with a finger NGZG01
to remove bubbles and establish a fuel level of If the timing marks did not align when performing
approximately 1/2 the height of the nozzle. the Checking Fuel Injection Timing on page 6-17,
17. Very slowly rotate the crankshaft clockwise until the following steps must be performed to properly
the fuel level in the nozzle of the “spill timing” time the engine.
tool, or in the delivery valve, just begins to 1. Leave the “spill-timing” tool installed in the fuel
move. Immediately stop rotating the crankshaft. injection pump.
18. Check the position of the flywheel target timing 2. Determine if the timing is “advanced” or
mark (Figure 6-27, (1)) on the flywheel grid in “retarded” by comparing the position of the
relation to the timing reference mark target timing mark on the flywheel grid
(Figure 6-27, (2)) on the flywheel housing or (Figure 6-29, (1)) with the timing mark on the
back plate. If the two marks are aligned, the fuel flywheel housing or back plate
injection timing is correct. If the marks do not (Figure 6-29, (2)).
align, the fuel injection timing must be adjusted.
See Adjusting Fuel Injection Timing on
page 6-20.
19. Repeat Steps 13 - 17 two or three times to
verify timing. 2 1

20. Remove the “spill-timing” tool.

21. Reinstall the shut-off solenoid.
22. Reinstall the high-pressure fuel injection lines.
See Installation of High-Pressure Fuel Injection
Lines on page 6-10.
23. Replace the flywheel inspection port cover.
K0002469
24. Prime the fuel system. Operate the engine and
check for leaks. Figure 6-29
3. Loosen the nuts fastening the fuel injection
pump to the gear case.
4. If the injection timing was less than the target
timing, the injection timing is “retarded” and will
need to be “advanced.”
To “advance” the injection timing: Rotate the
top of the fuel injection pump away from the
engine.
If the injection timing was greater than the target
timing, the injection timing is “advanced” and will
need to be “retarded.”
To “retard” the injection timing: Rotate the top
of the fuel injection pump toward the engine.

6-20
Checking and Adjusting Fuel Injection Timing FUEL SYSTEM
5. Adjust the position of the fuel injection pump
and tighten the fuel injection pump mounting
nuts.
6. Recheck the fuel injection timing. Repeat the 2 1
fuel injection timing and adjustment procedures
until the timing is correct. See Checking Fuel
Injection Timing on page 6-17 and repeat steps
3 - 6.
7. Remove the “spill-timing” tool.
8. Reinstall the shut-off solenoid.
9. Reinstall the high-pressure fuel injection lines.
K0002469
See Installation of High-Pressure Fuel Injection
Lines on page 6-10. Figure 6-30
10. Replace the flywheel inspection port cover. 3. The new injection pump will come with a timing
11. Prime the fuel system. Operate the engine and grid sticker. Each line on the timing grid sticker
check for leaks. is 1°. Each line on the flywheel grid is also 1°.

■ 3CJ1-SDZP01
If the timing marks did not align when performing
the See Checking Fuel Injection Timing on
page 6-17, the following steps must be performed
to properly time the engine. 1 DIV. 1degree
CRANK-ANGLE
The fuel injection pump is fixed with four bolts. K0007044
Adjust the injection timing by rotating the pump
drive gear on the pump flange. Figure 6-31

1. Leave the “spill-timing” tool installed in the fuel 4. Observe the flywheel grid again and determine
injection pump. how many degrees you need to advance or
2. Determine if the timing is “advanced” or retard the timing.
“retarded” by comparing the position of the 5. Clean the area of the gear by the pointer on the
target timing mark on the flywheel grid timing cover and put the sticker on the drive
(Figure 6-30, (1)) with the timing mark on the gear, aligning the timing mark on the timing
flywheel housing or back plate cover (Figure 6-32, (1)) with the center of the
(Figure 6-30, (2)). sticker.
6. Loosen the four bolts (Figure 6-32, (2))
fastening the injection pump drive gear to the
flange.

6-21
FUEL SYSTEM Checking and Adjusting Fuel Injection Timing

15. Apply ThreeBond Liquid Gasket No. 1212,

1
Isuzu Part No. *-****-****-*, or equivalent
sealant to the sealing surface of the fuel
injection pump drive gear access cover. Install
1 DIV. 1degree
CRANK-ANGLE
the cover on the front of the gear case and
tighten the bolts.
16. Replace the flywheel inspection port cover.
17. Prime the fuel system. Operate the engine and
2
check for leaks.
2

K0007049

Figure 6-32
7. If the injection timing was less than the target
timing, the injection timing is “retarded” and will
need to be “advanced.”
To “advance” the injection timing: Rotate the
crankshaft counterclockwise.
If the injection timing was greater than the target
timing, the injection timing is “advanced” and will
need to be “retarded.”
To “retard” the injection timing: Rotate the
crankshaft clockwise.
8. Slowly rotate the crankshaft while watching the
pointer on the timing cover and the timing grid
sticker on the injection pump gear. Turn it the
required number of degrees that was
determined earlier when observing the flywheel
grid.
9. Tighten the pump drive gear mounting bolts.
10. Recheck the fuel injection timing. Repeat the
fuel injection timing and adjustment procedures
until the timing is correct.
11. Remove the sticker from the pump drive gear.
12. Remove the “spill-timing” tool.
13. Install the shut-off solenoid.
14. Install the high-pressure fuel injection lines. See
Installation of High-Pressure Fuel Injection
Lines on page 6-10.

6-22
Fuel Injectors FUEL SYSTEM

FUEL INJECTORS Testing of Fuel Injectors

Removal of Fuel Injectors WARNING

1. Close any fuel valves in the fuel supply line. High-Pressure Hazard
2. Clean the area around the fuel injection pump • Avoid skin contact with the
and fuel injectors to keep contaminants from high-pressure diesel fuel spray
entering the engine or fuel system. caused by a fuel system leak such
as a broken fuel injection line.
3. Remove the high-pressure fuel injection lines
High-pressure fuel can penetrate
as an assembly. See Removal of High-Pressure
your skin and result in serious
Fuel Injection Lines on page 6-10.
injury. If you are exposed to high-
4. Remove nut (Figure 6-33, (1)). Remove the pressure fuel spray, obtain
fuel return line (Figure 6-33, (2)) and copper prompt medical treatment.
washer (Figure 6-33, (3)) from the fuel
injectors. See Removal of Fuel Return Line on • Nwver check for a fuel leak with your hands.
page 6-11. Always use a piece of wood or cardboard.
Have your Isuzu Distributor repair the
Note: The fuel injectors used on IDI engines damage.
screw into the cylinder head.
• Failure to comply could result in death or
5. Remove the fuel injectors (Figure 6-33, (4)). serious injury.
1
WARNING
2
To prevent possible eye injury,
always wear safety glasses while
servicing the engine.
3

6 NOTICE
Never use a steel wire brush to clean fuel injectors.
5 Damage to the nozzle and other components is
likely to result.

1. Thoroughly clean the fuel injector nozzle using

clean diesel fuel and a brass wire brush.
K0002213
2. Visually inspect the fuel injectors and nozzle
Figure 6-33 protectors for deposits or damage. Clean, repair
6. Remove the injector nozzle gaskets or replace as necessary.
(Figure 6-33, (5)) and protector Note: Test the fuel injector using an injection
(Figure 6-33, (6)) from the cylinder head. nozzle tester. Operate the tester
following the information provided by the
tester manufacturer. Use clean, filtered
fuel or FIE calibration fluid for the test.

6-23
FUEL SYSTEM Fuel Injectors

3. Using the correct adapter, connect a fuel

injector to a nozzle tester. Aim the fuel injector
into a suitable container to catch the fuel spray
(Figure 6-34).

OFF
P-

OFF
E -
ON AG
-G

K0000581

Figure 6-34
4. Pump the operating lever of the tester slowly,
observing the pressure reading at the point
where the fuel injector begins spraying fuel.
See Test and Adjustment Specifications on
page 6-6 for correct pressure readings.
Note: Opening pressure of a new fuel injector
will be approximately 72.5 psi (0.5 MPa;
5 kgf/cm2) higher than one that has been
operated for five hours or longer.
5. Pump the operating lever slowly to hold the
pressure steady at a point just below the
opening pressure and hold that pressure for five
seconds. Observe the injector to see that it is
sealing properly and is not “dripping.” If fuel
leaks from the return line fitting, check that the
nozzle case nut is tight. Service or replace the
injector if fuel continues to leak from either the
return line fitting or nozzle.
6. Pump the operating lever more rapidly to
repeatedly “pop” the injector and observe the
spray pattern. The pattern should be a very fine
uniform spray. If dripping or an uneven pattern
is seen, service or replace the injector. See
Fuel injector test results on page 6-25.

6-24
Fuel Injectors FUEL SYSTEM
■ Fuel injector test results
A B C D E

Injection pattern

K0001742 K0001744
K0001746
K0001743 K0001745

120 120 120 120 120

0 0 0 0 0

Pressure gauge K0001747 K0001748 K0001749 K0001750 K0001751

reading Gauge needle Gauge needle Gauge needle Although the gauge Pressure does not
fluctuates around fluctuates around stays at a position needle reaches the increase even
the valve opening the valve opening near the valve valve opening when the tester
pressure. pressure. opening pressure. pressure, the lever is operated.
pressure drop is
large.
Although atomized
Atomization is Bar shape with
5° - 10° cone and (burner like shape),
Atomization pattern excessively excessive after Drops.
roughly uniform. the needle does not
one-sided. drops.
pulsate.
Sticking of needle.
Excessively
Normally caused by
Caused by Damage to the damaged or worn
carbon
excessive carbon seat. seat.
contamination of
contamination of Contamination of Contamination of
(Normal, injector is the nozzle tip.
Possible cause the nozzle tip. seat by fine foreign seat by foreign
good) Sometimes caused
Sometimes caused particles. matter.
by flaws in or
by internal Excessively worn Damaged or
damage to the
contamination. seat. broken internal
needle tip.
parts or nozzle
case nut.

Note: If the fuel injector fails any tests, it should be serviced or replaced as necessary. If the pressure is
outside specified limits, adjust the pressure. See Adjusting Fuel Injector Pressure on page 6-27.

6-25
FUEL SYSTEM Fuel Injectors

Disassembly and Inspection of Fuel 2. Place the fuel injector in a soft-jawed vise with
the nozzle pointing up.
Injectors
3. Remove the nozzle case nut.
NOTICE 4. Carefully remove the injector from the vise.
Never use a steel wire brush to clean fuel injectors. 5. Turn the injector over and remove the nozzle
Damage to the nozzle and other components is body, nozzle valve, valve stop spacer, nozzle
likely to result. spring seat, nozzle spring, and shims.
6. Inspect the sealing surfaces (Figure 6-36, (2))
between the valve stop spacer and nozzle body
1. Clean carbon from used injectors using clean for nicks or scratches. Check the contact area
diesel fuel. Hardened deposits or varnish can between the valve stop spacer and the nozzle
be cleaned using a brass wire brush. valve (Figure 6-36, (1)) for scoring or pitting.
Use a magnifying glass to inspect.
1
2 1

2
3

5
6
7
033108-00X

8
Figure 6-36

9 7. Perform a nozzle valve slide test:

1- Wash nozzle body and valve in clean diesel
10 fuel.
K0002214 2- While holding the nozzle body vertical, pull
the nozzle valve about 2/3 of the way out
1 – Return fuel fitting nut
2 – Return fuel fitting
(Figure 6-37).
3 – Injector body 3- Release the valve. It should fall smoothly to
4 – Pressure adjusting shims its seat by its own weight.
5 – Spring
6 – Spring seat
7 – Valve stop spacer
8 – Nozzle valve
9 – Nozzle body
10 – Nozzle case nut
Figure 6-35

033109-00X

Figure 6-37
Replace the fuel injector assembly if it fails any
inspection.

6-26
Fuel Injectors FUEL SYSTEM
Adjusting Fuel Injector Pressure
1
The fuel injectors open when pressure reaches a
2
predetermined pressure threshold. They close
when the pressure is reduced below that threshold.
The pressure threshold can be adjusted by adding 3
or removing shims (Figure 6-38, (4)).

