Removal and Installation of ISUZU Euro 4 N Series Engine 4JJ1 Flywheel

     Removal and Installation of ISUZU  Euro 4 N Series Engine 4JJ1 Flywheel

         This article is about how to remove and install the ISUZU 4JJ1 Euro 4 N Seriesf engine lywheel

ISUZU Truck Workshop Service Repair Manual PDF

 

Legend

1. Pressure plate(M/T vehicles)6. Bearing stopper(M/T vehicles)

2. Clutch disk(M/T vehicles)

7. Flywheel housing

3. Pilot bearing(M/T vehicles)8. Flywheel(Smoother vehicles,A/T vehicles)

4. Washer

9. Flexible plate(Smoother vehicles,A/T vehicles)

5. Flywheel(M/T vehicles)

Removal

1. Remove the starter.

Special Tool

2. Remove the transmission. Pilot bearing remover:5-8840-2000-0

Refer to "Transmission Assembly"in Section 5B, Sliding hammer:5-8840-0019-0

Automatic Transmission(Smoother) for details on the Smoother vehicle.

Refer to "Transmission Assembly"in Section 5C, Manual Transmission, for details on M/T vehicles.

3. Remove the clutch ASM.

(M/T vehicles only)

Refer to "Clutch ASM"in Section 5E, Clutch, for details on M/T vehicles.

4. Remove the pilot bearing using the special tool.

(M/T vehicles only)

Special Tool

Pilot bearing remover:52Sliding hammer:5-8840-0019-0

5. Install the crankshaft stopper to the flywheel housing starter installation section, and make sure the crankshaft does not rotate.

NOTE: Check that the stopper securely bites into the ring gear and that it is installed.

Special Tool Crankshaft stopper:5-8840-2230-0

6. Remove the flywheel.

· Gradually loosen the flywheel mounting bolts in the order of numbers shown in the diagram while making sure that the flywheel does not rotate.

· Loosen all of the bolts, then remove the stopper and the flywheel.

If the measurement allows polishing or sanding within the stan

dard value and limit value, proceed to repair.

Replace the flywheel if the measured value exceeds the limit.

Depth:From pressure plate installation surface

to friction surface

Installation

1. Install the ring gear.

Tap the ring gear onto the flywheel after uniformly heating using a gas burner. Heating temperature should be 200℃(392癋) or less.

When shrink-fitting the ring gear and cooling, apply a load of 68.6kN(7000 kg/15435 Ib) and hold evenly.

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

 

NOTE:

Install it with the chamfered side of the ring gear facing the front.

After shrink-fitting, check that the ring gear is airtight against the flywheel.

2. Install the flywheel.

3. Install the washer.

Apply engine oil to the threaded portion of the bolt.

Install the crankshaft stopper to the flywheel housing starter installation section.

Tighten the bolts at the specified torque in the order shown in the diagram. Flywheel tightening torque: First time:59 N-m(6.0kg-m/43 Ib-ft)

Second time:60皌o 90?

Special Tool Angle gauge:5-8840-0266-0

LNW71BSH001301

Smoother vehicles,A/T vehicles

Install the flywheel.

Install the flexible plate.

Install the washer with its tapered section facing the engine side.

4. Tap in the pilot bearing using the special tool.(M/T vehicles only)

Special Tool Installer:5-8840-0125-0

. Install the clutch ASM.

(M/T vehicles only)

Refer to "Clutch ASM"in Section 5E, Clutch, for details on M/T vehicles.

6. Install the transmission.

Refer to "Transmission Assembly"in Section 5B, Automatic Transmission(Smoother) for details on the Smoother vehicles.

Refer to"Transmission Assembly"in Section 5C, Manual Transmission, for details on M/T vehicles.

7. Install the starter.

Tightening torque:127 N:m(13 kg-m/94 lb-ft)

 

Isuzu E-IDSS Diagnostic Service System [03.2021]

(a)59 N.m(6.0kg-m/43lb-ft)→60to90

(b)59N-m(6.0kgm/43Ib-ft)-→60to90