Isuzu engine 4j series. Manual - part 9

 

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Isuzu engine 4j series. Manual - part 9

 

 

SERVICE INFORMATION  00 – 35

mm (in)

Service standard

Service limit

Parts

Items

4JG2

4JB1 / 4JB1T /

4JB1TC

4JG2

4JB1 / 4JB1T /

4JB1TC

Remarks

Push rod

Curvature

-

0.4 (0.0157) or less

Camshaft End play

Cam lobe height

Journal diameter

Runout

Camshaft bearing inside
diameter

Camshaft oil clearance

0.08 (0.0031)

42.02 (1.6543)

49.945 - 49.975(1.9663-1.9675)

0.02 (0.0008) or less

50.000 - 50.030

(1.9685 - 1.9697)

0.025 - 0.085

(0.0098 - 0.00334)

0.2 (0.0079)

41.65 (1.6397)

49.60 (1.9527)

0.10 (0.0039)

50.08(1.9716)

0.12 (0.0047)

Tappet

Outside diameter

Oil clearance
(Between tappet and
cylinder body)

12.97 - 12.99 (0.5106 - 0.5114)

0.03 (0.0118)

12.95 (0.5098)

0.10 (0.0039)

Rocker
arm
Assembly

Rocker shaft outside
diameter

Rocker arm inside
diameter

Oil clearance
(Between rocker arm and
rocker shaft)

Rocker shaft runout

18.98 - 19.00

(0.7472 - 0.7480)

19.036 - 19.060

(0.7494 - 0.7504)

0.06 - 0.08

(0.00235 - 0.00315)

-

18.90 (0.7440)

19.10 (0.7520)

0.10 (0.004)

0.2 (0.0079) or less

Oil clearance
Body and gear

0.14 (0.0055)

0.13 - 0.14

(0.0051-0.0055)

0.20 (0.0079)

0.15 (0.0059)

Oil pump

Body cover and gear

0.06 (0.0024)

0.02 - 0.07

(0.0008-0.0028)

0.15 (0.0059)

Crankshaft Thrust clearance

0.10 (0.0039)

0.30 (0.018)

Main bearing clearance
(Between main bearing
and Crankshaft)

0.031-0.063

(0.0012-0.0025)

0.035-0.080

(0.0014-0.0032)

0.11

(0.0043)

Crankshaft runout

Main journal diameter

Crankshaft pin diameter

Crankshaft Journal and
Crank Pin uneven wear

Crank Pin and Bearing
Clearance.

0.05 (0.00197) or less

69.917 - 69.932 (2.7526 - 2.7532)

52.915 - 52.930 (2.0833 - 2.0839)

0.05 (0.002) or less

0.029 - 0.066 (0.0011 - 0.0026)

0.08 (0.0031)

69.91 (2.7524)

52.90 (2.0827)

0.08 (0.003)

0.100 (0.0039)

00 – 36

  SERVICE INFORMATION

mm (in)

Service standard

Service limit

Parts

Items

4JG2

4JB1 / 4JB1T /

4JB1TC

4JG2

4JB1 / 4JB1T /

4JB1TC

Remarks

Piston diameter

95.365 - 95.404

(3.7545-3.9039)

92.985 - 93.024

(3.6600-3.6623)

-

Piston,
Piston
pin,
Piston
ring and
Connect-
ing rod

Piston Clearance
(Between piston and
Cylinder liner)

Piston ring gap

1st

2nd

Oil

Piston ring clearance

1st

2nd

0.047 - 0.065

(0.0019-0.0026)

0.20 - 0.35

(0.0079 –

0.0138)

0.37 - 0.52

(0.0146 -

0.0205)

0.20 - 0.40

(0.0079 -

0.00157)

0.09 - 0.13

(0.0035 -

0.0051)

0.05 - 0.09

(0.002 -

0.0035)

0.025 - 0.045

(0.0010-0.0018)

0.20 - 0.40

(0.0079 –

0.0157)

0.20 - 0.40

(0.0079 -

0.00157)

0.10 - 0.30

(0.0039 -

0.0118)

0.090 - 0.125

(0.0035 -

0.0049)

0.050 - 0.075

(0.0020 -

0.0030)

-

1.5 (0.0591)

1.5 (0.0591)

1.5 (0.0591)

0.15 (0.0059)

Oil

0.03 - 0.07

(0.0012 - 0.0028)

0.15 (0.0059)

Piston pin diameter

33.995 - 34.000

(1.3384-1.3386)

30.995 - 31.000

(1.2202-1.2204)

33.970

(1.3374)

30.970

(1.2190)

Fitting interference
(Between connecting
rod and piston pin)

Fitting interference
(Between piston and
piston pin)

Connecting rod
alignment Bend

Twist

Piston pin and Connecting
Rod Bushing Clearance

Connecting rod thrust
clearance

0.008 - 0.020

(0.0003 - 0.0008)

0.002 - 0.015

(0.0001 - 0.0006)

0.08 (0.0031) or less

0.05 (0.0020) or less

0.008 - 0.020

(0.0003 - 0.0008)

0.230 (0.0091)

0.05 (0.0020)

0.04 (0.0016)

0.20 (0.0079)

0.15 (0.0059)

0.050 (0.0020)

0.35 (0.0138)

0.029 -0.083

0.029 - 0.066

0.100 (0.0039)

(0.0014 -

(0.0011 -

Oil clearance
(Between crank pin and
Connecting rod)

0.0033)

0.0026)

Per 100

(3.94)

Per 100

(3.94)

SERVICE INFORMATION  00 – 37

mm (in)

Service standard

Service limit

Parts

Items

4JG2

4JB1 / 4JB1T /

4JB1TC

4JG2

4JB1 / 4JB1T /

4JB1TC

Remarks

Cylinder
Block

Warpage
(Upper surface of the
cylinder block)

-

0.20 (0.0079)

Cylinder bore diameter

97.000 - 97.040 95.011 - 95.040

(3.8189 -

(3.7406 -

3.8205)

3.7417)

Cylinder liner projection

0.0-0.1

(0.00-0.0039)

Cylinder liner inside

95.420 - 95.460 93.020 - 93.060

diameter

(3.7567 -

(3.6622 -

3.7583)

3.6638)

Cylinder liner outside

97.011-97.050 95.011 - 95.050

diameter

(3.8193 -

(3.7405 -

3.8209)

3.7421)

00 – 38

  SERVICE INFORMATION

SERVICING

Servicing refers to general maintenance procedures to be
performed by qualified service personnel.

MODEL IDENTIFICATION

Engine Serial Number

The engine number is stamped on the front left hand side
of the cylinder body.

AIR CLEANER

Dry Type Paper Element
Element cleaning procedures will vary according to the
condition of the element.

Dust fouled Element

Rotate the element with your hand while applying
compressed air to the inside of the element.  This will
blow the dust free.

Compressed air pressure

kPa (kg/cm

2

 /Psi)

                                                                                                                   

392 - 490 (4 - 5/57 - 71)

                                                                                                                   

CAUTION

Do not bang the element against another object in an
attempt to clean it.  Damage to the element will result.

Carbon and Dust Fouled Element

1. Prepare a cleaning solution of Isuzu Genuine Element

Cleaner (Donaldson D1400) diluted with water.

2. Submerge the element in the solution for twenty

minutes.

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