WORKSHOP MANUAL 2011-2014MY TF SERIES ENGINE 4JK1/4JJ1 MODELS SECTION 6 “JZ cmc CHEVROLET Lile Cycle Business Promotion DeptENGINE MECHANICAL (4JK1/4JJ1) 6A-1 SECTION 6A ENGINE MECHANICAL (4JK1/4JJ1) TABLE OF CONTENTS ISUZUIGM DIESEL ENGINE (4JK1/4JJ1). 6A Inspection. 6A.50 Service Precautions 6A Installation 6A.50 Trouble Shooting 6A Torque Specifications. 6A-52 Main Data and Specifications. 6A13 Exhaust Manifold Special Tools... seonnnnnnnnnesssns BANG (High Output Euro4 Specification) .....nne BASS Engine Assembly. 6A-15 ‘Components. 6A-53 Removal.. oo oo 6A15 ReMOVAl rr oo snes CABO Installation 6A-18 Inspection. 6A-54 ‘Special Tools. 6A-20 Installation 6A54 Engine MOUnt ...nnnnnnnnnnnnnnnnnnene OBL Torque Specifications....nnnnninnnnnnnnees OSB ‘Components. 6A21 Timing Gear Train 6A-57 Removal . oe oe 6A22 ‘Components. 6A-57 Installation 6A.22 Removal 6A-58 Torque Specifications. 6-23 Inspection. 6A-60 Cylinder Head Cover 6A.24 Installation 6A6t ‘Components. 6A24 Torque Specifications. GA-64 Removal 6A-25 Camshaft Assembly 6A-65 Installation 6.26 Components. 6A-65 Intake Manifold... sn 6A-28 Removal rr as sees BABB ‘Components (Standard Output) 6A.28 Inspection. 667 ‘Components (High Output) 6.29 Installation snes 66D Removal 6A-30 Torque Specifications, 6A71 Installation 6A-32 Valve Stem Seal and Valve Spring 6a72 ‘Torque Specifications. nee BABE ‘Components. - OAT2 Turbocharger and Exhaust Manifolé Removal 6A-73 (Standard Output)... eam seve GAB Inspection rene mn OATS ‘Components. 6A-35 Installation 6A-75 Removal 6A-36 ‘Special Tools. 6A-76 Inspection. 6A-38 Cylinder Head. 6A77 Installation 6A39 ‘Components. 6A-77 ‘Torque Specifications. 6a42 Removal 6A77 ‘Turbocharger (High Output) 6a43 Disassembly. GA-86 ‘Components. 6A.43 Inspection... sn sone: BABB Removal 6A44 Reassembly 6A-92 Inspection .nnnnnnenne snr: CAS Installation o seonnnnnnnnn CABS Installation 6-46 Torque Specifications, 6A-107 Torque Specifications. nee GABB ‘Special Tools, : 6A-107 Exhaust Manifold Piston and Connecting Rod... 64-108 (High Output Euro3 Specification) 6a4g ‘Components. 6A-108 Component... cama seve GAAS Removal 6108 Removal 6A-50 Disassembly. 6A-1096A-2 ENGINE MECHANICAL (4JK1/4JJ41) Reassembly. Installation ‘Torque Specifications. Special Tools. Fiywheel ‘Components. Removal . Inspection Installation ‘Torque Specifications. ‘Special Tools. Gear Case Assembly... ‘Components. Removal Installation Torque Specifications. Crankshaft Front Oil Seal ‘Components. Removal . Installation Torque Specifications... ‘Special Tools. Crankshaft Rear Oil Seal ‘Components. Removal Installation ‘Special Tools. Crankshaft, ‘Components. Removal Disassembly. Reassembly, Inspection. Installation ‘Torque Specifications. Cylinder Block ‘Components. Removal Inspection. Installation Lubrication System: Service Precautions Functional Check ii Filter Cartridge ‘Components. Removal Installation Special Tools. ii Filter Assembly and Oil Cooler. ‘Components. BA114 BAN15 6AAI7 BANI7 A118 A118 A118 6A-120 6A-120 6A-122 BA-122 6A-123 6A-123 BAN24 6A-125 BAAQT 6A-128 GA-128 6A-128 BA-129 6A-130 6A-130 6A-131 6A-131 GA-132 6A-132 6A-133 A134 BA-134 6A-135 6A-136 GA-136 6A-137 A141 6A144 BA-145 BA-145 A145 BA-146 A147 BA-149 6A-149 6A-150 6A-152 6A-152 GA-152 6A-152 BA-153 6A-154 BA-154 Removal Installation Crank Case and Oil Pan ‘Components. Removal Disassembly. Reassembly . Installation Torque Specifications. il Pump ‘Components. Removal Disassembly. Reassembly Inspection: Installation Oil Pressure SW ‘Components. Removal Inspection. Installation Circuit check, Air Cleaner Element Removal Cleaning Installation 6A-154 GA-155 6A-158 6A-158 6A-159 6A-160 6A-160 6A-161 6A-163, BATES 6A-164 on BAN6S 6A-165, 6A-166, 6A-166 6A-167 6A-170 6A-170 o6AATA 6A-171 wn 6AATA 6A-171 6A-172 on BAAT2 6A-172 on 6ANT2ENGINE MECHANICAL (4JK1/4JJ1) 6A-3 ISUZU DIESEL ENGINE (4JK1/4JJ1) Service Precautions Matters that maintenance