Copyright ©

SERVICE MANUAL
4JJ1
ISUZU ENGINE

Copyright © 2006 CNH France S.A.

Printed in France
CNH Lep 87606795A November 2006
 Copyright ©

Lep 9-94200EN Issued 11/06

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General Information
General Information
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 0A-2
Reading the Model. . . . . . . . . . . . . . . . . . . . . . . 0A-6
General Information . . . . . . . . . . . . . . . . . . . . . . 0A-6
General information OA-2 Copyright ©
General Information
Service Precautions
In order to carry out work safely
1. Always use an engine stand when taking the
engine down from the vehicle.
Do not place the engine directly onto the ground, or
place in a manner that interferes with the oil pan.
2. If you are working together with others, always pay
attention to each other's safety.
3. If you are repairing any part of the electrical
system, always remove the minus side cable from
the battery terminal before starting work. If you are
removing the battery cover, always remove the
cover in a place that is away from sources of fire/
heat.

WSHK0190

6. All regular tools, gauges and special tools should

be regularly inspected, and prepared before
starting work. Do not use bent spanners, hammers
with damaged edges, chipped chisels, or any other
faulty or damaged tools.

4. Do not perform painting work or leave the engine

running for long periods of time in an enclosed or
badly ventilated indoor workshop.
5. Always use the correct specialized tool indicated in
the instructions. Using the incorrect tool may cause
damage to the parts or injury to the person using
the tool.

7. Always pay close attention to safety and handling

requirements when using grinders, cranes,
welders, and other such equipment.
Moreover, always wear the correct protective
garments and use the necessary safety tools for
the job in hand.
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WSHK0191 WSHK0192

8. Always check that there are no fuel leaks when

performing maintenance work on the fuel system. Replacement parts and part numbers.
(It may cause a fire.) 1. Always replace packing, oil seals, o-rings, caulking
lock nuts, folding lock plates, split pins and other
such parts with brand new parts.
2. The parts numbers contained in this manual may
not represent the supply condition of the parts, and
the part numbers may be changed due to revisions.
Therefore, parts should always be checked against
a parts catalogue before use.

Liquid gasket
1. Each time you disassemble parts that use liquid
gasket, completely remove the old gasket residue
from each of the parts and matching sections using
a scraper, then clean each of the parts to
completely remove oil, water, and dirt etc. from the
various surfaces. Using the specified type of liquid
gasket, apply new liquid gasket to each of the
surfaces before reassembling the parts.
2. In order to make it easier to clean liquid gasket
9. Pay close attention to the risk of ignition if you are surfaces, apply gasket remover liquid (Pando-
handling parts that carry a high voltage. 391D made by Three Bond Co., Ltd.) and leave the
Furthermore, any oil or grease spilt onto rubber part to stand for approximately 10 minutes, after
parts must be wiped off immediately, as it will cause which the old liquid gasket residue will be easier to
deterioration of the rubber. remove.
However, this should not be used on resin
components or painted components.
3. Please take care not to apply too much or too little
liquid gasket.
Also, you should always re-apply the liquid gasket
upon itself when you start and finish application.
4. Make sure that there are no gaps when re-installing
the liquid gasket parts to each other. If there are
gaps between the two parts, re-apply the liquid
gasket. Some parts, especially the oil pan, use the
same size studs as a guide to eliminate the need
for knock pin positioning etc.
5. Re-install these parts within 5 minutes of applying
the liquid gasket.
General information OA-4 Copyright ©
If more than 7 minutes passes, remove the
previous liquid gasket and re-apply it.
6. Please wait for at least 30 minutes since the last
part is installed before starting the engine.

Liquid gasket

Seal section Product name Manufacturer's name

Between cylinder head and upper timing chain cover 1207B Three Bond
Between cylinder block and crank case 1207B Three Bond
Between oil cooler ASM and gear case cover 1207B Three Bond
Between gear case and cylinder head 1207B Three Bond
Between gear case and gear case cover 1207B Three Bond
Among gear case and cylinder block and crank case 1207B Three Bond
Between gear case cover and lower timing chain cover 1207B Three Bond
Among cylinder block and crank case and retainer 1207B Three Bond
Between cylinder head and cam end packing 1207B Three Bond
Cylinder block, head plug nipple, unit, switches 262 Loctite

• Always use the liquid gasket products listed above,

or a liquid gasket identical to the ones listed above.
• Use the correct quantity of liquid gasket. Always
follow the handling instructions for each product.

