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ISUZU 4HK1 DIESEL ENGINE Service Repair Manual

service repair manual

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ISUZU 4HK1 DIESEL ENGINE Service Repair Manual

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  1. 93207-01050 October 2014 4HK1 (62Z7/67Z7) SHOP MANUAL Troubleshooting Information SHOP MANUAL ISUZU DIESEL ENGINE 4HK1 General Information General Information Troubleshooting Information 93207-01050 (For Kawasaki Wheel Loader 62Z7, 67Z7) ©2014 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 アメリカ用 ) Serial No. 62J1-5001 and up Serial No. 65J5-5001 and up

  2. 93207-01060 October 2014 4HK1 (62Z7/67Z7) SHOP MANUAL Disassembly & Reassembly SHOP MANUAL ISUZU DIESEL ENGINE 4HK1 Removal & Installation Removal & Installation Disassembly & Reassembly Inspection 93207-01060 (For Kawasaki Wheel Loader 62Z7, 67Z7) ©2014 KCM Corporation. All rights reserved. Printed in Japan (K) ( アメリカ用 アメリカ用 ) Serial No. 62J1-5001 and up Serial No. 65J5-5001 and up

  3. 1B-2 Mechanical (4HK1) Cylinder head cover removal 1. Cylinder head cover removal 1. Disconnect the oil level gauge guide tube from the cylinder head cover. 2. Disconnect the ventilation hose from the air breather. 1. 2. Ventilation hose Oil level gauge guide tube 3. Remove the cylinder head cover from the lower cover. 4. Remove the head cover gasket from the cylinder head cover. 1. 2. 3. Cylinder head cover Gasket Lower cover

  4. Mechanical (4HK1) 1B-3 installation tightening torque： 19 N・m { 1.9 kgf・m / 14 lb・ft } 1. Cylinder head cover installation 1. Align the head cover gasket to the cylinder head cover. 2. Install the cylinder head cover to the lower cover. tightening torque： 18 N・m { 1.8 kgf・m / 13 lb・ft } Note： ・ Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them. 1. 2. Ventilation hose Oil level gauge guide tube 1. 2. 3. Cylinder head cover Gasket Lower cover 3. Connect the ventilation hose to the air breather. 4. Connect the oil level gauge guide tube to the cylinder head cover.

  5. 1B-4 Mechanical (4HK1) Cylinder head assembly removal 1. Battery ground cable disconnect 1. Disconnect the battery ground cable from the battery. 2. Coolant drain 1. Drain the coolant from the radiator. Caution： ・ After the coolant is discharged, make sure to tighten the drain plug. 3. Engine harness disconnect 1. Disconnect the engine harness from the engine assembly. Note： ・ Disconnect each connector. 4. Turbocharger assembly removal 1. Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. 2. Remove the air intake hose from the turbocharger assembly and the intercooler. 3. Remove the exhaust pipe from the turbocharger assembly. 4. Disconnect the oil feed pipe from the turbocharger assembly. 1. 2. 3. Turbocharger assembly Oil feed pipe Oil return pipe Note： ・ Remove the clip. 8. Disconnect the water return pipe from the turbocharger assembly. 5. Remove the oil feed pipe from the oil port cover. 9. Remove the water return pipe from the water pump assembly. Note： ・ Remove the clip. 10. Disconnect the water feed pipe from the turbocharger assembly. 6. Disconnect the oil return pipe from the turbocharger assembly. Note： ・ Remove the clip. 7. Remove the oil return pipe from the cylinder block. 11. Remove the water feed pipe from the cylinder block. Note： ・ Remove the clip.

  6. Mechanical (4HK1) 1B-5 14. Remove the turbocharger assembly from the exhaust manifold. 1. 2. Exhaust manifold Turbocharger assembly 5. Box-shaped EGR cooler assembly removal 1. Disconnect the water rubber hose from the EGR cooler assembly. 1. 2. Water return pipe Water feed pipe 12. Remove the exhaust manifold stay from the cylinder block and the turbocharger assembly. 1. Water rubber hose 2. Remove the EGR heat protector from the EGR pipe A. 1. 2. 3. Turbocharger assembly Exhaust manifold Exhaust manifold stay 13. Disconnect the harness connector from the turbocharger assembly.