Fuel injector shim Kit 4

Part No. 5-8640-1610-0
(Includes one each of the following shims) 5
6
5-8640-2424-0 0.0039 in. (0.10 mm)
7
5-8640-2425-0 0.0079 in. (0.20 mm)
5-8640-2426-0 0.0118 in. (0.30 mm) 8
5-8640-2427-0 0.0157 in. (0.40 mm)
5-8640-2428-0 0.0197 in. (0.50 mm) 9

5-8640-2429-0 0.0205 in. (0.52 mm)

10
5-8640-2430-0 0.0213 in. (0.54 mm)
K0002214
5-8640-2431-0 0.0220 in. (0.56 mm)
1 – Return fuel fitting nut
5-8640-2432-0 0.0228 in. (0.58 mm)
2 – Fuel return fitting
5-8640-2433-0 0.0315 in. (0.80 mm) 3 – Injector body
4 – Pressure adjusting shims
5 – Spring
6 – Spring seat
7 – Valve stop spacer
8 – Nozzle valve
9 – Nozzle body
10 – Nozzle case nut
Figure 6-38
The injection pressure will change by
approximately 100 - 142 psi (0.69 - 0.98 MPa; 7 -
10 kgf/cm2) for every 0.004 in. (0.1 mm) shim
thickness.
See the parts catalog for available shims.
1. Disassemble the fuel injector assembly. See
Disassembly and Inspection of Fuel Injectors
on page 6-26.
2. Remove or add adjusting shims as needed.
3. Reassemble the fuel injector assembly. See
Reassembly of Fuel Injectors on page 6-28.
4. Retest the fuel injector. See Testing of Fuel
Injectors on page 6-23. If the injector cannot be
adjusted to the appropriate pressure, discard
the fuel injector.

6-27
FUEL SYSTEM Fuel Injectors

Reassembly of Fuel Injectors

1. Secure the injector in a soft-jawed vise with the
nozzle end up.
2. Reinstall the shims, nozzle spring, nozzle
spring seat, valve stop spacer, nozzle valve,
and nozzle body.
3. Reinstall the nozzle case nut. Tighten it to
specification.

Installation of the Fuel Injectors

1. Insert the nozzle gaskets (Figure 6-39, (5)) and
nozzle protector (Figure 6-39, (6)) in the
cylinder head.
2. Reinstall the fuel injector (Figure 6-39, (4)) in
the cylinder head and tighten to specification.
3. Reinstall new copper washers
(Figure 6-39, (3)), high-pressure and return
fuel lines (Figure 6-39, (2)). See Installation of
High-Pressure Fuel Injection Lines on
page 6-10 and Installation of Fuel Return Line
on page 6-11. Tighten fuel line nuts
(Figure 6-39, (1)) to specifications.
4. Prime the fuel system. See Priming the Fuel
System on page 3-13.
5. Operate the engine and check for fuel leaks.

K0002213

Figure 6-39

6-28
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TNV IDI Service Manual

Section 7

COOLING SYSTEM
Page
Before You Begin Servicing ............................................................ 7-3
Introduction...................................................................................... 7-4
Cooling System Diagram................................................................. 7-4
Engine Coolant Pump Components ................................................ 7-5
Engine Coolant System Check........................................................ 7-6
Engine Coolant Pump ..................................................................... 7-6
Disassembly of Engine Coolant Pump ...................................... 7-6
Cleaning and Inspection ............................................................ 7-7
Reassembly of Engine Coolant Pump....................................... 7-8

7-1
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COOLING SYSTEM

This Page Intentionally Left Blank

7-2
Before You Begin Servicing COOLING SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

7-3
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COOLING SYSTEM Introduction

INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the engine coolant
pump.
This engine coolant pump is representative of the engine coolant pumps used on Isuzu C series engines.
For specific part detail, see the parts catalog for the engine you are working on.

COOLING SYSTEM DIAGRAM

4
6

5 K0002046

1 – Cylinder head 4 – Radiator

2 – Thermostat 5 – Coolant recovery tank
3 – Engine coolant pump 6 – Cylinder block
Figure 7-1

7-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Engine Coolant Pump Components COOLING SYSTEM

ENGINE COOLANT PUMP COMPONENTS

1
7 2

3 4

9
11

6
5
8
10
K0001959

1 – Thermostat cover 7 – Engine coolant pump gasket

2 – Thermostat 8 – V-belt
3 – Special O-ring 9 – Engine coolant pump V-pulley
4 – Engine coolant pump 10 – Spacer
5 – Temperature switch 11 – Engine coolant fan
6 – Gasket
Figure 7-2

7-5
COOLING SYSTEM Engine Coolant System Check

ENGINE COOLANT SYSTEM ENGINE COOLANT PUMP

CHECK Disassembly of Engine Coolant
Check the engine coolant system for leakage. Pump
1. With the radiator properly filled, install a cooling Verify the condition of the engine coolant pump
system tester (Figure 7-3, (1)). before disassembling it from the engine. Check the
engine coolant pump shaft bearing for abnormal
noise, sticking, excessive play and water leakage.
Replace the coolant pump if any of these conditions
are present.

CAUTION
Pinch Hazard
1
Carefully rotate the alternator
K0000577AX
toward the cylinder block while
Figure 7-3 loosening the V-belt. Failure to
comply may result in minor or
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05 moderate injury.
kgf/cm²) to the cooling system. If the pressure
reading drops, the engine coolant system is
NOTICE
leaking. Identify the source of the leak and
repair. If the engine coolant pump must be replaced,
replace the engine coolant pump as an assembly
only. Do not attempt to repair the engine coolant
pump or replace individual components.

1. Make sure the engine and engine coolant are

not hot.
2. Before removing the engine coolant pump or
thermostat, it will be necessary to drain the
engine coolant. Drain the coolant into a clean
container if the coolant is to be reused.
Otherwise, properly dispose of the coolant.
• Drain the coolant from the radiator. See steps
1 - 4 in Drain, flush and refill cooling system
with new coolant on page 4-20.
3. Loosen the alternator mounting bolts. Loosen
and remove the V-belt and rotate the alternator
away from the engine and out of the way.
4. Remove the engine coolant fan guard (if
equipped), engine coolant fan (Figure 7-4, (1)),
spacer (Figure 7-4, (2)) and engine coolant
pump V-pulley (Figure 7-4, (3)).

7-6
Engine Coolant Pump COOLING SYSTEM

4
Cleaning and Inspection
■ Temperature switch
3
1. Check for proper operation of the temperature
2
1 switch. Connect a continuity light or ohmmeter
to the temperature switch. Connect one lead to
the terminal of the switch (Figure 7-6, (1)) and
the other lead to the metal portion of the switch
(Figure 7-6, (2)).

3 1
K0001959B

Figure 7-4
5. Disconnect the coolant hoses and the 2
temperature switch lead wire from the engine
coolant pump.
6. Remove the engine coolant pump
(Figure 7-4, (4)). Discard the gasket.
K0000576AX
7. Remove the thermostat cover (Figure 7-5, (1)).
Figure 7-6
2. Place the temperature switch and an accurate
1
thermometer (Figure 7-6, (3)) in engine
coolant.
2 3. Slowly increase temperature of the fluid using
an external heat source.
4. The temperature switch is normal if the
continuity light or ohmmeter indicates continuity
4 when the fluid temperature reaches 225 °F -
3 235 °F (107 °C - 113 °C).

K0001959A

Figure 7-5
8. Remove the thermostat (Figure 7-5, (2)).
Remove the temperature switch
(Figure 7-5, (3)) and gasket (Figure 7-5, (4)).
Discard the gasket.

7-7
COOLING SYSTEM Engine Coolant Pump

■ Thermostat Reassembly of Engine Coolant Pump

1. Check for proper operation of the thermostat. 1. Reinstall the thermostat (Figure 7-9, (1)).
Place the thermostat (Figure 7-7, (1)) and an
accurate thermometer (Figure 7-7, (2)) in warm
water.

2 2
6
1

5
1

K0000578A 4
3 K0001959C
Figure 7-7
Figure 7-9
2. Slowly increase temperature of the water using
an external heat source. 2. Reinstall the thermostat cover (Figure 7-9, (2)).
3. The thermostat is normal if it starts to open at Tighten the thermostat cover bolts.
the temperature value stamped on the flange of 3. Reinstall the temperature switch
the thermostat, and fully opens as the (Figure 7-9, (3)) and a new gasket
temperature of the water is increased. (Figure 7-9, (4)).
4. Position the engine coolant pump on the engine
■ Radiator cap and install a new gasket (Figure 7-9, (6)). Use
1. Check for proper operation of the radiator cap. a new special O-ring (Figure 7-9, (5)) on
Install the radiator cap (Figure 7-8, (1)) on a assembly between the engine coolant pump
cooling system tester. and the joint.

NOTICE
Use a new special O-ring between the engine
coolant pump and the joint. Be sure to use the
special O-ring for each engine model. Although
the O-ring dimensions are the same as a
1 K0000579A
commercially available O-ring, the material is
different.
Figure 7-8
2. Apply 10.8 - 14.8 psi (75 - 105 kPa; 0.75 - 1.05 5. Reinstall the engine coolant pump bolts.
kgf/cm²) to the radiator cap. The radiator cap Tighten the bolts.
relief valve must open within the specified
range. 6. Inspect and reinstall the coolant hoses and the
temperature switch lead wire.

7-8
Engine Coolant Pump COOLING SYSTEM
7. Reinstall the engine coolant pump V-pulley
(Figure 7-10, (3)), spacer (Figure 7-10, (2)) NOTICE
engine coolant fan (Figure 7-10, (1)) and • Only use the engine coolant specified. Other
engine coolant fan guard (if equipped). engine coolants may affect warranty coverage,
cause an internal buildup of rust and scale
4 and/or shorten engine life.
• Prevent dirt and debris from contaminating the
3 engine coolant. Carefully clean the radiator
2 cap and the surrounding area before you
1 remove the cap.
• Never mix different types of engine coolants.
This may adversely affect the properties of the
engine coolant.

K0001959B

Figure 7-10
8. Inspect the condition of the V-belt. There must
be clearance (Figure 7-11, (1)) between the
V-belt and the bottom of the pulley groove. If
there is no clearance (Figure 7-11, (2))
between the V-belt and the bottom of the pulley
groove, replace the V-belt.

2
1

K0000584

Figure 7-11
9. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and adjust cooling
fan V-belt on page 4-15.
10. Reinstall and tighten the drain plug or close the
drain cock in the radiator. Reinstall and tighten
the engine block drain plug or reconnect the
coolant hose at the oil cooler.
11. Fill radiator and engine with engine coolant.
See Drain, flush and refill cooling system with
new coolant on page 4-20.

7-9
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COOLING SYSTEM Engine Coolant Pump

This Page Intentionally Left Blank

7-10
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TNV IDI Service Manual

Section 8

LUBRICATION
SYSTEM
Page
Before You Begin Servicing ............................................................ 8-3
Introduction...................................................................................... 8-4
Oil Pump Service Information.......................................................... 8-4
Lubrication System Diagram ........................................................... 8-5
Checking Engine Oil Pressure ........................................................ 8-6
Trochoid Oil Pump
(3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01) ......................... 8-6
Oil Pump Components .............................................................. 8-6
Disassembly of Oil Pump .......................................................... 8-7
Cleaning and Inspection ............................................................ 8-8
Reassembly of Oil Pump ........................................................... 8-9
Trochoid Oil Pump (3CJ1-SDZP01) .............................................. 8-10
Components ............................................................................ 8-10
Disassembling the Oil Pump ................................................... 8-10
Cleaning and Inspection .......................................................... 8-11
Assembling the Oil Pump ........................................................ 8-12

8-1
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LUBRICATION SYSTEM

This Page Intentionally Left Blank

8-2
Before You Begin Servicing LUBRICATION SYSTEM

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

8-3
LUBRICATION SYSTEM Introduction

INTRODUCTION
This section of the Service Manual describes the procedures necessary to service the trochoid oil pumps.
Note: See Replace engine oil and engine oil filter on page 4-14 for engine oil and engine oil filter
replacement procedures.

