Assemblyo 4 N Series Engine gearbox of the ISUZU 4JJ1 Eur

          This article is to introduce how to assemble the ISUZU 4JJ1 Euro 4 N Series  engine gearbox

ISUZU US-IDSS Diagnostic Service Truck Diagnostic System [06.2021]

 

Removal
1.Remove the engine assembly from the vehicle.
Refer to "Engine Assembly"in this Section.
2.Remove the cylinder head.
Refer to "Cylinder Head"in this Section.
3.Remove the generator bracket.
4.Remove the vacuum pump.
Refer to "Timing Gear Train"in this Section.
5.Remove the power steering pump.
·Remove the power steering pump at the engine side with the hose attached.
· Fasten the power steering pump with hose attached to any suitable position with a wire.

6. Remove the water pump.
Refer to "Water Pump"in this Section 1C, Engine Cooling

7. Remove the fuel supply pump.
Refer to "Supply Pump"in this Section 1D, Engine Fuel

8. Remove the crank pulley

9. Remove the gearcase cover.
10. Remove the idle gear A, idle gear A shaft, idle gear C, and idle gear C shaft.
Refer to "Timing Gear Train"in this Section.
11. Remove the oil pump.
Refer to "Oil Pump"in Section 1H, Engine Lubrication.
12. Remove the gearcase(1) and gasket(2).

  

Isuzu G-IDSS Diagnostic Service System [03.2022]

NOTE:
Do not remove the bolt(10) when attaching/detaching the gearcase.

Installation
1. Install the gasket.
· Apply liquid gasket(TB-1207B or equivalent) to the area indicated in the diagram(1).
· The gasket applies it to the both sides
· After applying the liquid gasket, install the gearcase within five minutes.

2. install the gearcase.
· Do not remove the bolt (10) when attaching/
detaching the gearcase.

Legend
1. Gearcase
2. Bolt L=20 mm(0.79 in)3. Bolt L=60 mm(2.36 in)
4. Bolt L=45mm(1.77 in)
5. Bolt L=35 mm(1.38 in)6. Bolt L=16 mm(0.63 in)7. Bolt L=20 mm(0.79 in)
8. Bolt L=25mm(0.98in)
9. Nut
· Tighten the bols at the specified torque.
Tightening torque:25 N-m(2.5kgm/18 lb-ft)
3. Install the oil pump.
Refer to "Oil Pump"in Section 1H, Engine Lubrication.
4. Install the idle gear A, idle gear A shaft, idle gear C, and idle gear C shaft.
Refer to "Timing Gear Train"in this Section.
5. Install the gearcase cover.
Refer to "Timing Gear Train"in this Section.
6. Install the crankshaft pulley.
· Install the crankshaft pulley, washer and bolt and tighten them at the specified torque. At this time, apply engine oil to the bolt seat surface and threaded portion.
Tightening torque:185N-m(18.9kg-m/137 lb-ft)
NOTE:
Do not reuse the bolt and washer of the crankshaft pulley.
7. Install the fuel supply pump.
Refer to "Supply Pump"in this Section 1D, Engine Fuel
8. Install the water pump.
Refer to "Water Pump"in this Section 1C, Engine Cooling
9. Install the power steering pump and tighten it at the specified torque.
Tightening torque:25N-m(2.5kg-m/18 lb-ft)
10. Install the vacuum pump.
Refer to "Timing Gear Train"in this Section.
11. Install the generator.
Refer to "Generator"in this Section 1E, Engine Electrical.
12. Install the cylinder head.
Refer to "Cylinder Head"in this Section.
13. Install the engine assembly to the vehicle.
Refer to "Engine Assembly"in this Section.
List of Tightening Torques

Isuzu E-IDSS Diagnostic Service System [03.2021]

(a)25Nm(2.5kg-m/18lb-ft)
(b)40N-m(4.1kg-m/30 lb-ft)(c)25N·m(2.5kg-m/18 lb-ft)