Application procedure
1. Wipe the contact surfaces clean of all water, fat or
oil. The contact surfaces should be dry.
2. Apply a regular bead width of liquid gasket to one
of the contact surfaces. Make sure that the bead
does not break at this point.

Notes:
If there are special regulations concerning the
application procedure in the repair document, please
follow those regulations.

Work procedure
1. Wipe the joint surfaces of the bolt, bolt hole, and
Important:
screw thread section clean of water, fat and oil. The
After tightening the bolt, do not apply excessive torque
contact surfaces should be dry.
or try to rotate the bolt until at least one hour has
2. Apply Loctite to the top 1/3 of the screw. passed, and the Loctite has hardened.
3. Tighten the bolt to the correct tightening torque.
Procedure for using the Plastigauge

Type Measurable range mm (in)

PG-1 (Green) 0.025 – 0.076 (0.001 – 0.003)
PR-1 (Red) 0.051 – 0.152 (0.002 – 0.006)
PB-1 (Blue) 0.102 – 0.229 (0.004 – 0.009)

Example: Procedure for measuring the clearance

between the connecting rod bearing and crank pin.
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• Clean the connecting rod and bearing, and install • Clean the clamp face of the cylinder block and
the bearing to the rod. crankcase bearing, and also the bearing, and
• Cut the plastigauge to the same width as the crank install the cylinder block to the crankcase.
pin, and while avoiding the oil pore of the crank pin • Gently rest the crankshaft on the cylinder block,
lay the gauge parallel to the pin. and rotate it approximately 30 degree to stabilize it.
• Line up the marks on the connecting rod and cap • Cut the plastigauge to the same size as the journal
and install the crank pin, apply molybdenum width, and while avoiding the oil pore of the journal
disulphide to the thread section and bearing lay the gauge parallel to the journal.
surface of the fastening bolt, and rotate both cap • Gently rest the crank case on the cylinder block,
and bolt to the correct torque. apply molybdenum disulphide to the thread section
and bearing surface of the fastening bolt, and
Important: tighten in sequence to the correct torque.
Do not move the connecting rod while using the
plastigauge. Important:
• Gently remove the cap and connecting rod, and Do not rotate the crankshaft while using the
measure the crushed width of the plastigauge plastigauge.
(clearance between rod and pin) using the scale • Gently remove the crankcase, and measure the
printed on the bag. crushed width of the plastigauge (clearance
between bearing and journal) using the scale
printed on the bag.

Example: Measuring the clearance between the crank

bearing and crank journal
General information OA-6 Copyright ©
Reading the Model
Engine number stamping position

Front Rear

WSJJ0181

General Information
Terminology, description of abbreviations
Terminology definitions
Term Explanation
Maintenance standard The generic name for reference values required for maintenance, such as nominal
dimension, selection of a reference point, and limit.
Nominal dimension Shows the standard value at the point of manufacture that does not include the
common difference.
Selection of a reference point Shows the standard value after assembling, repairing, or adjusting.
Limit When this value (dimensions) is reached, it shows that the part has reached its full
limit and must be replaced or repaired.
Front ⋅ rear, left ⋅ right, upper ⋅ These show each orientations of parts installed to the vehicle when looking from
lower the vehicle's forward direction.
Unit Units written to SI conventions (mainly torque, pressure, force)
[Example] Length: mm, Torque: N⋅m {kgf⋅m}
Warning Items that carry the warning mark pose a danger to life or threat of serious injury if
not strictly observed.
Caution Items that carry the caution mark may cause injury or lead to accidents if not strictly
observed.
Important Items that carry the important mark may cause the vehicle to break down, or may
prevent the guaranteed normal operation of the system or related parts if not strictly
observed.
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Term Explanation
Notes Items that should receive special mention within a work procedure.