To prevent damage to the engine and ensure reliability of its performance, pay attention to the following in ‘maintaining the engine: ‘+ When lifting up or supporting the engine, do not apply a jack on the oil pan. When taking down the engine on the ground, do not make the bearing surface of the oil pan touch the ground directly. Use a wooden frame, for ‘example, to support the engine with the engine foot and the flywheel housing. Because there is only a small clearance between the oil pan and the oil pump strainer, it can damage the oil pan and the oil strainer. ‘+ When the air duct or air cleaner is removed, cover the air intake opening to prevent foreign matter from getting into the cylinder. If it gets contaminated, it can considerably damage the cylinder and others while the engine is operating ‘* When maintaining the engine, never fail to remove the battery earth cable. If not, it may damage the wire harness or electrical parts. If you need electricity on for the purpose of inspection, for instance, watch out for short circuits and others. ‘+ Apply engine oil to the sliding contact surfaces of the engine before reassembling it. This ensures adequate lubrication when the engine is first started, * When valve train parts, pistons, piston rings, connecting rods, connecting rod bearings or crankshaft journal bearings are removed, put them in order and keep them. ‘+ When installing them, put them back in the same location they were removed from. ‘* Gaskets, oil seals, O-rings, etc. must be replaced with new ones when the engine is reassembled. + As for parts where a liquid gasket is used, remove an old liquid gasket completely and clean it up thoroughly so that no oil, water or dust is clinging to them, Then, apply the designated liquid gasket to each place anew before assembly. require attention in terms of ‘+ Surfaces covered with liquid gasket must be assembled within 5 minutes of gasket application, If more than 5 minutes has elapsed, remove the existing liquid gasket and apply a new liquid gasket * When assembling or installing parts, fasten them with the prescribed tightening torque so that they are installed property. Matters that require attention in specifically dealing with this engine. Holes or clearances in the fuel system, which serve as ‘a passage of fuel, including the inside of the injector, are made with extreme precision. For this reason, they are highly sensitive to foreign matter and, if it gets in, it can lead to an accident on the road, for instance; thus, make sure that foreign matter is prevented from getting in, When servicing the fuel system, every precaution must be taken to prevent the entry of foreign material into the system, ‘+ Before beginning the service procedure, wash the fuel line and the surrounding area, ‘+ Perform the service procedures with clean hands. Do not wear work gloves. ‘+ Immediately after removing the fuel hose and/or fuel pipe, carefully tape vinyl bags over the exposed ends of the hose or pipe. ‘+ If parts are to be replaced (fuel hose, fuel pipe, etc.) do not open the new part packaging until installation, Work procedure ‘+ The fuel opening must be quickly sealed when removing the fuel pipe, injection pipe, fuel injector, fuel supply pump, and fuel ral ‘+ The eyebolts and gasket must be stored in a clean Parts box with a lid to prevent adhesion of foreign matter. ‘+ Fuel leakage could cause fires. Therefore, after finishing the work, wipe off the fuel that has leaked out and make sure there is no fuel leakage after starting the engine.6A-4 ENGINE MECHANICAL (4JK1/4JJ1) How to read the model (This illustration is 4JK1 engine) J 4JK1 = g 20 Ol |S \\ OO © ©) LI Legend 1. Engine Model (Stamped) 3. Front 2. Engine Number (Stamped) Electronic engine control The cylinder head is aluminum-alloy and there are 4 With the control unit, the range from injection to air valves per cylinder. The angular tightening method of