OIL PUMP SERVICE INFORMATION

■ Engine oil pressure
Model at rated engine speed at low idle speed
42 - 64 psi 8.8 psi (0.06 MPa; 0.6 kfg/cm2) or
3CH1, 3CJ1
(0.29 - 0.44 MPa; 2.96 - 4.49 kgf/cm2) greater

■ Outer rotor outside clearance

Model Standard Limit Reference page
0.0039 - 0.0063 in. 0.0098 in.
3CJ1-SDZP01
(0.10 - 0.16 mm) (0.25 mm)
Check outer rotor outside
3CH1-NGZG01 clearance on page 8-8
0.0047 - 0.0083 in. 0.0118 in.
3CH1-SDZP01
(0.12 - 0.21 mm) (0.30 mm)
3CJ1-NGZG01

■ Outer rotor side clearance

Model Standard Limit Reference page
0.0019 - 0.003 in. 0.0059 in.
3CJ1-SDZP01
(0.05 - 0.10 mm) (0.15 mm)
Check outer rotor side
3CH1-NGZG01 clearance on page 8-8
0.0008 - 0.0028 in. 0.0047 in.
3CH1-SDZP01
(0.02 - 0.07 mm) (0.12 mm)
3CJ1-NGZG01

■ Outer rotor to inner rotor tip clearance

Model Standard Limit Reference Page
0.0063 in. Outer rotor to inner rotor tip
3CH1, 3CJ1 –
(0.16 mm) clearance on page 8-8

■ Inner Rotor and Gear Boss Clearance (3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01)

Standard
Standard
Item Parts Standard dimension clearance Reference page
clearance
limit
Gear boss 2.0886 - 2.0925 in.
Inside clearance diameter (53.05 - 53.15 mm) 0.012 - 0.020 in. 0.024 in.
of inner rotor 2.1043 - 2.1083 in. (0.3 - 0.5 mm) (0.6 mm) Check inner rotor
Rotor diameter
(53.45 - 53.55 mm) and gear boss
Width across flat 1.9468 - 1.9587 in. clearance on
Inner rotor width of gear boss (49.45 - 49.75 mm) page 8-9
0.008 - 0.024 in. 0.028 in.
across flat
Width across flat 1.9665 - 1.9705 in. (0.2 - 0.6 mm) (0.7 mm)
clearance
of rotor (49.95 - 50.05 mm)

8-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Lubrication System Diagram LUBRICATION SYSTEM

LUBRICATION SYSTEM DIAGRAM

Oil filter

Bypass valve

Fuel
injection pump

Oil pressure
switch

Cylinder body - main gallery

Pressure
regulator valve
Idle gear Camshaft Crank
Oil pump
shaft bearing journal

Rocker arm Crank pin

Oil suction pipe bearing
strainer

Rocker arm

Tappet cam
face

Oil pan
K0001624

Figure 8-1

8-5
LUBRICATION SYSTEM Checking Engine Oil Pressure

CHECKING ENGINE OIL TROCHOID OIL PUMP

PRESSURE (3CH1-NGZG01, 3CH1-SDZP01,
Perform an engine oil pressure check if there is any 3CJ1-NGZG01)
indication of low oil pressure such as the oil
pressure indicator is on or the oil pressure gauge Oil Pump Components
indicates low oil pressure. See Engine oil pressure
on page 8-4 for the engine oil pressure 1
specification. 2
5
1. Disconnect the wire lead from the oil pressure 6
switch or sending unit (Figure 8-2, (1)).

1
4 K0001955A

1 – Crankshaft
2 – Oil pump cover
3 – Oil pressure regulator
4 – Gear case cover
5 – Outer rotor
6 – Inner rotor
K0000020A
Figure 8-3
Figure 8-2
2. Remove the oil pressure switch.
3. Install a mechanical oil pressure gauge in the
oil pressure switch port.
4. Start the engine:
• If the mechanical oil pressure test gauge
indicates good oil pressure, replace the faulty
oil pressure switch or sending unit or faulty
machine oil pressure gauge in instrument
panel.
• If the mechanical oil pressure test gauge
indicates low oil pressure, troubleshoot the
lubrication system to locate the cause of the
low oil pressure. See Troubleshooting Charts
on page 12-7. Repair as necessary.

8-6
 LUBRICATION SYSTEM
Trochoid Oil Pump (3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01)

Disassembly of Oil Pump 2

1
NOTICE 3
If the oil pump must be replaced, replace it as an 4
assembly only. Do not replace individual
components.

1. Remove the engine cooling fan guard (if

equipped), engine cooling fan (Figure 8-4, (1)),
spacer (Figure 8-4, (2)), engine coolant pump
V-pulley (Figure 8-4, (3)) and V-belt.
K0001955B
4
Figure 8-5
3 4. Remove the oil pump cover (Figure 8-5, (1))
2 from the gear case.
1
5. Remove the outer rotor (Figure 8-5, (3)) and
inner rotor (Figure 8-5, (4)) from the gear case
cover.
6. Remove the oil pressure regulator valve
(Figure 8-6, (1)) from the oil pump cover
K0001959B
(Figure 8-6, (2)).

Figure 8-4 2

2. Remove the front crankshaft pulley and gear

case cover. See Removal of timing gear case
cover on page 5-39.
3. Remove the seven oil pump cover screws
(Figure 8-5, (2)).
Note: The oil pump cover screws are installed 1 K0001958A

using a liquid thread lock. It may be Figure 8-6

necessary to used “localized heat” (small
propane torch) and an impact-type
screwdriver to remove these screws.

8-7
LUBRICATION SYSTEM
Trochoid Oil Pump (3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01)

Cleaning and Inspection ■ Outer rotor to inner rotor tip clearance

Wash the oil pump cover, the oil pressure regulator Determine the outer rotor to inner rotor tip
valve, the oil pump cavity and the inner and outer clearance. Insert a feeler gauge between the top of
rotors. Inspect the parts for wear or damage. an inner rotor tooth (Figure 8-8, (1)) and the top of
Replace as necessary. an outer rotor tooth (Figure 8-8, (2)) and measure
the clearance.
Note: If the oil pump cavity is damaged, the gear
case cover must be replaced.

NOTICE
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly.

■ Check outer rotor outside clearance

1. Reinstall the outer and inner rotors. The dots on 1 2 K0001150B
the rotor faces must face “up.” Make sure that
the pilot on the back of the inner rotor fits into Figure 8-8
the bore of the oil pump cavity and the top Record the measurement. See Outer rotor to inner
surface of the inner rotor is flush with the top rotor tip clearance on page 8-4 for the service limit.
surface of the outer rotor.
2. Determine the outside clearance of the outer ■ Check outer rotor side clearance
rotor. Insert a feeler gauge between the outer Determine the side clearance of the outer rotor
rotor (Figure 8-7, (1)) and the gear case oil across the pump cavity. While pressing down on
pump cavity (Figure 8-7, (2)). the outer rotor, measure the depression using a
depth micrometer (Figure 8-9).
1

K0001151A

Figure 8-7
Record the measurement. See Outer rotor outside K0001152B
clearance on page 8-4 for the service limit.
Figure 8-9
Record the measurement. See Outer rotor side
clearance on page 8-4 for the service limit.

8-8
 LUBRICATION SYSTEM
Trochoid Oil Pump (3CH1-NGZG01, 3CH1-SDZP01, 3CJ1-NGZG01)

■ Check inner rotor and gear boss 2. Reinstall the outer rotor in the gear case. The
clearance dot mark on the face of the outer rotor must
face up toward the oil pump cover.
3. Reinstall the inner rotor into the gear case cover
5 with the dot mark also facing up. Make sure that
the pilot on the back side of the inner rotor fits
3 into the bore in the gear case cover and the top
surface of the inner rotor is flush with the top
surface of the outer rotor.
4. Reinstall the oil pressure regulator valve
(Figure 8-11, (4)) into the oil pump cover
1 (Figure 8-11, (5)). Apply LOCTITE? 242 (red) to
6
4 the valve plug, following the manufacturer’s
2 K0000076A instructions.
1 – Crank gear 5. Reinstall the oil pump cover (Figure 8-11, (5)).
2 – Inner rotor Apply LOCTITE 290 (green) or LOCTITE 262
3 – Inside width across flats of inner rotor (red) to the oil pump cover screws. Tighten the
4 – Overall inside diameter of inner rotor pump cover screws to 52 - 70 in·lb (5.9 - 7.9
5 – Overall inside diameter of gear boss N·m, 0.6 - 7.9 kgf·m).
6 – Outside width across flats of gear boss
6. Reinstall the crankshaft pulley and gear case
Figure 8-10 cover. See Removal of timing gear case cover
Record the measurement. See Inner Rotor and on page 5-39.
Gear Boss Clearance (3CH1-NGZG01, 3CH1- 7. Reinstall the engine coolant pump V-pulley
SDZP01, 3CJ1-NGZG01) on page 8-4 for service (Figure 8-12, (3)), spacer (Figure 8-12, (2)),
limits. engine cooling fan (Figure 8-12, (1)) and
engine cooling fan guard (if equipped).
Reassembly of Oil Pump
4
5
1 3
2 2
1

K0001959B

Figure 8-12
3 K0001976A

8. Reinstall the V-belt. Tighten the V-belt to the

Figure 8-11
proper tension. See Check and adjust cooling
1. Lubricate the outer rotor (Figure 8-11, (1)), fan V-belt on page 4-9.
inner rotor (Figure 8-11, (2)) and pump bore in
the gear case cover (Figure 8-11, (3)) with
clean engine oil.

8-9
LUBRICATION SYSTEM Trochoid Oil Pump (3CJ1-SDZP01)

TROCHOID OIL PUMP Disassembling the Oil Pump

(3CJ1-SDZP01) NOTICE
Components If the oil pump must be replaced, replace it as an
assembly only. Do not replace individual
The oil pump on TNM engines is located in the front components.
gear case and is driven by the same gear train that
drives the camshaft and fuel injection pump. You
must remove the front gear case cover to gain 1. Remove the coolant fan guard (if equipped),
access to the oil pump. cooling fan (Figure 8-14, (3)), spacer
(Figure 8-14, (2)), coolant pump V-pulley
(Figure 8-14, (1)) and V-belt.

1 2 3

5 6

4
3

7
2 027029-00X
027030-00X

1 – Body Figure 8-14

2 – Shaft
2. Remove the crankshaft pulley and gear case
3 – Inner rotor
4 – Outer rotor cover. See See Removal of timing gear case
5 – Cover cover on page 5-39.
6 – Drive gear 3. Remove the lubricating oil pump assembly
7 – Pressure regulator valve mounting bolts. Remove the lubricating oil
Figure 8-13 pump assembly (Figure 8-15, (1)) from the
gear case flange (Figure 8-15, (2)).
4. You can remove by hand the lubricating oil
pump cover (Figure 8-13, (5)) and outer rotor
(Figure 8-13, (4)).

027031-00X

Figure 8-15

8-10
Trochoid Oil Pump (3CJ1-SDZP01) LUBRICATION SYSTEM

Cleaning and Inspection ■ Checking outer rotor to inner rotor tip

clearance
Clean the lubricating oil pump, pressure regulator
valve (Figure 8-13, (7)) and rotor inserting portion. Inspect the tip clearance between the outer and
Check the parts for wear or flaw. Replace the parts inner rotors. To inspect this, insert a feeler gauge
with new ones as needed. between the inner rotor tooth tip (Figure 8-17, (1))
and the outer rotor tooth tip (Figure 8-17, (2)), and
measure the clearance.
NOTICE
If any oil pump component clearance exceeds its
limit, the oil pump must be replaced as an
assembly.
1

■ Checking outer rotor outside clearance

Inspect the outside diameter clearance of the outer
rotor. To inspect this, insert a feeler gauge between
the outer rotor (Figure 8-16, (1)) and the lubricating
oil pump body (Figure 8-16, (2)).

Figure 8-17
2 Record the measurement(s). See Outer rotor to
inner rotor tip clearance on page 8-4 for the service
limits.

■ Checking outer rotor side clearance

Figure 8-16 Inspect the side clearance between the lubricating
Record the measurement(s). See Outer rotor oil pump body and the outer rotor. To measure the
outside clearance on page 8-4 for the service limits. side clearance, use a straightedge and feeler
gauge (as shown in Figure 8-18) or a depth
micrometer.

8-11
LUBRICATION SYSTEM Trochoid Oil Pump (3CJ1-SDZP01)

Assembling the Oil Pump

1. Apply clean lubricating oil to the lubricating oil
pump body and inner rotor assembly as well as
to the outer rotor.
2. Insert the outer rotor into the lubricating oil
pump body and inner rotor assembly and install
the cover.
3. Replace the packing with new one.
4. Install the lubricating oil pump assembly to the
gear case flange by tightening the bolts with the
specified torque.
5. Install the gear case cover. For more
Figure 8-18 information, see Installation of gear case cover
(3CJ1-SDZP01) on page 5-62.
Record the measurement(s). See Outer rotor side 6. Install the crankshaft pulley.
clearance on page 8-4 for the service limits.
7. Install the coolant pump V-pulley
■ Checking rotor shaft clearance (Figure 8-20, (1)), spacer (Figure 8-20, (2)),
coolant fan (Figure 8-20, (3)) and fan guard (if
Inspect the rotor shaft clearance. Measure the
equipped).
outside diameter of the rotor shaft
(Figure 8-19, (1)) and the inside diameter of the
1 2 3
cover.
Determine the clearance by subtracting the outside
diameter of the rotor from the inside diameter of the
cover.

Item Specification
0.499 - 0.500 in.
Rotor shaft O.D.
(12.685 - 12.695 mm)
0.500 - 0.501 in.
Cover I.D.
(12.711 - 12.734 mm) 027030-00X

0.000630 - 0.00193 in. Figure 8-20

Clearance
(0.016 - 0.049 mm)
8. Install the V-belt. Adjust the belt to uniform
1 tensile strength in accordance with the
instructions given in See Check and adjust
cooling fan V-belt on page 4-9.