Description of abbreviations Abbreviation Description

FWD Forward
Abbreviation Description Forward
AC Alternating Current F/C Fuel Cut
Alternating Current Fuel Cut
ACC Accessory GND Ground
Accessory Earth
ACG Alternating Current Generator IC Integrated Circuit
Alternating current generator Integrated circuit
API American Petrol Institute ID Plate Identification plate
American Petroleum Institute Identification plate, ID plate
ASM (Assy) Assembly IN Intake, Intake
Assembly Intake
ATDC After Top Dead Center ISO International Organization for
After Top Dead Center Standardization
International Organization for
BAT, BATT Battery
Standardization
Battery
I/PUMP Injection Pump
BRG, Brg Bearing
Injection Pump
Bearing
JIS Japanese Industrial Standard
BKT, BRKT Bracket
Japanese Industrial Standard
Bracket
L/H, LH Left Hand
BTDC Before Top Dead Center
Left hand side
Before Top Dead Center
M/V Magnetic Valve
CO Carbon Oxide
Magnetic valve
Carbon Monoxide
NOx Nitrogen Oxide
CONN Connector
Nitrogen Oxide
Connector
N-TDC Number - Top Dead Center
CPU Central Processing Unit
Top dead center rotational frequency
Central processing unit
OPT Option
C/U Control Unit
Option
Control unit
P Pole(S)
DC Direct Current
Pole
Direct current
PCV Pump Control Valve/ Positive
DI Direct Injection
Crankcase Ventilation
Direct injection
Pump control valve/ Positive crankcase
ECU Engine Control Unit / Electronic Control ventilation
Unit
PM Particulate Matter
Engine control unit / control unit
Particulate matter
ECM Engine Control Module
PS Pre-Stroke
Engine control module
Pre-stroke
EGR Exhaust Gas Recirculation
PTO Power Take Off
Exhaust gas recirculation
Power take off
Exh, EXH Exhaust
QOS Quick On System
Exhaust
Rapid preheating system
Ft, FRT Front
Rr, RR Rear
Front
Rear
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Abbreviation Description SI (International System of Units)

R/H, RH Right Hand With regards the conversion to SI (International

Right hand side System of Units)
The introduction of the SI systems aims to
R/L Relay
internationally unify the metric system and the various
Relay
units used by different countries (traditional weights and
STD Standard measures, the foot pound method etc.), and to curb the
Standard confusion that occurs between the different units
SW Switch (conversion calculations etc.).
Switch The new calculating method which adopted SI units
was completely adopted in Japan in 1992, and is
TICS Timing & Injection rate Control System standardized by JIS-Z-8203.
A type of injection system All of the units in this manual are written in line with the
VGS Turbo Variable Geometry turbocharger International System of Units SI units, and conventional
System units are written in { } brackets.
Adjustable turbo, VGS turbo SI
W/L Warning Lamp French) Abbreviated name of Le Systeme International
Warning lamp d’Unites

Connection between main SI units and conventional units

SI Conventional Unit Item, unit conversion

Length m m Same as the conventional unit
Weight (Mass) kg kg Same as the conventional unit
Force N * kg, kgf 1 kgf = 9.80665 N
Torque N⋅m * kg⋅m, gf⋅m 1 kgf⋅m = 9.80665 N⋅m
Pressure Pa *kg/cm2, mmHg 1 kgf/cm2 = 9.80665 kPa, 1 mmHg = 133.3 Pa
Dynamic force, horsepower W PS 1 PS = 0.74 kW
Capacity, air volume displacement m3 Litle, L, cc 1 Litle = 1 dm3, 1 cc = 1mLitle = 1cm3
Fuel consumption g/(kW⋅h) g/(PS⋅h) 1 g/(PS⋅h) = 1.360 g/(kW⋅h)

*1 Published service data may conveniently use kg for

force and mass (weight) instead of kgf.
*2 Some conversion results may be rounded off to 1 or
2 decimal places.
Converting expressions of quantity
When converting, prefixes such as k (kilo) or m (mili)
are used.

M Mega 106 1,000,000

k Kilo 103 1,000
2
h Hecto 10 100
d Deci 10-1 0.1
-2
c Centi 10 0.01
m Milli 10-3 0.001
μ Micro 10 -6
0.000001

• 200 kgf/cm2 = 19,620 kPa = 19.6 MPa

• 40 mmHg = 5,332 Pa = 5.3 kPa
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Table of standard Isuzu tightening torque

The tightening torque values in the table below apply to
all situations unless a special tightening torque is
specified.
Isuzu standard bolts, nuts