  7. 1B-6 Mechanical (4HK1) 1. EGR heat protector 1. 2. 3. 4. 5. 6. EGR valve EGR pipe C EGR cooler B EGR pipe B EGR cooler A EGR pipe D 3. Remove the EGR pipe A from the EGR cooler A and exhaust manifold. 6. Cylindrical EGR cooler assembly removal 1. Disconnect the water rubber hose from the EGR cooler assembly. 1. 2. 3. EGR cooler A EGR pipe A Exhaust manifold 4. Remove the EGR cooler A from the EGR pipe B. 5. Remove the EGR pipe B from the EGR cooler B. 2. Remove the EGR heat protector from the exhaust manifold 6. Remove the EGR cooler B from the EGR pipe C. 7. Remove the EGR pipe C from the EGR valve.

  8. Mechanical (4HK1) 1B-7 1. EGR heat protector 1. 2. 3. 4. EGR cooler C EGR pipe C EGR valve EGR pipe D 3. Remove the EGR cooler A from the exhaust manifold and the EGR pipe A. 4. Remove the EGR pipe A from the EGR cooler B. 8. EGR cooler water pipe removal 5. Remove the EGR cooler B from the EGR pipe B. 1. Remove the fan guide stay from the fan guide and the fan guide bracket. 6. Remove the EGR pipe B from the EGR valve. 2. Remove the fan guide bracket from the cylinder head assembly. 1. 2. 3. 4. 5. 6. EGR valve EGR pipe B EGR cooler B EGR pipe A EGR cooler A EGR pipe C 1. 2. 3. Fan guide Fan guide stay Fan guide bracket 3. Disconnect the radiator upper hose from the water outlet pipe. 7. EGR valve removal 1. Disconnect the harness connector from the EGR valve. 4. Remove the EGR cooler water pipe from the engine assembly. 2. Remove the EGR valve from the EGR pipe D.

  9. 1B-8 Mechanical (4HK1) Note： ・ Remove the EGR cooler water feed pipe and EGR cooler water return pipe. 1. 2. 3. Lock operation section Lock release Lock 3. Remove the intake throttle valve from the inlet pipe. 1. 2. EGR cooler water feed pipe EGR cooler water return pipe 9. Intake throttle valve removal 1. Remove the air duct from the intake throttle valve. 2. Disconnect the harness connector from the intake throttle valve. Note： ・ Pull the lock operation portion to release the lock. 1. 2. 3. 4. 5. Boost temperature sensor Boost sensor Inlet pipe Gasket Intake throttle valve 10. Inlet pipe removal 1. Disconnect the harness connector from the boost sensor. 2. Disconnect the harness connector from the boost temperature sensor. 3. Disconnect the harness connector from the EGR valve.

  10. Mechanical (4HK1) 1B-9 4. Disconnect the harness connector from the IMT sensor. 3. Disconnect the oil level gauge guide tube from the case. 5. Remove the harness clip from the inlet pipe. 4. Remove the oil level gauge guide tube from the cylinder block. 1. 2. 3. 4. 5. Boost sensor IMT sensor EGR valve Harness clip Boost temperature sensor 1. 2. 3. 4. Cylinder head cover Oil level gauge guide tube Case Cylinder block 6. Remove the inlet pipe from the case. 12. Glow plug removal 1. Remove the glow plug connector from the glow plug. 2. Remove the glow plug from the cylinder head assembly. 1. 2. 3. Case Gasket Inlet pipe 11. Oil level gauge guide tube removal 13. Injection pipe removal 1. Remove the oil level gauge from the oil level gauge guide tube. 1. Remove the clip from the bracket. 2. Disconnect the oil level gauge guide tube from the cylinder head cover. 2. Remove the injection pipe from the injector and the common rail assembly.