Figure 8-19

8-12
TNV_IDI_ServiceManual_A4.book Page 1 Saturday, July 4, 2015 5:50 PM

TNV IDI Service Manual

Section 9

STARTER MOTOR
Page
Before You Begin Servicing ............................................................ 9-3
Introduction...................................................................................... 9-4
Starter Motor Information ................................................................ 9-4
Starter Motor Specifications ............................................................ 9-5
Starter Motor Troubleshooting......................................................... 9-6
Starter Motor Components .............................................................. 9-7
Starter Motor ................................................................................... 9-8
Removal of Starter Motor .......................................................... 9-8
Disassembly of Starter Motor .................................................... 9-8
Cleaning and Inspection .......................................................... 9-11
Reassembly of Starter Motor................................................... 9-15
Check Pinion Projection Length .............................................. 9-17
No-Load Test........................................................................... 9-17
Installation of Starter Motor ..................................................... 9-18

9-1
TNV_IDI_ServiceManual_A4.book Page 2 Saturday, July 4, 2015 5:50 PM

STARTER MOTOR

This Page Intentionally Left Blank

9-2
Before You Begin Servicing STARTER MOTOR

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

9-3
TNV_IDI_ServiceManual_A4.book Page 4 Saturday, July 4, 2015 5:50 PM

STARTER MOTOR Introduction

INTRODUCTION
This section of the Service Manual covers the servicing of starter motor. For specific part detail, see the
parts catalog for the engine being serviced.

STARTER MOTOR INFORMATION

No load Loaded
Mfg.
Part No. Mfg. Specification Terminal Amperage Terminal Amperage
model No. RPM Torque RPM
voltage draw voltage draw
42 in.-lb
5-8640- 428000- DC 12 V - 1.3 hp 90 A 3000 1240
Denso 11.5 8.0 200 (Max.) (4.7 N·m;
0995-0 2190 (1.0 kW) (Max.) (Min.) (Min.)
0.48 kgf·m)
61 in.-lb
5-8640- 428000- DC 12 V - 1.5 hp 90 A 3000 1130
Denso 11.5 8.7 230 (Max.) (6.9 N·m;
0749-0 1590 (1.1 kW) (Max.) (Min.) (Min.)
0.70 kgf·m)
119 in.-lb
5-8640- 428000- DC 12 V - 1.9 hp 90 A 3000 1000
Denso 11.5 8.5 350 (Max.) (13.5 N·m;
2434-0 3310 (1.4 kW) (Max.) (Min.) (Min.)
1.38 kgf·m)
51 in.-lb
5-8640- DC 12 V - 1.6 hp 90 A 3440 1500
Hitachi S114-940 11.0 8.4 250 (Max.) (5.8 N·m;
2435-0 (1.2 kW) (Max.) (Min.) (Min.)
0.59 kgf·m)

9-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Starter Motor Specifications STARTER MOTOR

STARTER MOTOR SPECIFICATIONS

Part No. 5-8640-0749-0 5-8640-0995-0
Nominal output 1.5 hp (1.1 kW) 1.34 hp (1.0 kW)
Weight 6.6 lb (3.0 kg) 6.3 lb (2.85 kg)
Revolution direction (as viewed from pinion) Clockwise Clockwise
Engagement system Magnetic shift Magnetic shift
Terminal voltage/current 11.5 V/90 A max. 11.5 V/90 A max.
No-load -1
Revolution 3000 min (rpm) 3000 min-1 (rpm)
Terminal voltage/current 8.7 V/230 A 8.0 V/230 A
Loaded Torque 61 in·lb (6.9 N·m; 0.70 kgf·m) 41.7 in·lb (4.7 N·m; 0.48 kgf·m)
-1
Revolution 1130 min (rpm) 1240 min-1 (rpm)
Terminal voltage/current 2.5 V/325 A max. 2.5 V/260 A max.

Stalled 73 in.-lb 43.5 in.-lb

Torque (8.24 N·m; 0.84 kgf·m) (4.9 N·m; 0.5 kgf·m)
minimum minimum
Clutch system Overrunning Overrunning
Pinion projection voltage at 212 °F (100 °C) 8.0 V max. 8.0 V max.
Pinion DP or module/number of teeth M2.54/9 M2.54/9
Application Standard Standard
3.1 - 4.0 lbf 3.1 - 4.0 lbf
Spring force
(13.7 - 17.6 N; 1.4 - 1.8 kgf) (13.7 - 17.6 N; 1.4 - 1.8 kgf)
Brush
Standard 0.55 in. (14 mm) 0.55 in. (14 mm)
Length
Service limit 0.44 in. (11.1 mm) 0.44 in. (11.1 mm)
Solenoid Pull-in coil resistance 0.484 W at 68 °F (20 °C) 0.484 W at 68 °F (20 °C)
switch Hold-in coil resistance 1.055 W at 68 °F (20 °C) 1.055 W at 68 °F (20 °C)
Outside Standard 1.102 in. (28.0 mm) 1.102 in. (28.0 mm)
diameter Service limit 1.063 in. (27.0 mm) 1.063 in. (27.0 mm)
Standard 0.001 in. (0.02 mm) 0.001 in. (0.02 mm)
Commutator Run-out
Service limit 0.002 in. (0.05 mm) 0.002 in. (0.05 mm)
Insulation Standard 0.024 in. (0.6 mm) 0.024 in. (0.6 mm)
depth Service limit 0.008 in. (0.2 mm) 0.008 in. (0.2 mm)

9-5
9-6
Is the shift lever at NO Move shift lever to Is battery fully charged NO ‡&KDUJHRUUHSODFHEDWWHU\
NEUTRAL position? NEUTRAL position. and terminals clean? ‡&OHDQWHUPLQDOV

YES
Engine does not start? Inspect wiring up to solenoid switch
Is starter motor solenoid and repair if necessary.
NO ‡.H\VZLWFK
switch actuating sound
STARTER MOTOR

YES heard? ‡6DIHW\UHOD\

‡6ROHQRLGVZLWFKDVVHPEO\
NO NO ‡(OHFWULFDOFRQQHFWLRQV
Does engine crank? Is starter motor operating? YES

YES
‡$GMXVWSLQLRQSURMHFWLRQOHQJWK
‡,QVSHFWVKLIWOHYHUIRUGHIRUPDWLRQ
Pinion and ring gear NO return spring for fatigue and pinion
meshing normal? for sliding.
YES ‡5HSDLUPHVKLQJEHWZHHQSLQLRQDQG
ring gear or replace as needed.
TNV_IDI_ServiceManual_A4.book Page 6 Saturday, July 4, 2015 5:50 PM

YES
&RQQHFW0WHUPLQDORIVWDUWHU NO ‡,QVSHFWEUXVKDQGUHSODFHLIZRUQ
Pinion roller clutch or motor directly to battery. ‡,IEUXVKHVDUHQRWZRUQUHSODFHDUPDWXUH
reduction gear damaged. Does starter motor operate? assembly.
Inspect and replace.

YES

Solenoid switch assembly  ,IVWDUWHUPRWRUEHFRPHVZHWUHSODFHVROHQRLGVZLWFK

contact defective. Repair assembly even if function is normal.
STARTER MOTOR TROUBLESHOOTING

NO or replace.
(slow revolution) NO
Is revolution normal? Is battery fully charged ‡&KDUJHRUUHSODFHEDWWHU\ If a problem occurs:
and terminals clean? ‡&OHDQWHUPLQDOV Immediately disconnect battery negative terminal.

YES YES

Inspect fuel system. Is the engine oil NO Engine does not stop
Replace engine oil.
viscosity correct? even when key switch is
turned OFF.
YES

Does engine turn when YES Repair or replace 5HSDLURUUHSODFHNH\VZLWFKVWDUWLQJ

starter motor is replaced? starter motor. motor relay or magnetic switch assembly.

Slow Revolution

Inspect condition of engine.

K0000102E
Starter Motor Troubleshooting
TNV_IDI_ServiceManual_A4.book Page 7 Saturday, July 4, 2015 5:50 PM

Starter Motor Components STARTER MOTOR

STARTER MOTOR COMPONENTS

14

13

11 12

3 10
9 15
2 7
17
1 6
5
4

16
19

21
20 18
22
23

24

K0002486

1 – Nut 13 – Reduction gear

2 – Needle bearing 14 – Washer
3 – Pinion housing 15 – Through bolt
4 – Pinion retaining ring 16 – End housing
5 – Pinion stop 17 – Brush plate and holder
6 – Pinion 18 – Field assembly
7 – Shift lever 19 – Armature
8 – Solenoid switch assembly 20 – Bushing
9 – Snap ring 21 – Plate
10 – Washer 22 – Planetary gear (3 used)
11 – Bushing 23 – Washer (3 used)
12 – Intermediate housing 24 – Pinion shaft
Figure 9-1

9-7
STARTER MOTOR Starter Motor

STARTER MOTOR Disassembly of Starter Motor

1. Make alignment marks across all mating joints.
WARNING 2. Disconnect the field wire from the solenoid
Shock Hazard switch (Figure 9-3).
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks,

abrasions, and damaged or corroded
connectors. Always keep the connectors and
terminals clean.
• Failure to comply could result in death or
serious injury.

Note: While starter motor design varies between

models, the basic repair procedures are the
same. The following procedures are typical K0000138

and may differ from the starter being Figure 9-3

serviced.
3. Remove the two bolts or nuts retaining the
Removal of Starter Motor solenoid switch assembly (Figure 9-4, (1)) to
1. Disconnect the battery cables at the battery, the pinion housing. Remove the solenoid switch
negative (-) cable first. assembly and dust covers (Figure 9-4, (2)).
Remove the plunger (Figure 9-4, (4)) and
2. Remove the electrical wires from the solenoid torsion spring (Figure 9-4, (3)) from the pinion
switch assembly. housing.
3. Remove the starter mounting bolts
(Figure 9-2, (1)). Remove the starter motor
from the flywheel housing.

3
2
1
K0000140A

Figure 9-4
K0002126

Figure 9-2

9-8
Starter Motor STARTER MOTOR
4. Remove the two bolts (Figure 9-5, (1)) securing 7. Remove the brush plate and holder
the rear cover (Figure 9-5, (2)) to the brush (Figure 9-7, (1)).
holder assembly (Figure 9-5, (3)).
2 1

3
3
1
K0000142A K0000144A

Figure 9-5 Figure 9-7

5. Remove the two through bolts. Remove the rear 8. Pull the field assembly (Figure 9-7, (3)) off from
cover (Figure 9-5, (2)). the armature assembly (Figure 9-7, (2)).
6. Pull the brush springs up using a brush spring 9. Remove the armature from the intermediate
puller. On the negative (-) side, bring the brush housing.
spring into contact with the side of the brushes 10. Remove the intermediate housing, gear and
to hold the brushes clear of the commutator pinion shaft assembly (Figure 9-8, (4)) from the
surface. On the positive (+) side, remove the pinion housing (Figure 9-8, (3)). Disengage
brushes from the brush holder assembly from the shift lever as it is removed.
(Figure 9-6).
11. Remove the shift lever (Figure 9-8, (2)), pin,
and spacer (Figure 9-8, (1)).

1
2
3

K0000143 4 K0000148A

Figure 9-6 Figure 9-8

9-9
STARTER MOTOR Starter Motor

12. Pull the pinion stop (Figure 9-9, (1)) down to 14. Remove the snap ring (Figure 9-11, (1)).
expose the retaining ring. Using a flat-blade Remove the pinion shaft (Figure 9-11, (5)),
screwdriver, remove the retaining ring planetary gears (Figure 9-11, (6)), washers,
(Figure 9-9, (2)) from the pinion shaft. and reduction gear (Figure 9-11, (4)) from the
intermediate housing (Figure 9-11, (3)).

2 1
K0000151A

7
Figure 9-9
13. Remove the pinion stop (Figure 9-10, (3)), 6
return spring (if equipped), and pinion clutch
assembly (Figure 9-10, (2)), from the pinion
shaft (Figure 9-10, (1)). 5 K0002487

2 Figure 9-11
15. Inspect the intermediate bushing
(Figure 9-11, (2)) and replace if worn or
damaged.
16. Inspect armature bushing (Figure 9-11, (7))
and replace if worn or damaged.

4 3 K0000152B

Figure 9-10

9-10
Starter Motor STARTER MOTOR
Cleaning and Inspection Measure commutator insulation depth
Measure the depth of the insulating material
■ Armature (Figure 9-14, (1)) between commutator segments
(Figure 9-14, (2)). If the depth measures less than
Commutator surface inspection the limit, use a hacksaw blade (Figure 9-14, (3)) to
If the commutator surface is rough, polish the remove the insulating material until the depth is
surface with a #500 to #600 emery cloth. within the limit. See Starter Motor Specifications on
page 9-5 for service limit.
A normal commutator condition is indicated in
(Figure 9-14, (4)). An abnormal commutator
condition is indicated in (Figure 9-14, (5)).