intake/exhaust, including fuel injection quantity, injection intake air restriction, EGR, and idling rpm, is ‘The piston is aluminum-alloy and a thermal flow piston with a strut cast, while the combustion chamber is a round reentrant type. the cylinder head bolt further increases reliability and durability.ENGINE MECHANICAL (4JK1/4JJ1) 64-5 EGR system Based upon data, including water temperature, engine speeds or engine loads, it is controlled via Engine Control Module (ECM) to purify exhaust by recycling part of it. Its main components include an EGR valve, an EGR cooler and various sensors. Connecting rod cap bolt The angular tightening method of the connecting rod cap bolt further increases reliability and durability. Fuel rail-type electronic control injection system The fuel rail-type electronic control injection system is, composed of a fuel supply pump that sets the target pressure of high-pressure fuel and supply it, a fuel rall thal measures such high-pressure fuel and a fuel injector that tums it into a fine spray and injects it. Each is controlled via ECM based upon various signals, while injection timing or fuel injection quantity is controlled under every possible driving condition Fuel injector The fuel injector is a 6-hole nozzle that adjusts fuel injection quantity or injection timing by opening or closing an electromagnetic valve on the head of the fuel, injector. ECM corrects the disper between fuel injector according to ID code data in memory. At the replacement of fuel injector, ID code data should be stored in ECM. Fuel filter with sedimenter Itis a fuel filter with sedimenter that gets rid of water by making use of the difference in specific gravity between, light oil and water, which comes with an indicator that notifies you that its filled with water. Preheating system ‘The preheating system consists of the ECM, the glow relay, glow plugs and the glow indicator lamp. The preheating system is operated when the engine coolant temperature is low, and makes the engine easy to start Lubrication system Itis an oll fiter with full-flow bypass, which uses a water-cool oil cooler and oil jet to cool the piston. Functional inspection Inpection/agjust ment of valve clearance 1. Inspection of valve clearance Remove the fuel injector harness assembly. © Remove the leak off hose. + Remove the cylinder head cover. * Rotate the crankshaft to make the No.1 cylinder meet the compression top dead center (TDC). Legend i 4, Toc6A-6 ENGINE MECHANICAL (4JK1/4JJ1) = Insert 2 0.15 mm (0.006 in) thickness gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm. Valve clearance mm (i) Intake valve 0.45 (0.006) Exhaust valve (0.15 (0.006) 3 S Note: Adjust while cold. 2. Adjustment of valve clearance + Loosen each adjusting screw of the rocker arm roo completely. Legend 1. Cam; Exhaust 2. Cam; Intake 3. Roller; Intake 4, Roller; Exhaust Tightening torque: Rocker arm adjustment screw nut 48 Nem (1.8 kg-m /13 lb-ft) Adjustment table Cylinder No. | 1 2 3 4 weeyement IN| EX] IN Lex | IN Ex |W | Ex No. 1 cylinder Compression |O | O |O ° Legend Tc 1. Screwdriver No.4 eylinder 2. Ring Spanner Compression x|x} |x} x 3. Valve Clearance Adjust Nut Wrench TDC ‘Special too! Valve clearance adjust nut wrench: 5-8840-2622-0 © Insert 2 0.15 mm (0.006 in) thickness gauge between the roller of the rocker arm and the camshaft to tighten up the adjusting screw of the rocker arm. When the movement of the thickness gauge becomes tight, fasten the adjusting screw nut of the rocker arm. ‘Ifthe No.1 cylinder is the compression TDC, adjust a valve clearance with © mark given on the table and if the No. 4 cylinder is the compression TDC, adjust that with » mark. ‘= Install the cylinder head cover. Refer to "Cylinder Head Cover.” ‘= Install the leak off hose. ‘Install the fuel injector hamess assembly. Compression pressure inspection = Warm up the engine. ‘+ Disconnect the negative battery cable.