  11. 1B-10 Mechanical (4HK1) Caution： ・ Do not reuse the removed injection pipe. ・ Seal the common rail and injector to prevent foreign material from entering. 1. 2. 3. 4. Common rail assembly Cylinder head assembly Fuel leak-off pipe Fuel supply pump 16. Common rail assembly removal 1. 2. 3. 4. 5. 6. 7. No.1 injection pipe No.2 injection pipe No.3 injection pipe No.4 injection pipe Fuel leak-off pipe Fuel pipe Common rail assembly 1. Disconnect the harness connector from the fuel pressure sensor. 2. Remove the common rail assembly from the inlet cover and the common rail bracket. 3. Remove the common rail bracket from the oil cooler assembly. 14. Fuel pipe removal 1. Remove the fuel pipe from the fuel supply pump and the common rail assembly. Note： ・ Remove the clip. Caution： ・ Do not reuse the removed fuel pipe. 15. Fuel leak off pipe assembly removal 1. Disconnect the fuel leak-off pipe from the cylinder head assembly. 2. Remove the fuel leak-off pipe from the fuel supply pump. Note： ・ Remove the eyebolt tightened together with the fuel feed pipe. 1. 2. 3. Common rail assembly Fuel pressure sensor Common rail bracket 3. Disconnect the fuel leak-off pipe from the common rail assembly. 4. Remove the fuel leak-off pipe from the case. 17. Cylinder head cover removal Note： ・ Remove the clip. 1. Disconnect the ventilation hose from the air breather.

  12. Mechanical (4HK1) 1B-11 2. Remove the cylinder head cover from the lower cover. 3. Remove the head cover gasket from the cylinder head cover. 1. 2. Lower cover Connector 5. Remove the gasket from the lower cover. 6. Remove the rubber plug from the cylinder head assembly. 1. 2. 3. Cylinder head cover Gasket Lower cover 19. Injector removal 1. Remove the injector leak-off pipe from the injector. 18. Lower cover removal 2. Remove the injector from the cylinder head assembly. 1. Remove the connector from the lower cover. Caution： ・ Do not pull the wire, or pry the connector with a screwdriver. Note： ・ When it is difficult to remove the injector, use a special tool. 2. Disconnect the injector harness from the injector. Caution： ・ Be careful not to damage the injector side stud bolts. 3. Remove the injector harness from the cylinder head assembly. Note： ・ Remove the bracket tightening bolts and then remove the injector harness together with the bracket. SST: 5-8840-2826-0 - injector remover 4. Remove the lower cover from the cylinder head assembly. SST: 5-8840-0019-0 - sliding hammer

  13. 1B-12 Mechanical (4HK1) 20. Rocker arm shaft removal 1. Loosen the adjust screw using the wrench. Note： ・ Loosen all valve clearance adjustment screws. 1. 2. 3. Sliding hammer Fuel injector remover Injector Caution： ・ Confirm that the sleeve is not pulled out together when pulling out the injector using a special tool. ・ Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. ・ Be extremely careful not to damage the injector nozzle. 2. Remove the rocker arm shaft from the cylinder head assembly. Note： ・ Evenly loosen the rocker arm shaft bracket and the rocker arm assembly bracket tightening bolts from both ends and remove them. Caution： ・ Be careful not to remove the bolt shown in the diagram.

  14. Mechanical (4HK1) 1B-13 Caution： ・ Be careful not to drop the bridge cap into the engine. 2. Remove the bridge from the bridge guide. Note： ・ After removing, organize to avoid a mix-up with other installation locations. 21. Camshaft removal 1. Remove the camshaft bearing cap from the cylinder head assembly. 2. Remove the camshaft bearing from the camshaft bearing cap. 3. Remove the camshaft from the cylinder head. 4. Remove the camshaft bearing from the cylinder head assembly. 1. 2. Bridge cap Bridge Note： ・ Temporarily assemble the removed caps and bearings in the original position to avoid a mix- up after the bearings have been inspected. 23. Cylinder head assembly removal 1. Remove the cylinder head assembly from the cylinder block. Note： ・ Loosening order of the head bolts 22. Bridge removal 1. Remove the bridge cap from the bridge.