K0000117

Figure 9-12 2
1
Measure commutator outside diameter
Measure the commutator outside diameter.
Replace the armature if the measurement is less
than the limit. See Starter Motor Specifications on 5 4 K0000118

page 9-5.
Figure 9-14

Armature coil continuity test

Check for continuity between the commutator
segments using a multimeter (Figure 9-15). The
multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the armature.
K0000113

Figure 9-13

K0000114

Figure 9-15

9-11
STARTER MOTOR Starter Motor

Armature coil insulation test ■ Field coil

Check for continuity between a commutator
Field coil continuity test
segment and the shaft or armature using a
multimeter (Figure 9-16). The multimeter should Check for continuity between the field coil terminals
not indicate continuity. using a multimeter (Figure 9-18). The multimeter
should indicate continuity.
If the multimeter indicates continuity, replace the
armature. If the multimeter does not indicate continuity,
replace the field coil assembly.

K0000115

Figure 9-16

Measure armature and commutator run-out K0000119

Measure the armature core run-out and the Figure 9-18

commutator run-out using a dial indicator
(Figure 9-17). Replace the armature if either of the Field coil insulation test
measurements is not within specifications. See Check for continuity between either field coil
Starter Motor Specifications on page 9-5 for service terminal and the yoke using a multimeter
limit. (Figure 9-19). The multimeter should not indicate
continuity.
If the multimeter indicates continuity, replace the
field coil assembly.

K0000116

Figure 9-17

K0000120

Figure 9-19

9-12
Starter Motor STARTER MOTOR
Measure brush length Brush spring test
Measure the length of the brush (Figure 9-20). Test the spring force for each brush spring
Replace the brush if the length is less than the limit. (Figure 9-22). Replace the brush spring if the force
See Starter Motor Specifications on page 9-5 for is not within the range. See Starter Motor
service limit. Specifications on page 9-5 for the service limit.

K0000123

K0000121
Figure 9-22

Figure 9-20 ■ Solenoid switch

■ Brush holder If the starter motor becomes wet, replace the
solenoid switch even if the solenoid switch
Brush holder insulation test assembly function is normal.
Check for continuity between each brush holder Shunt coil continuity test
and the base using a multimeter (Figure 9-21). The
Check for continuity between the “S” terminal and
multimeter should not indicate continuity.
the switch body using a multimeter (Figure 9-23).
If the multimeter indicates continuity, replace the The multimeter should indicate continuity.
brush holder.
If the multimeter does not indicate continuity,
replace the solenoid switch.

K0000122

Figure 9-21 K0000124

Figure 9-23

9-13
STARTER MOTOR Starter Motor

Series coil continuity test ■ Pinion clutch assembly

Check for continuity between the “S” and “M”
Pinion clutch assembly inspection
terminals using a multimeter (Figure 9-24). The
multimeter should indicate continuity. Manually rotate the pinion clutch assembly in the
drive direction. It should rotate freely in the drive
If the multimeter does not indicate continuity, direction and is locked by turning it in the opposite
replace the solenoid switch. direction (Figure 9-26). Replace the pinion clutch
assembly if the results are different.

K0000127

K0000125
Figure 9-26
Figure 9-24
Slide the pinion clutch assembly on the shaft
Coil resistance test (Figure 9-27). It should slide smoothly on the shaft.
See Starter Motor Specifications on page 9-5 for Rust, too much grease, or damage could prevent
service limit. the pinion clutch from sliding smoothly. If the pinion
clutch assembly does not slide smoothly, clean the
Contact continuity test shaft and pinion clutch assembly or replace the
Depress the plunger at the bottom of the solenoid damaged component.
switch. Check for continuity between the “B” and
“M” terminals using a multimeter (Figure 9-25).
The multimeter should indicate continuity.
If the multimeter does not indicate continuity,
replace the solenoid switch.

K0000128

Figure 9-27

K0000126

Figure 9-25

9-14
Starter Motor STARTER MOTOR
Reassembly of Starter Motor 2
1. Apply a appropriate starter bendix grease
(obtain locally) to the pinion shaft.
2. Reassemble the reduction gear
(Figure 9-28, (4)), pinion shaft
(Figure 9-28, (5)), planetary gears
(Figure 9-28, (6)), and washers into the
intermediate housing (Figure 9-28, (3)).
Reinstall snap ring (Figure 9-28, (1)).
1
4
4 3 K0000152B

3 Figure 9-29
4. Apply a small amount of high temperature
lithium grease (obtain locally) to the contact
2 surfaces of the shift lever. Reassemble the shift
lever (Figure 9-30, (2)), spacer (if equipped)
1 (Figure 9-30, (1)), and pin.
5. Reinstall the pinion shaft assembly
(Figure 9-30, (4)) in the pinion housing
(Figure 9-30, (3)). Be sure the shift lever
7 properly engages the pinion.

1
6 2
3

5 K0002487

Figure 9-28
3. Reinstall the pinion clutch assembly
(Figure 9-29, (2)), return spring (if equipped)
and pinion stop (Figure 9-29, (3)) onto the
pinion shaft (Figure 9-29, (1)). Reinstall the 4 K0000148A

retaining ring (Figure 9-29, (4)) in the groove in

the pinion shaft. Slide the pinion stop over the Figure 9-30
retaining ring. 6. Apply a small amount of high temperature
lithium grease (obtain locally) to the surface of
the plunger and the hole that engages the shift
lever.
7. Attach the plunger to the shift lever.

9-15
STARTER MOTOR Starter Motor

8. Reinstall the plate onto the intermediate 13. Reinstall the two through bolts and tighten
housing and carefully reinstall the armature securely.
assembly (Figure 9-31, (2)) into the pinion 14. Reinstall the return spring (if equipped)
shaft assembly. (Figure 9-33, (3)) on the solenoid plunger
(Figure 9-33, (4)). Reinstall the solenoid switch
2 1 coil (Figure 9-33, (1)) and dust covers
(Figure 9-33, (2)). Secure with nuts or bolts.

3 4

K0000144A

Figure 9-31 3
2
1
9. Reinstall the field assembly (Figure 9-31, (3)) K0000140A

over the armature assembly and align to the Figure 9-33

pinion housing.
15. Reconnect the wire to the solenoid switch
10. Position the brush springs in brush holders.
assembly. Tighten the nut. Reinstall the cover
Reinstall the brushes in the brush holders.
over the connection.
Reversing the brushes will cause the starter
motor to turn backwards.
11. Carefully reinstall the brush holder
(Figure 9-32, (3)) assembly.
12. Reinstall the rear cover (Figure 9-32, (2)) and
secure with two bolts (Figure 9-32, (1)).

3
1 K0000138

K0000142A
Figure 9-34
Figure 9-32

9-16
Starter Motor STARTER MOTOR
Check Pinion Projection Length No-Load Test
1. Connect the positive (+) lead from a battery to Test the characteristics of the starter motor by
the “S” terminal. performing a no load test.
2. Connect the negative (-) lead to the “M”
terminal. NOTICE
3. Lightly pull the pinion away from the gear The starter motor can be damaged if operated
housing. continuously longer than 10 seconds while
4. Turn the switch ON and measure the pinion performing the no-load test.
moving distance L in the thrust direction
(Figure 9-35). Perform this test within 10
seconds. 1. Secure the starting motor in a vise or other
suitable fixture.
2. Connect an ammeter (Figure 9-37, (1)) in
series between the battery positive (+) terminal
(Figure 9-37, (2)) and the main positive (+)
terminal (Figure 9-37, (3)) on the starter motor.
Note: The ammeter and all wire leads used in
this test must have a capacity equal to or
K0000132
greater than the amperage draw
specification for the starter motor being
Figure 9-35 tested.
See Starter Motor Specifications on page 9-5 for
service limit.
3
5. If the measured L dimension is outside the
standard range, adjust the dust covers to obtain 6 1
the standard range. Dust covers M 8
(Figure 9-36, (1)) are available in 0.020 in. (0.5 2
mm) and 0.031 in. (0.8 mm) thicknesses. 7

1 4 K0002127A

Figure 9-37
3. Connect a wire lead between the mounting
base of the starter motor (Figure 9-37, (4)) and
the battery negative terminal (Figure 9-37, (5)).
4. Connect a voltmeter (Figure 9-37, (7)) to the
battery negative (-) terminal (Figure 9-37, (5))
and the main positive (+) battery terminal
K0000133
(Figure 9-37, (3)) on the starter motor.
Figure 9-36

9-17
STARTER MOTOR Starter Motor

5. Install a switch (Figure 9-37, (6)) in a circuit Installation of Starter Motor

between the battery positive (+) terminal
(Figure 9-37, (2)) and the starter solenoid 1. Reinstall the starter motor to the flywheel
switch terminal (Figure 9-37, (8)) on the starter housing.
motor. 2. Reinstall the starter mounting bolts
6. Use a suitable tachometer to monitor the rpm of (Figure 9-38, (1)). Tighten the bolts to
the starter. specification. See Tightening Torques for
Standard Bolts and Nuts on page 3-24.
7. Turn the switch to the ON position to energize
the solenoid and operate the starter. Monitor 1
the rpm, amperage draw and voltage. For test
specifications, see Starter Motor Information on
page 9-4 for the appropriate starter motor.

K0002126

Figure 9-38
3. Reconnect the electrical wires to the solenoid
switch assembly. Be sure to place the cover
over the battery positive (+) cable connection.
4. Reconnect the battery, negative (-) cable last.

9-18
TNV_IDI_ServiceManual_A4.book Page 1 Saturday, July 4, 2015 5:50 PM

TNV IDI Service Manual

Section 10

ALTERNATOR
Page
Before You Begin Servicing .......................................................... 10-3
Introduction.................................................................................... 10-4
Standard and Optional Dynamo Information ................................. 10-4
Standard and Optional Alternator Information............................... 10-4
Alternator Specifications................................................................ 10-5
Dynamo Specifications.................................................................. 10-5
Alternator Troubleshooting ............................................................ 10-6
Alternator Components ................................................................. 10-7
Alternator Wiring Diagram ............................................................. 10-8
Alternator Standard Output .......................................................... 10-9
Alternator .................................................................................... 10-10
Removal of Alternator............................................................ 10-10
Disassembly of Alternator...................................................... 10-10
Reassembly of Alternator ...................................................... 10-12
Installation of Alternator......................................................... 10-14
Dynamo Component Location..................................................... 10-15
Dynamo Wiring Diagram ............................................................. 10-16
Operation of Dynamo .................................................................. 10-16
Dynamo Standard Output ........................................................... 10-17
Testing of Dynamo ...................................................................... 10-18
Testing Stator Coil Continuity ................................................ 10-18
Testing Stator Coil Short-to-Ground ...................................... 10-18
Testing Dynamo Regulated Output ....................................... 10-18

10-1
TNV_IDI_ServiceManual_A4.book Page 2 Saturday, July 4, 2015 5:50 PM

ALTERNATOR
Dynamo ........................................................................................ 10-18
Removal of Dynamo............................................................... 10-18
Disassembly of Dynamo......................................................... 10-19
Reassembly of Dynamo ......................................................... 10-19
Installation of Dynamo............................................................ 10-20

10-2
Before You Begin Servicing ALTERNATOR

BEFORE YOU BEGIN

SERVICING
Before performing any service procedures within
this section, read the following safety information
and review the Safety section on page 2-1.

10-3
TNV_IDI_ServiceManual_A4.book Page 4 Saturday, July 4, 2015 5:50 PM

ALTERNATOR Introduction

INTRODUCTION
This section of the Service Manual describes the servicing of the dynamos and alternators. Part No. 5-
8640-0240-0 alternator is used in this section to show the service procedures for the representative
alternator. Part No. 5-8640-0284-0 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the parts catalog for the engine you are working on.