N⋅m {kgf⋅m}
Strength 4.8
7T
classification 4T
Bolt head
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
section shape
* M10 × 1.5 19.6 ~ 33.3 {2.0 ~ 3.4} 22.3 ~ 37.2 {2.3 ~ 3.8} 27.5 ~ 45.1 {2.8 ~ 4.6} 30.3 ~ 50.4 {3.1 ~ 5.1}
68.1 ~ 102.1 {6.9 ~
M12 × 1.25 49.0 ~ 73.5 {5.0 ~ 7.5} 54.9 ~ 82.3 {5.6 ~ 8.4} 60.8 ~ 91.2 {6.2 ~ 9.3}
10.4}
* M12 × 1.75 45.1 ~ 68.6 {4.6 ~ 7.0} 51.0 ~ 76.5 {5.2 ~ 7.8} 56.9 ~ 84.3 {5.8 ~ 8.6} 62.7 ~ 94.0 {6.4 ~ 9.6}
76.5 ~ 114.7 {7.8 ~ 83.0 ~ 124.5 {8.5 ~ 93.2 ~ 139.3 {9.5 ~ 100.8 ~ 151.1 {10.3 ~
M14 × 1.5
11.7} 12.7} 14.2} 15.4}
71.6 ~ 106.9 {7.3 ~ 77.2 ~ 115.8 {7.9 ~ 88.3 ~ 131.4 {9.0 ~ 94.9 ~ 142.3 {9.7 ~
* M14 × 2
10.9} 11.8} 13.4} 14.5}
104.0 ~ 157.0 {10.6 ~ 115.6 ~ 173.3 {11.8 ~ 135.3 ~ 204.0 {13.8 ~ 150.1 ~ 225.2 {15.3 ~
M16 × 1.5
16.0} 17.7} 20.8} 23.0}
100.0 ~ 149.1 {10.2 ~ 109.4 ~ 164.2 {11.2 ~ 129.4 ~ 194.2 {13.2 ~ 142.5 ~ 213.8 {14.5 ~
* M16 × 2
15.2} 16.7} 19.8} 21.8}
151.0 ~ 225.6 {15.4 ~ 195.2 ~ 293.2 {19.9 ~
M18 × 1.5 — —
23.0} 29.9}
151.0 ~ 225.6 {15.4 ~ 196.1 ~ 294.2 {20.0 ~
* M18 × 2.5 — —
23.0} 30.0}
206.0 – 310.0 {21.0 ~ 269.7 ~ 405.0 {27.5 ~
M20 × 1.5 — —
31.6} 41.3}
190.2 ~ 286.4 {19.4 – 249.1 ~ 374.6 {25.4 ~
* M20 × 2.5 — —
29.2} 38.2}
251.1 – 413.8 {25.6 ~ 362.8 ~ 544.3 {37.0 ~
M22 × 1.5 — —
42.2} 55.5}
217.7 ~ 327.5 {22.2 ~ 338.3 ~ 507.0 {34.5 ~
* M22 × 2.5 — —
33.4} 51.7}
358.9 ~ 539.4 {36.6 ~ 430.5 ~ 711.0 {43.9 ~
M24 × 2 — —
55.0} 72.5}
338.3 ~ 507.0 {34.5 ~ 406.0 ~ 608.0 {41.4 ~
* M24 × 3 — —
51.7} 62.0}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
General information OA-10 Copyright ©