  15. 1B-14 Mechanical (4HK1) Caution： ・ Since the idle gear C protrudes from the bottom surface of the cylinder head, be careful not to damage the gear. 1. Idle gear C 2. Remove the cylinder head gasket from the cylinder block. Caution： ・ Do not reuse the cylinder head gasket.

  16. Mechanical (4HK1) 1B-15 disassembly 1. Engine hanger bracket removal 1. Remove the front engine hanger bracket from the cylinder head assembly. 2. Remove the rear engine hanger bracket from the cylinder head assembly. 1. 2. 3. 4. EGR pipe D Case Gasket Inlet cover Caution： ・ Do not forget to remove the bolts indicated by the arrow in the diagram. 1. 2. 3. 4. Front engine hanger Front engine hanger bracket Rear engine hanger Rear engine hanger bracket 2. Inlet cover removal 1. Remove the case from the inlet cover. Note： ・ Remove it together with the EGR pipe D. 3. Exhaust manifold removal 1. Remove the exhaust manifold bracket from the exhaust manifold. 2. Remove the inlet cover from the cylinder head assembly. 2. Remove the exhaust manifold from the cylinder head assembly. 3. Remove the exhaust manifold bracket from the cylinder head assembly.

  17. 1B-16 Mechanical (4HK1) 1. 2. Overheat switch Engine coolant temperature sensor 7. CMP sensor removal 1. Remove the CMP sensor from the cylinder head assembly. 1. 2. 3. 4. 5. Distance tube Washer Exhaust manifold bracket Exhaust manifold bracket Exhaust manifold 4. Thermostat removal Caution： ・ Be careful not to subject the sensor to shock. 1. Remove the water outlet pipe from the cylinder head assembly. 8. Idle gear C removal 2. Remove the thermostat from the cylinder head assembly. 1. Press the idle gear C cover using the driver. 3. Remove the gasket from the thermostat. Note： ・ Lightly tap the outer perimeter of the cover using a screwdriver and tilt the cover. 5. Overheat switch removal 1. Remove the overheat switch from the cylinder head assembly. 2. Remove the idle gear C cover from the cylinder head assembly using the pliers. 6. Engine coolant temperature sensor removal 1. Remove the engine coolant temperature sensor from the cylinder head assembly. 3. Remove the idle gear C from the cylinder head assembly.

  18. Mechanical (4HK1) 1B-17 1. 2. Idle gear C Idle gear shaft 2. Remove the split collar from the spring seat. 3. Remove the special tool from the cylinder head assembly. 9. Valve spring removal 4. Remove the valve spring seat from the valve spring. 1. Press the valve spring using the special tool. 5. Remove the valve spring from the cylinder head assembly. Note： ・ Store the removed valve springs according to the cylinders. 10. Inlet valve removal SST: 5-8840-2621-0 - valve spring replacer 1. Remove the inlet valve from the cylinder head assembly. Note： ・ Organize the removed valve according to the cylinders. 11. Exhaust valve removal 1. Remove the exhaust valve from the cylinder head assembly. SST: 8-9439-6862-0 - pivot ASM Note： ・ Organize the removed valve according to the cylinders.