STANDARD AND OPTIONAL DYNAMO INFORMATION

Part No. Mfg. Mfg. Part No. Specification
5-8640-0284-0 Kokusan GP8138 DC 12 V - 15 A
5-8640-1047-0 Kokusan GP9191 DC 12 V - 20 A

STANDARD AND OPTIONAL ALTERNATOR INFORMATION

Part No. Mfg. Mfg. Part No. Specification
5-8640-1822-0 Denso 100211-4531 DC 12 V - 40 A
5-8640-0240-0 Denso 101211-1170 DC 12 V - 40 A with pulse
5-8640-2436-0 Denso 101211-2591 DC 12 V - 55 A
5-8640-1999-0 Denso 101211-2951 DC 12 V - 55 A with pulse

10-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Alternator Specifications ALTERNATOR

ALTERNATOR SPECIFICATIONS
Part No. 5-8640-0240-0
Nominal output (13.5 V heat) 40 A
Weight 6.17 lb (2.8 kg)
Revolution direction (as viewed from pulley) Clockwise
Rating Continuous
Battery voltage 12 V
Rated revolution 5000 min-1 (rpm)
Operating range 1350 - 18000 min-1 (rpm)
Grounding characteristics Negative (-) side of circuit
Integrated regulator IC regulator
Outside diameter of pulley 2.724 in. (69.2 mm)
Belt shape Type A

DYNAMO SPECIFICATIONS
Part No. 5-8640-1047-0
Nominal output 20 A
Weight 3.97 lb (1.8 kg)
Revolution direction (as viewed from pulley) Clockwise
Rating Continuous
Battery voltage 12 V
Rated revolution 3500 min-1 (rpm)
Operating range 1400 - 6600 min-1 (rpm)
Grounding characteristics Negative (-) side of circuit
Regulator Current limiter (Part No. 5-8640-2437-0)
A-belt 2.56 in. (65 mm)
Outside diameter of pulley
Special M-belt 2.28 in. (58 mm)
Belt shape Type A or type special M

10-5
10-6
Turn key switch ON. OFF Disconnect harness L terminal Ground drive machine side OFF Replace the battery indicator.
Does battery indicator and IG terminal at alternator L terminal. Does battery Battery indicator is available from
turn ON? indicator turn on? driven machine manufacturer.
ALTERNATOR

ON ON Inspect rotor assembly and

brushes.
Start Engine.

Inspect or replace V-belt.

Battery indicator ON. Inspect alternator.

At idle, does battery Battery indicator flashes. Inspect diode positive (+) side.
indicator turn OFF?
TNV_IDI_ServiceManual_A4.book Page 6 Saturday, July 4, 2015 5:50 PM

Battery indicator
OFF is dim.
Increase engine speed to
1500 rpm. Turn light switch ON.
ALTERNATOR TROUBLESHOOTING

Battery voltage minus

L terminal voltage is Excessive voltage drop between
greater than 0.5 volt. BAT and batt ( + side) terminal.
Does battery indicator Battery indicator With engine idling,
come ON? is dim. measure voltage at L
terminal and at battery.
Battery voltage minus Check condition of L terminal.
L terminal voltage is Inspect diode negative (-) side.
OFF less than 0.5 volt.
With engine running at 1500
rpm, measure voltage at Battery voltage greater
than 15.5 volts. Replace regulator.
battery.

Battery voltage
is between 13 With engine idling, Does battery indicator ON Inspect auxiliary diode.
and 15 volts. turn light switch ON. come ON?

OFF
Notes: Not abnormal.
1. Use a fully charged battery
2. DC voltmeter: 0 to 30 V, 0.5 class
3. The check method is also applicable to the bench test
Alternator Troubleshooting
TNV_IDI_ServiceManual_A4.book Page 7 Saturday, July 4, 2015 5:50 PM

Alternator Components ALTERNATOR

ALTERNATOR COMPONENTS
Part No. 5-8640-0240-0 alternator is used in this section to show the service procedures for the
representative alternator. For specific part detail, see the parts catalog for the engine you are working on.

14
12 13
10 11

8 9
6
5
29
4

7 19
3
2
16 18
1 17
25
15
28
27
26
24
23
22
21
20 K0000255

1 – Nut 16 – Nut
2 – Pulley 17 – Insulation bushing
3 – Collar 18 – Spring (2 used)
4 – Front frame housing 19 – Brush holder
5 – Stator assembly 20 – Rear frame housing
6 – Stud (2 used) 21 – Bolt (2 used)
7 – Front frame housing bearing 22 – Holder
8 – Bearing cover 23 – IC regulator assembly
9 – Bearing cover bolt (4 used) 24 – Bolt (2 used)
10 – Rotor assembly 25 – Bolt
11 – Rear frame housing bearing 26 – Brush (2 used)
12 – Bearing cover 27 – Bolt
13 – Thrust washer 28 – Rear cover
14 – Thrust washer 29 – Bolt (3 used)
15 – Nut (2 used)
Figure 10-1

10-7
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ALTERNATOR Alternator Wiring Diagram

ALTERNATOR WIRING DIAGRAM

IG 1
IG P
B

PI P L
2
F
IC
L
3 3
0.5μF B
4A
E T

5 6 037685-00X00

1 – Key switch 4 – Battery

2 – Charge lamp (3.4 W max.) 5 – Alternator assembly
3 – Load 6 – IC regulator assembly
Figure 10-2

NOTICE NOTICE
Do not short-circuit the charging system between Do not remove the positive (+) battery cable from
alternator terminals IG and L. Damage to the alternator terminal B while the engine is operating.
alternator will result. Damage to the alternator will result.

NOTICE
Do not connect a load between alternator terminals
L and E. Damage to the alternator will result.

10-8
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Alternator Standard Output ALTERNATOR

ALTERNATOR STANDARD OUTPUT

Output current
60

Cold
50

temperature at 77 °F (25 °C)

13.5 V, constant ambient
Hot
40

30

20

10

0 1 2 3 4 5 6 7 8
-1
Alternator speed (× 10³ min )

Figure 10-3

10-9
ALTERNATOR Alternator

ALTERNATOR
4. Remove the nut (Figure 10-4, (2)) from the
WARNING gear case stud. Remove the alternator.
Shock Hazard
• Turn off the battery switch (if
equipped) or disconnect the
negative battery cable before
servicing the electrical system.

• Check the electrical harnesses for cracks,

abrasions, and damaged or corroded 2 1
connectors. Always keep the connectors and K0000264

terminals clean.
Figure 10-4
• Failure to comply could result in death or
serious injury. Disassembly of Alternator
1. Remove the nut (Figure 10-5, (1)) from the
shaft of the rotor assembly. Remove the pulley
Removal of Alternator (Figure 10-5, (2)).
CAUTION
Pinch Hazard
Carefully rotate the alternator
toward the cylinder block while
loosening the V-belt. Failure to
comply may result in minor or
moderate injury.

1. Disconnect the electrical wires from the

alternator.
2. Loosen the V-belt. 2
1 K0000256

3. Remove the V-belt adjuster from the alternator

bolt (Figure 10-4, (1)). Figure 10-5

10-10
Alternator ALTERNATOR
2. Remove the three bolts (Figure 10-6, (1)) 6. Remove the nut (Figure 10-7, (3)) retaining the
retaining the rear cover (Figure 10-6, (2)) to the insulation bushing (Figure 10-7, (4)). Remove
rear frame assembly. the insulation bushing.
7. Remove the two bolts (Figure 10-8, (1)) and
two nuts (Figure 10-8, (2)) securing the rear
frame housing to the front frame housing.
3 1
2

4 2 1
5

K0000257A

Figure 10-6 K0000265A

3. Remove the brush holder (Figure 10-6, (3)). Figure 10-8

Remove the brush springs (Figure 10-6, (4))
8. Using a press, remove the rotor assembly
and brushes (Figure 10-6, (5)).
(Figure 10-9, (1)) from the front frame housing
4. Remove the bolt retaining the regulator (Figure 10-9, (2)) and rear frame housing
assembly (Figure 10-7, (1)) to the holder (Figure 10-10, (1)).
(Figure 10-7, (2)).
3
3
1 1
4
2

2
K100266A

Figure 10-9
K0000258A

Figure 10-7
5. Remove the bolts retaining the holder
(Figure 10-7, (2)) to the rear frame housing.
Remove the holder.

10-11
ALTERNATOR Alternator

9. Remove the stator assembly Reassembly of Alternator

(Figure 10-10, (1)) from the front frame
housing. 1. If removed, reinstall the two thrust washers
(Figure 10-12, (3)) and bearing cover
4 (Figure 10-12, (2)) in the rear frame housing.
Lubricate the outside diameter of a new bearing
(Figure 10-12, (1)). Press the bearing into the
3 rear frame housing.

1 3
2
1

K0000259A

Figure 10-10
10. If it is necessary to replace the bearing
(Figure 10-10, (2)) in the front frame housing, K0000260A

remove the four bolts (Figure 10-10, (3)) Figure 10-12

securing the plate (Figure 10-10, (4)) to the
front frame housing. Remove the plate. Use a 2. If removed, lubricate the outside diameter of a
puller to remove the bearing. Discard the new front frame housing bearing. Press the
bearing. bearing (Figure 10-13, (2)) into the front frame
11. If it is necessary to replace the bearing housing. Reinstall the plate (Figure 10-13, (4))
(Figure 10-11, (1)) in the rear frame housing, to the front housing. Tighten the four bolts
use a puller to remove. Discard the bearing. (Figure 10-13, (3)).
Remove the bearing cover (Figure 10-11, (2))
4
and two thrust washers (Figure 10-11, (3)).

3
2
1
1

K0000259A

K0000260A Figure 10-13

Figure 10-11

10-12
Alternator ALTERNATOR
3. Position the stator assembly (Figure 10-13, (1)) 6. Reinstall the insulation bushing
on the front frame housing studs. (Figure 10-16, (4)) and nut (Figure 10-16, (3)).
4. Lubricate the shaft of the rotor assembly
3
(Figure 10-14, (1)). Press the rotor assembly
into the front frame housing (Figure 10-14, (2)) 1
4
and rear frame housing (Figure 10-14, (3)).

K0000258A

Figure 10-16
K100266A
7. Reassemble the regulator assembly
Figure 10-14 (Figure 10-16, (1)) to the holder
(Figure 10-16, (2)).
5. Align the front frame housing with the rear
8. Reinstall the brush holder (Figure 10-17, (3)),
frame housing. Reinstall the two bolts
springs (Figure 10-17, (4)) and brushes
(Figure 10-15, (1)) and two nuts
(Figure 10-17, (5)).
(Figure 10-15, (2)).
9. Reattach the regulator assembly and holder to
2 the rear frame housing.

3 1
1

4 2
K0000265A 5

Figure 10-15

K0000257A

Figure 10-17

10-13
ALTERNATOR Alternator

10. Reinstall the rear cover (Figure 10-17, (2)) to Installation of Alternator
the rear frame housing with three bolts
(Figure 10-17, (1)). 1. Position the alternator on the gear case.
Loosely reinstall the nut (Figure 10-19, (2)) on
the gear case stud and the V-belt adjuster bolt
(Figure 10-19, (1)).

2 1
K0000264

2
1 K0000256 Figure 10-19
Figure 10-18 2. Reconnect the electrical wires to the alternator.
Tighten the nuts to 15 - 20 in.-lb (1.7 - 2.3 N·m;
11. Reassemble the pulley (Figure 10-18, (2)) and
17 - 23 kgf·m).
nut (Figure 10-18, (1)) to the shaft of the rotor
assembly. Tighten the nut. 3. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and adjust cooling
fan V-belt on page 4-15.
4. Start the engine. Listen for any unusual sounds
from the alternator.

NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.

5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.

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Dynamo Component Location ALTERNATOR

DYNAMO COMPONENT LOCATION

Part No. 5-8640-0284-0 dynamo is used in this section to show the service procedures for the
representative dynamo. For specific part detail, see the parts catalog for the engine you are working on.

2
3
4
7

5
0002140
8 9

6 10

11 12

13

14

K0002140X

1 – Rear cover 8 – Spacer

2 – Nut 9 – Stator assembly
3 – Lock washer 10 – Front bearing (2 used)
4 – Flat washer 11 – Flat washer
5 – Rear bearing 12 – Flywheel assembly
6 – Output wire and connector 13 – Pulley half
7 – Plate 14 – Through bolt
Figure 10-20

10-15
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ALTERNATOR Dynamo Wiring Diagram

DYNAMO WIRING DIAGRAM

5 6

4
2

K0002137X

1 – Dynamo 4 – Charge lamp (3.4 W max.)

2 – Current limiter assembly 5 – Battery
3 – Key switch 6 – Load
Figure 10-21

OPERATION OF DYNAMO
The dynamo consists of a series of permanent magnets that rotate around a stationary stator coil. The
magnets are attached to the flywheel which is rotated via the engine cooling fan drive belt. The resultant
output is an AC (Alternating Current) signal. The AC is converted to DC (Direct Current) by the current
limiter. The current limiter outputs charging DC current to the battery.