N⋅m {kgf⋅m}
9.8
Strength classification 8.8
9T
Bolt head section
Hexagon head bolt Flange bolt Hexagon head bolt Flange bolt
shape
5.6 ~ 11.2 {0.6 ~ 6.6 ~ 12.2 {0.6 ~
M6 × 1 — —
1.1} 1.2}
13.4 ~ 25.7 {1.4 ~ 15.3 ~ 28.4 {1.6 ~ 16.7 ~ 30.4 {1.7 ~ 18.1 ~ 33.6 {1.9 ~
M8 × 1.25
2.6} 2.9} 3.1} 3.4}
31.3 ~ 52.5 {3.2 ~ 35.4 ~ 58.9 {3.6 ~ 37.3 ~ 62.8 {3.8 ~ 42.3 ~ 70.5 {4.3 ~
M10 × 1.25
5.4} 6.1} 6.4} 7.2}
31.3 ~ 51.4 {3.2 ~ 34.5 ~ 57.5 {3.5 ~ 36.3 ~ 59.8 {3.7 ~ 40.1 ~ 66.9 {4.1 ~
* M10 × 1.5
5.2} 5.8} 6.1} 6.8}
69.3 ~ 104.0 {7.1 ~ 77.7 ~ 116.5 {7.9 ~ 75.5 ~ 113.8 {7.7 ~ 85.0 ~ 127.5 {8.7 ~
M12 × 1.25
10.6} 11.9} 11.6} 13.0}
64.8 ~ 96.1 {6.6 ~ 71.4 ~ 107.2 {7.3 ~ 71.6 ~ 106.9 {7.3 ~ 79.5 ~ 119.2 {8.1 ~
* M12 × 1.75
9.8} 10.9} 10.9} 12.2}
106.2 ~ 158.8 {10.8 114.9 ~ 172.3 {11.7 113.8 ~ 170.6 {11.6 123.4 ~ 185.1 {12.6
M14 × 1.5
~ 16.2} ~ 17.6} ~ 17.4} ~ 18.9}
100.6 ~ 149.8 {10.3 108.2 ~ 162.2 {11.1 106.9 ~ 160.0 {10.9 115.5 ~ 173.3 {11.8
* M14 × 2
~ 15.3} ~ 16.6} ~ 16.3} ~ 17.7}
154.3 ~ 232.5 {15.7 171.1 ~ 256.7 {17.4 160.0 ~ 240.3 {16.3 176.9 ~ 265.3 {18.0
M16 × 1.5
~ 23.7} ~ 26.2} ~ 24.5} ~ 27.1}
147.6 ~ 221.4 {15.0 162.5 ~ 243.8 {16.6 153.0 ~ 229.5 {15.6 168.5 ~ 252.7 {17.2
* M16 × 2
~ 22.6} ~ 24.9} ~ 23.4} ~ 25.8}
222.5 ~ 334.3 {22.7 229.5 ~ 345.2 {23.4
M18 × 1.5 — —
~ 34.1} ~ 35.2}
223.6 ~ 335.4 {22.8 230.5 ~ 346.2 {23.6
* M18 × 2.5 — —
~ 34.2} ~ 35.3}
307.4 ~ 461.7 {31.4 316.8 ~ 475.6 {32.3
M20 × 1.5 — —
~ 47.1} ~ 48.5}
284.0 ~ 472.1 {29.0 293.2 ~ 440.3 {29.2
* M20 × 2.5 — —
~ 43.5} ~ 44.9}
413.6 ~ 620.5 {42.2 424.6 ~ 636.5 {43.3
M22 × 1.5 — —
~ 63.3} ~ 64.9}
385.7 ~ 578.0 {39.3 394.2 ~ 592.3 {40.0
* M22 × 2.5 — —
~ 58.9} ~ 60.4}
490.8 ~ 810.5 {50.0 554.1 ~ 830.6 {56.5
M24 × 2 — —
~ 82.7} ~ 84.7}
462.8 ~ 693.1 {47.2 520.7 ~ 781.6 {53.1
* M24 × 3 — —
~ 70.7} ~ 79.7}

The * mark indicates where soft materials have been used for internal thread sections, such as castings.
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Designations for Isuzu standard bolt heads

Legend
1. Hexagon Head Bolt (4.8, 4T) 9. Hexagon Head Bolt (Un-Refined 8.8)
2. Hexagon Head Bolt (4.8, 4T) 10. Hexagon Head Bolt Un-Refined 8.8)
3. Flange Bolt (4.8, 4T) 11. Flange Bolt (8.8)
4. Flange Bolt (4.8, 4T) 12. Flange Bolt (8.8)
5. Hexagon Head Bolt (7T) 13. Hexagon Head Bolt (9.8, 9T)
6. Flange Bolt (7T) 14. Hexagon Head Bolt (9.8, 9T)
7. Hexagon Head Bolt (Refined 8.8) 15. Flange Bolt (9.8, 9T)
8. Hexagon Head Bolt (Refined 8.8) 16. Flange Bolt (9.8, 9T)

Flare nut

Pipe diameter tightening torque Flare nut 2 side width (mm)

(for medium and large
Old New
size vehicles)
Flare nut tightening torque (service φ4.76 mm 12.8 ~ 18.6 {1.3 ~ 1.9} 14 14
standard value) N⋅m {kgf⋅m}
φ6.35 mm 23.5 ~ 49 {2.4 ~ 5.0} 17 17
φ8.0 mm 23.5 ~ 49 {2.4 ~ 5.0} 19 17
φ10.0 mm 44.1 ~ 93.2 {4.5 ~ 9.5} 22 19
φ12.0 mm 58.8 ~ 137.3 {6.0 ~ 14.0} 27 24
φ15.0 mm 78.5 ~ 156.9 {8.0 ~ 16.0} 30 30
General information OA-12 Copyright ©
Taper screw from connectors (brass)

N⋅m {kgf⋅m}
Screw size PT(R) 1/8 PT(R) 1/4 PT(R) 3/8 PT(R) 1/12
— 2.0 ~ 14.7 4.9 ~ 15.7 9.8 ~ 16.7 9.8 ~ 17.7
(0.2 ~ 1.5) (0.5 ~ 1.6) (1.0 ~ 1.7) (1.0 ~ 1.8)