2004 ISUZU TF SERIES 4jh1

6A – 114 ENGINE MECHANICAL








23. Injection Pump
1. Install the O-ring (1) to the injection pump flange (2).
2. Attach the noise insulator rubber to the cylinder body .
3. Install the injection pump to the timing gear case.Align
the idler gear "B" (3) mark with the injection pump timing
gear (4) mark.












RTW36AMH000101



























4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.

Injection Pump Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

5. Install the injection pump bracket (6) and the bracke
t
bolts (7) and (8) to the cylinder body.
Temporarily tighten the bracket bolts.
6. Tighten the bracket bolts (7) to the specified torque.
7. Tighten the bracket bolt (8) to the specified torque.
NOTE:
Tighten the bracket bolt (7) first.

Injection Pump Bracket Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




020RY00039

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler Water Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

ENGINE MECHANICAL 6A – 123




15. Starter Motor
Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N·m(kg·m/Ib ft)
85 (8.7/63)

16. Injection Pump
17. Injection Pump Cover (4JA1TC/4JH1TC only)


18. Engine Foot
Install the engine foot to the cylinder body and tighten the
bracket bolts to the specified torque.
Engine Foot Bolt Torque N·m(kg·m/Ib ft)
Right Side M10
1.25
40 (4.1/30)
M10
1.25
40 (4.1/30) Left Side
M14
1.50
127 (13/93)









4JA1L, 4JH1TC
022R300003
















4JA1TC
RTW46ASH002601







RTW36ASH001001
















19. Intake Manifold
1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts
to the specified torque.
Intake Manifold Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)

Intake Manifold Flange Nut Torque N·m(kg·m/Ib ft)
24 (2.4/18)

4) Connect the PCV hose to the cylinder head cover.

5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10
1.25
37 (3.8/28)
2
3M8
1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)




















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

ENGINE MECHANICAL 6A – 125







25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque N·m(kg·m/Ib ft)
31 (3.1/23)

Connector the vacuum hose.





025R100008
RTW36ASH000301













26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)

EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)


RTW48ASH001801
26-2. EGR Cooler (EURO III model only)
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct N·m(kg·m/Ib ft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
RTW36ASH000201












28. Clutch Assembly or Flex Plate

6A – 138 ENGINE MECHANICAL

Illustration Tool Number Tool Name
5-8840-2040-0 (4JA1L/TC)
5-8840-2313-0 (4JH1TC) Cylinder Liner Installer
5-8840-2038-0 Bearing Replacer; Camshaft
5-8840-2000-0 Pilot Bearing Remover
5-8522-0024-0 Pilot Bearing Installer
5-8840-2033-0 Oil Seal Installer
5-8840-9018-0 Piston Ring Compressor
5-8840-2359-0 Oil Seal Installer
9-8522-0020-0 Crankshaft Timing Gear Installer
5-8840-0266-0 Angle Gauge
5-8840-0214-0 Gear Stopper
5-8840-2039-0 (4JA1L/TC)
5-8840-2304-0 (4JH1TC) Cylinder Liner Remover

6B – 6 ENGINE COOLING



110RS001
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3

122.7 kPa (13.5

17.8 psi) pressure. (No oil cooler provided for M/T)





F06RW005
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system
capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC
See section 0B MAINTENACE AND LUBRICATION.





PTW46BSH000201
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE

FUEL SYSTEM 6C – 3

MAIN DATA AND SPECIFICATIONS
Description Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type
Bosch distributor
VE type Bosch distributor VP44 type
Governor type Mechanical variable
(Half speed oil
pressure) Electrical controled
Timer type Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
19.1 (195) 19.0 (194) 19.5 (199) Injection nozzle designed operating
pressure MPa (kg/cm2) 1st
2nd 25.0 (255) 33.5 (328) 33.8 (331)
Main fuel filter type Disposable cartridge paper element


Precautions
When working on the fuel system, there are several things
to keep in mind:

Any time the fuel system is being worked on,
disconnect the negative battery cable except fo
r
those tests where battery voltage is required.

Always keep a dry chemical (Class B) fire
extinguisher near the work area.
 Replace all pipes with the same pipe and fittings that
were removed.
 Clean and inspect “O" rings. Replace if required.
 Always relieve the line pressure before servicing any
fuel system components.
 Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
 Adhere to all Notices and Cautions.

NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.