10-16
TNV_IDI_ServiceManual_A4.book Page 17 Saturday, July 4, 2015 5:50 PM

Dynamo Standard Output ALTERNATOR

DYNAMO STANDARD OUTPUT

Standard characteristics (12 V)

25

20
Output current (A)

15

10

0
1 2 3 4 5 6 7 × 103

Alternator speed (min-1) K0002138E

Figure 10-22

10-17
ALTERNATOR Testing of Dynamo

TESTING OF DYNAMO DYNAMO

Use a circuit tester or multimeter to perform the
following tests.
Removal of Dynamo

Testing Stator Coil Continuity CAUTION

1. Disconnect the dynamo output wire connector. Pinch Hazard
2. Connect one meter lead to each of the stator Carefully rotate the alternator
wire terminals and read the meter. toward the cylinder block while
loosening the V-belt. Failure to
Results: The meter reading should indicate comply may result in minor or
continuity. If continuity is not indicated, the windings moderate injury.
are open and the stator must be replaced.

Testing Stator Coil Short-to-Ground 1. Disconnect the output wire connector from the
1. Disconnect the dynamo output wire connector. dynamo.
2. Test continuity between each stator wire 2. Loosen the V-belt.
terminal and engine ground. 3. Remove the V-belt adjuster from the dynamo
Results: The meter reading should indicate infinity. bolt (Figure 10-23, (1)).
If the meter reading indicates continuity, the 4. Remove the nut (Figure 10-23, (2)) from the
windings are shorted to ground and the stator must gear case stud. Remove the dynamo.
be replaced.

Testing Dynamo Regulated Output

1. Test and record the battery voltage with the
engine OFF.
2. Start the engine and operate it at normal
operating rpm.
3. Check the battery voltage with the engine
running. 1
2 K0002141X
Results: The meter reading with the engine
running must be higher than with the engine not Figure 10-23
running.
• If results are not correct, test the stator for
continuity and shorts to the ground.
• Check the charging system wiring.
• If no problems are found in previous checks,
replace the IC regulator.

10-18
Dynamo ALTERNATOR
Disassembly of Dynamo 3
1. Remove the rear cover (Figure 10-24, (1)).
2. Remove the nut (Figure 10-23, (2)), lock
washer (Figure 10-24, (3)), and flat washer
(Figure 10-24, (4)).
2
1
1
2
3
4

K0002145X

Figure 10-26

Reassembly of Dynamo
1. Reinstall the rear bearing (Figure 10-26, (3)).
2. Reinstall the stator (Figure 10-26, (1)).
K0002143X
3. Reinstall screws (Figure 10-26, (1)).
Figure 10-24 4. Reinstall the front bearings (Figure 10-27, (5))
and spacer (Figure 10-27, (6)).
3. Remove the through bolt (Figure 10-25, (1)),
pulley half (Figure 10-25, (2)), flywheel 5. Reinstall the flat washer (Figure 10-27, (4)),
(Figure 10-25, (3)), flat washer flywheel (Figure 10-27, (3)), pulley half
(Figure 10-25, (4)), bearings (Figure 10-27, (2), and through bolt
(Figure 10-25, (5)), and spacer (Figure 10-27, (1)).
(Figure 10-25, (6)).

6
6 5
5 4
4 3
3 2
2 1
1

K0002144X

K0002144X
Figure 10-27
Figure 10-25
4. Remove the screws (Figure 10-26, (1)) and the
stator assembly (Figure 10-26, (2)).
5. Remove the rear bearing (Figure 10-26, (3)).

10-19
ALTERNATOR Dynamo

6. Reinstall the flat washer (Figure 10-28, (4)), Installation of Dynamo

lock washer (Figure 10-28, (3)), and nut
(Figure 10-28, (2)). Tighten the nut to the 1. Position the dynamo on the gear case. Loosely
specified torque. reinstall the nut (Figure 10-29, (2)) on the gear
case stud and the V-belt adjuster bolt
7. Reinstall the rear cap (Figure 10-28, (1)). (Figure 10-29, (1)).
1
2
3
4

1
2 K0002141X

Figure 10-29
K0002143X 2. Reconnect the dynamo output wire connector.
Figure 10-28 3. Reinstall the V-belt. Tighten the V-belt to the
proper tension. See Check and adjust cooling
fan V-belt on page 4-15.
4. Start the engine. Listen for any unusual sounds
from the alternator.

NOTICE
Do not operate the engine if the alternator is
producing unusual sounds. Damage to the
alternator will result.

5. Verify that the charge indicator is ON while the

engine is operating. If the charge indicator is
not ON, repair the problem before operating the
engine.

10-20
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TNV IDI Service Manual

Section 11

ELECTRIC WIRING
Page
Electric Wiring Precautions .......................................................... 11-3
Electric Wire Resistance ............................................................... 11-4
Battery Cable Resistance.............................................................. 11-5
Electrical Wire Sizes - Voltage Drop ............................................. 11-6
Conversion of AWG to European Standards................................. 11-7

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ELECTRIC WIRING

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Electric Wiring Precautions ELECTRIC WIRING

ELECTRIC WIRING NOTICE

PRECAUTIONS Reversing the battery cable connections at the
Failure to follow these precautions may result in the battery or on the engine will destroy the SCR diode
failure of an electrical component and the loss of in the current limiter. This will cause the charging
warranty coverage on that item as well as related system to malfunction and may cause damage to
items. Make sure that all users read and the electrical harnesses.
understand these precautions.

NOTICE
Do not reverse the positive (+) and negative (-)
ends of the battery cable. The alternator diode and
stator coil will be damaged.

NOTICE
When the battery indicator goes out, it should not
come on again. The battery indicator only comes
on during operation if the alternator fails. However,
if an LED is used in the battery indicator, the LED
will shine faintly during normal operation.

NOTICE
Make sure that the combined total resistance of the
battery cable in both directions between the starter
motor and the battery is within the value indicated
in the Battery Cable Resistance chart in the Electric
Wiring Section of this manual. The starter motor will
malfunction and fail if the resistance is higher than
the specified value.

NOTICE
Removing the battery cables or the battery while
the engine is operating may cause damage to the
current limiter depending on the electrical
equipment being used. This situation could cause
loss of control of output voltage. The continuous
high voltage of 23 - 24 V (for 5000 min-1 (rpm)
dynamo) will damage the current limiter and other
electrical equipment.

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ELECTRIC WIRING Electric Wire Resistance

ELECTRIC WIRE RESISTANCE

AWG Metric nominal mm² Ohms/foot
20 0.5 0.009967
18 0.8 0.006340
16 1.25 0.004359
14 2 0.002685
12 3 0.001704
10 5 0.001073
8 8 0.000707
6 15 0.000421
4 20 0.000270
2 30 0.000158
1 40 0.000130
0 (1/0) 50 0.000103
00 (2/0) 60 0.000087
000 (3/0) 85 0.000066
0000 (4/0) 100 0.000051

Wiring voltage drop should not exceed 5 % [0.05] × 12 Volts = 0.6 Volts.
Voltage drop = Current [Amps] × Length of wire [Feet] × Resistance per Foot [Ohms]
Example:
Current draw of 100 Amps × 3 feet of 4 AWG wire
100 Amps × 3 Feet × 0.000270 = 0.08 Volts [Voltage drop]

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Battery Cable Resistance ELECTRIC WIRING

BATTERY CABLE RESISTANCE

Maximum total battery cable length
(positive cable + negative cable + a*)
AWG mm² 12 V starter motor output
Less than 2.68 hp (2 kW) Greater than 2.68 hp (2 kW)
m ft m ft
6 15 1.5 4.75 N/A N/A
4 20 2.3 7.4 N/A N/A
2 30 3.8 12.6 2.3 7.5
1 40 4.6 15.3 2.8 9.2
0 (1/0) 50 5.9 19.5 3.5 11.6
00 (2/0) 60 7.0 22.8 4.2 13.7
000(3/0) 85 9.3 30.5 5.6 18.3
0000 (4/0) 100 11.9 39.0 7.1 23.4
00000 (5/0) 125 N/A N/A 8.3 27.3
000000 (6/0) 150 N/A N/A 10.1 33.3

Note:
• Total allowable resistance of the complete battery cable circuit (positive cable + negative cable + a*)
(a*: Resistance () of a battery switch or other electrical equipment having high resistance)
• For starter motors of less than 2.68 hp (2 kW): the total resistance must be less than 0.002 .
For starter motors of greater than 2.68 hp (2 kW): the total resistance must be less than 0.0012 .

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ELECTRIC WIRING Electrical Wire Sizes - Voltage Drop

ELECTRICAL WIRE SIZES - VOLTAGE DROP

Total Length of conductor from source of current to device and back to source (in feet)
current
on circuit 10 15 20 25 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170
in amps.
12 V Wire size (AWG)
5 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
10 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
15 12 10 10 8 8 6 6 6 4 4 2 2 2 2 2 1 1 1 1
20 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
25 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
30 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
40 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
50 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0
60 6 4 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0 4/0
70 6 4 2 2 1 0 2/0 3/0 3/0 4/0 4/0
80 6 4 2 2 1 0 3/0 3/0 4/0 4/0
90 4 2 2 1 0 2/0 3/0 4/0 4/0
100 4 2 2 1 0 2/0 3/0 4/0
24 V
5 18 18 18 16 16 14 12 12 12 10 10 10 10 10 8 8 8 8 8
10 18 16 14 12 12 10 10 10 8 8 8 6 6 6 6 6 6 6 6
15 16 14 12 12 10 10 8 8 6 6 6 6 6 4 4 4 4 4 2
20 14 12 10 10 10 8 6 6 6 6 4 4 4 4 2 2 2 2 2
25 12 12 10 10 8 6 6 6 4 4 4 4 2 2 2 2 2 2 1
30 12 10 10 8 8 6 6 4 4 4 2 2 2 2 2 1 1 1 1
40 10 10 8 6 6 6 4 4 2 2 2 2 1 1 1 0 0 0 2/0
50 10 8 6 6 6 4 4 2 2 2 1 1 0 0 0 2/0 2/0 2/0 3/0
60 10 8 6 6 4 4 2 2 1 1 0 0 0 2/0 2/0 3/0 3/0 3/0 3/0
70 8 6 6 4 4 2 2 1 1 0 0 2/0 2/0 3/0 3/0 3/0 3/0 4/0 4/0
80 8 6 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 3/0 4/0 4/0 4/0 4/0
90 8 6 4 4 2 2 1 0 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0 4/0 4/0
100 6 6 4 4 2 2 1 0 2/0 2/0 3/0 3/0 4/0 4/0 4/0

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Conversion of AWG to European Standards ELECTRIC WIRING

CONVERSION OF AWG TO EUROPEAN STANDARDS

Conductor size Conductor diameter Conductor cross-sectional area
(AWG) (mm) (mm2)
25 0.455 0.163
24 0.511 0.205
23 0.573 0.259
22 0.644 0.325
21 0.723 0.412
20 0.812 0.519
19 0.992 0.653
18 1.024 0.823
17 1.15 1.04
16 1.29 1.31
15 1.45 1.65
14 1.63 2.08
13 1.83 2.63
12 2.05 3.31
11 2.30 4.15
10 2.59 5.27
9 2.91 6.62
8 3.26 8.35
7 3.67 10.6
6 4.11 13.3
5 4.62 16.8
4 5.19 21.2
3 5.83 26.7
2 6.54 33.6
1 7.35 42.4
0 (1/0) 8.25 53.4
00 (2/0) 9.27 67.5
000(3/0) 10.40 85.0
0000 (4/0) 11.68 107.2
00000 (5/0) 13.12 135.1
000000 (6/0) 14.73 170.3
1.1 circular mil (CM)  0.0005067 mm2

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ELECTRIC WIRING Conversion of AWG to European Standards

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TNV IDI Service Manual

Section 12

TROUBLESHOOTING
Page
Special Service Tools.................................................................... 12-3
Troubleshooting By Measuring Compression Pressure ................ 12-4
Compression Pressure Measurement Method ........................ 12-4
Quick Reference Table For Troubleshooting ................................ 12-6

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TROUBLESHOOTING

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TNV_IDI_ServiceManual_A4.book Page 3 Saturday, July 4, 2015 5:50 PM

Special Service Tools TROUBLESHOOTING

SPECIAL SERVICE TOOLS

For measuring compression pressure

Compression gauge Kit
Part No. 5-8640-2422-0

K0000849

12-3
TROUBLESHOOTING Troubleshooting By Measuring Compression Pressure

TROUBLESHOOTING BY 3. Turn off the fuel supply valve in the fuel supply
line. Disconnect the fuel injection stop solenoid
MEASURING COMPRESSION at the connector. Crank the engine for a few
PRESSURE seconds with the stop solenoid disconnected
(no injection state) before installing the
Compression pressure drop is one of major causes compression gauge adapter (Figure 12-1, (1)),
of increasing blow-by gas (engine oil contamination this will expel any residual fuel from the
or increased engine oil consumption as a resultant cylinder.
phenomenon) or starting failure. The compression
pressure is affected by the following factors: 4. Install one injector gasket at the tip end of the
compression gauge adapter. Install the
1. Degree of clearance between piston and compression gauge and the compression
cylinder gauge adapter at the cylinder to be measured.
2. Degree of clearance at intake/exhaust valve 5. Crank the engine until the compression gauge
seat reading is stabilized.
3. Gas leak from nozzle gasket or cylinder head
gasket
The pressure will drop due to increased parts wear.
Pressure drop reduces the durability of the engine.
1
A pressure drop may also be caused by scratched
cylinder or piston by dust entrance from the dirty air
cleaner element or worn or broken piston ring.
Measure the compression pressure to determine
the condition of the engine.

Compression Pressure Measurement K0000801

Method Figure 12-1

1. Warm up the engine. 6. After performing the compression check,

remove the compression gauge and
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine. compression gauge adapter from the cylinder.
See Removal of High-Pressure Fuel Injection Reinstall the fuel injector, high-pressure fuel
injection lines and reconnect the stop solenoid.
Lines on page 6-10. Remove the fuel injector
from the cylinder to be measured. See Removal See Installation of the Fuel Injectors on
of Fuel Injectors on page 6-23. page 6-28 and Installation of High-Pressure
Fuel Injection Lines on page 6-10.
NOTICE 7. Turn on the fuel supply valve and reconnect the
injection pump stop solenoid.
Remove or install the high-pressure fuel injection
lines as an assembly whenever possible. 8. Prime the fuel system. Check for leaks. Test the
Disassembling the high-pressure fuel injection engine.
lines from the retainers or bending any of the fuel
lines will make it difficult to reinstall the fuel lines.

12-4
TNV_IDI_ServiceManual_A4.book Page 5 Saturday, July 4, 2015 5:50 PM

Troubleshooting By Measuring Compression Pressure TROUBLESHOOTING

■ Standard compression pressure
Engine compression pressure list (reference value)

Compression pressure at 250 min-1 (rpm)

Engine model Deviation between cylinders
Standard Limit
470 ± 15 psi 370 ± 15 psi
3CJ1
(3.24 ± 0.1 MPa; 33 ± 1 kgf/cm²) (2.55 ± 0.1 MPa; 26 ± 1 kgf/cm²) 29 to 43 psi
498 ± 15 psi 399 ± 15 psi (0.2 to 0.3 MPa; 2 to 3 kgf/cm²)
3CH1
(3.43 ± 0.1 MPa; 35 ± 1 kgf/cm²) (2.75 ± 0.1 MPa; 28 ± 1 kgf/cm²)

■ Engine speed and compression pressure (use for reference)

3CH1
569 psi
3.92 MPa
(40 kgf/cm2)
Compression pressure

498 psi
3.43 MPa
(35 kgf/cm2)

427 psi
2.94 MPa
(30 kgf/cm2)
3CJ1
356 psi
2.45 MPa
(25 kgf/cm2)

285 psi
1.96 MPa
(20 kgf/cm2)

200 250 300 350 400

Engine speed (min-1) K0001915-01

Figure 12-2

12-5
TNV_IDI_ServiceManual_A4.book Page 6 Saturday, July 4, 2015 5:50 PM

TROUBLESHOOTING Quick Reference Table For Troubleshooting

■ Measured value and troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.

No. Item Cause Corrective action

Clogged element Clean the element
1 Air cleaner element Broken element
Replace the element
Defect at element seal portion
2 Valve clearance Excessive or no clearance Adjust the valve clearance
3 Valve timing Incorrect valve clearance Adjust the valve clearance
Replace the gasket
4 Cylinder head gasket Gas leak from gasket Retighten the cylinder head bolts to the
specified torque
Intake/exhaust valve Sticking valve Replace the intake/exhaust valve
5 Gas leak due to worn valve seat
Valve seat Lap the valve seat
or foreign matter trapped in valve
Piston
Gas leak due to scratching or
6 Piston ring Perform honing and use an oversized part
wear
Cylinder

QUICK REFERENCE TABLE FOR TROUBLESHOOTING

The following table summarizes the general trouble symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a serious problem so as not to shorten the engine service
life.

12-6
Troubleshooting Charts TNV IDI Service Manual TROUBLESHOOTING
Troubleshooting Charts
Insufficient Poor
Trouble symptom Starting Engine Engine Air
engine exhaust Engine oil
problem surging coolant intake
output color
Engine
Exhaust During
starts but
color work
stops soon
Exhaust
smoke Corrective action Reference page

Cause

Engine does not start

None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work operation
Excessive engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive oil consumption
Dilution by diesel fuel
Oil with water
Low oil pressure
Excessive blow-by gas
Overheat
Low water temperature
Pressure drop
Pressure rise
Exhaust temperature rise
Improper intake/exhaust valve See Measuring and Adjusting Valve
O O O O O O Adjust the valve clearance
clearance Clearance on page 5-33.
Compression leakage from valve See Valve face and valve seat on
O O O O O O O O Lap the valve seat
seat page 5-27.
Correct or replace intake/exhaust See Inspection of intake and exhaust
Intake/exhaust valve seizure O O O O O O O O O O O
valve valves on page 5-26.
See Disassembly of Cylinder Head on
Cylinder head gasket blowout O O O Replace the gasket
page 5-21.
See Reassembly of cylinder head on
Seized or broken piston ring O O O O O O O O O O O O Replace the piston ring
page 5-30.
Perform honing and use oversize
Worn piston ring, piston or cylinder O O O O O O O See Honing and Boring on page 5-54.
parts
See Inspection of Crankshaft and
Seized crankpin metal or bearing O O O O O O O Repair or replace
Camshaft Components on page 5-47.
Improper arrangement of piston ring See Reassembly of pistons on
O O O O Correct the ring joint positions
gaps page 5-56.

Engine system
See Reassembly of pistons on
Reverse assembly of piston rings O O O O Reassemble correctly
page 5-56.
See Inspection of Crankshaft and
Worn crankpin and journal bearing O O O O O O Measure and replace
Camshaft Components on page 5-47.
See Torque for Bolts and Nuts on
Loose connecting rod bolt O O O Tighten to the specified torque.
page 5-15.
Foreign matter trapped in See Disassembly of Cylinder Block
O O O O Disassemble and repair
combustion chamber Components on page 5-38.
See Checking timing gear backlash
Excessive gear backlash O Adjust gear meshing
on page 5-39.
See Inspection of valve guides on
Worn intake/exhaust valve guide O O O Measure and replace
page 5-26.

12-7
TROUBLESHOOTING Troubleshooting Charts

Insufficient Poor
Trouble symptom Starting Engine Engine Air
engine exhaust Engine oil
problem surging coolant intake
output color
Engine
Exhaust During
starts but
color work
stops soon
Exhaust
smoke Corrective action Reference page

Cause

Engine does not start

None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work operation
Excessive engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive oil consumption
Dilution by diesel fuel
Oil with water
Low oil pressure
Excessive blow-by gas
Overheat
Low water temperature
Pressure drop
Pressure rise
Exhaust temperature rise
See Check and adjust the governor
Governor adjusted incorrectly O O O O O Make adjustment lever and engine speed control on
page 4-15.

Engine
system
Improper open/close timing of intake/ See Measuring and Adjusting Valve
O O O O O O Adjust the valve clearance
exhaust valves Clearance on page 5-33.
See Disassembly of Engine Coolant
Excessive radiator cooling O O O Replace thermostat
Pump on page 7-6.
See Disassembly of Engine Coolant
Replace thermostat or check for
Insufficient radiator cooling O O O Pump on page 7-6. or Check and
loose fan belt
adjust cooling fan V-belt on page 4-15
Check water leakage from engine See Engine Coolant System Check
Insufficient engine coolant level O O O
coolant system on page 7-6.
See Disassembly of Engine Coolant
Cracked water jacket O O O Repair or replace
Pump on page 7-6.
See Check and adjust cooling fan V-

Engine coolant system

Stretched fan belt O O O Adjust the belt tension
belt on page 4-9.
See Disassembly of Engine Coolant
Defective thermostat O O O O Check or replace
Pump on page 7-6.
See Engine Oil Specifications on
Incorrect engine oil O O O O O O Use correct engine oil
page 3-14.
See Disassembly of Oil Pump on
Engine oil system leakage O O Repair
page 8-7.
Insufficient delivery capacity of See Disassembly of Oil Pump on
O Check and repair
trochoid pump page 8-7.
See Replace engine oil and engine oil
Clogged engine oil filter O O Clean or replace
filter on page 4-14.
See Disassembly of Oil Pump on
Defective pressure regulating valve O Clean, adjust or replace

Engine oil system

page 8-7.
Insufficient engine oil level O O Add correct engine oil See Adding Engine Oil on page 3-15.
See Checking Engine Oil on
Overfilled engine crankcase O Check engine oil
page 3-15.

12-8
Troubleshooting Charts TROUBLESHOOTING

Insufficient Poor
Trouble symptom Starting Engine Engine Air
engine exhaust Engine oil
problem surging coolant intake
output color
Engine
Exhaust During
starts but
color work
stops soon
Exhaust
smoke Corrective action Reference page

Cause

Engine does not start

None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work operation
Excessive engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive oil consumption
Dilution by diesel fuel
Oil with water
Low oil pressure
Excessive blow-by gas
Overheat
Low water temperature
Pressure drop
Pressure rise
Exhaust temperature rise
Too early timing of fuel injection See Checking and Adjusting Fuel
O O O Check and adjust
pump Injection Timing on page 6-17.
See Checking and Adjusting Fuel
Too late timing of fuel injection pump O O O O Check and adjust
Injection Timing on page 6-17.
See Diesel Fuel Specifications on
Incorrect diesel fuel O O O O O O Use correct fuel oil
page 3-8.
See Drain water separator on
Water in fuel system O O O O O O O Draining the fuel filter
page 4-10.
See Drain water separator on
Clogged fuel filter O O O Clean or replace
page 4-10.
See Priming the Fuel System on
Air in fuel system O O O Bleed the air
page 3-13.
See Check and replace fuel hoses
Clogged or cracked fuel line O O O Clean or replace and engine coolant hoses on
page 4-23.

Fuel system
Insufficient fuel supply to fuel Check the fuel tank cock, fuel See the appropriate procedure in
O O O
injection pump filter, fuel line, and fuel feed pump Periodic Maintenance on page 4-1
Uneven injection volume from fuel See Testing of Fuel Injectors on
O O O O O O O O O Check and adjust
injection pump page 6-23.
See Testing of Fuel Injectors on
Excessive fuel injection volume O O O O O O O Check and adjust
page 6-23.
Poor spray pattern from fuel injection See Testing of Fuel Injectors on
O O O O O O O O O Check and adjust
nozzle page 6-23.
Foreign matter trapped in the
See Fuel System Components on
Priming failure O valve inside the priming pump
page 6-9.
(disassemble and clean)
Clogged strainer at feed pump inlet O Clean the strainer See Drain fuel tank on page 4-13.

12-9
TROUBLESHOOTING Troubleshooting Charts

Insufficient Poor
Trouble symptom Starting Engine Engine Air
engine exhaust Engine oil
problem surging coolant intake
output color
Engine
Exhaust During
starts but
color work
stops soon
Exhaust
smoke Corrective action Reference page

Cause

Engine does not start

None
Little
Much
Ordinary
White
Black
White
Black
High knocking sound during combustion
Abnormal engine sound
Uneven combustion sound
During idling
During work operation
Excessive engine vibration
Difficulty in returning to low speed
Excessive fuel consumption
Excessive oil consumption
Dilution by diesel fuel
Oil with water
Low oil pressure
Excessive blow-by gas
Overheat
Low water temperature
Pressure drop
Pressure rise
Exhaust temperature rise
See Clean air cleaner element on
Clogged air filter O O O O O Clean air filter
page 4-16.
Engine used at high temperatures or Study output drop and load
O O O O O
at high altitude matching

Air/exhaust
gas system
Clogged exhaust pipe O O O O Clean exhaust pipe
Starting motor defect O Repair or replace stater motor See Starter Motor on page 9-8.
See Removal of Alternator on
Alternator defect O Repair or replace alternator page 10-10. or Removal of Dynamo
on page 10-18
Open-circuit in wiring O Repair open circuit

Electrical system
Battery voltage drop O Inspect and change the battery. See Check battery on page 4-12.

12-10
Published: July., 2015 All rights reserved.

Tier 4
WORKSHOP MANUAL
IDE-2399A
Issued by ISUZU MOTORS LIMITED
Service Group
Off-highway Powertrain Operations Dept.
6-26-1, Minami-oi, Shinagawa-ku, Tokyo, 140-8722, Japan

0-xxx
 ENGINE
Tier 4

WORKSHOP MANUAL 3CH1/3CJ1

IDE-2399A