  19. 1B-18 Mechanical (4HK1) 12. Valve stem oil seal removal 14. Valve seat insert removal 1. Remove the valve stem oil seal from the valve guide using the pliers. 1. Heat the valve seat insert with the gas burner. heating temperature： 700.0 to 800.0 ℃ { 1292 to 1472 °F } Caution： ・ Do not reuse the valve stem oil seal. ： 2 section(s) Inner surface of the insert 2. Remove the valve spring seat from the cylinder head assembly. Note： ・ Cool the valve seat insert naturally after heating. 13. Valve guide removal 1. Remove the valve guide from the cylinder head assembly using the special tool. specified time： 5 min Natural cool 2. Remove the valve seat insert from the cylinder head assembly using the driver. Caution： ・ Be careful not to damage the cylinder head. 15. Injector sleeve removal 1. Remove the injector sleeve from the cylinder head assembly using the special tool. SST: 5-8840-2628-0 - valve guide replacer Note： ・ Tap the valve guides out from the bottom surface of the cylinder head. SST: 5-8840-2623-0 - nozzle sleeve remover Note： ・ Tap the injector sleeve out from the bottom surface of the cylinder head.

  20. Mechanical (4HK1) 1B-19 Note： ・ Attach a rod from the inner surface of the cylinder head, and tap it to remove it to the outer side. 1. Injector sleeve Caution： ・ Be careful not to damage the bottom surface of the cylinder head. ・ Do not reuse the removed injector sleeve. 16. Bridge guide removal 1. Install the nut to the bridge guide. Note： ・ Electrically weld the nut to the top of the bridge guide. 2. Remove the bridge guide from the cylinder head assembly using the sliding hammer. 1. Nut 17. Oil seal removal 1. Remove the oil seal from the cylinder head assembly.

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  22. 1B-20 Mechanical (4HK1) inspection 1. Bridge cap inspection 1. Measure the bridge cap using the dial gauge. Note： ・ Measure the contact surface of the bridge cap and rocker arm. limit： 0.1 mm { 0.0039 in } Amount of worn on the bridge cap Caution： ・ Replace the bridge cap if the measured value exceeds the limit value. ・ Replace the bridge cap if it has an abnormal worn such as band-shaped worn. 1. 2. Bridge Bridge guide 3. Idle gear C inspection 1. Measure the clearance using the feeler gauge. Note： ・ Measure the clearance in the axis direction between the cylinder head and idle gear C. specified value： 0.090 to 0.145 mm { 0.0035 to 0.0057 in } limit： 0.2 mm { 0.0079 in } 2. Bridge inspection 1. Inspect the bridge. Note： ・ Confirm that the bridge moves smoothly. 2. Check the clearance of the bridge cap. specified value： 0.020 to 0.057 mm { 0.0008 to 0.0022 in } Between the bridge and bridge cap limit： 0.1 mm { 0.0039 in } Between the bridge and bridge cap 1. Idle gear C 2. Measure the idle gear shaft using the vernier caliper. Note： ・ Outer diameter of the idle gear shaft specified value： 30.00 mm { 1.1811 in } Diameter

  23. Mechanical (4HK1) 1B-21 limit： 29.85 mm { 1.1752 in } Diameter 4. Inlet valve inspection 1. Measure the inlet valve using the micrometer. Note： ・ Outer diameter of the valve stem measurement part： 3 section(s) specified value： 8.00 mm { 0.3150 in } Diameter limit： 7.88 mm { 0.3102 in } Diameter Caution： ・ Replace the inlet valve and valve guide if the measured value is under the limit value. 1. 2. 3. Valve The position 10 mm under the valve guide head Valve guide Caution： ・ Replace the inlet valve and valve guide if the measured value exceeds the limit value. 4. Measure the inlet valve using the micrometer. Note： ・ Valve thickness specified value： 1.71 mm { 0.0673 in } limit： 1.30 mm { 0.0512 in } 2. Install the inlet valve to the valve guide. 3. Measure the valve guide clearance using the dial gauge. Note： ・ Valve guide clearance specified value： 0.039 to 0.071 mm { 0.0015 to 0.0028 in } limit： 0.2 mm { 0.0079 in } Caution： ・ Replace the inlet valve and valve guide if the measured value exceeds the limit value. 5. Inspect the inlet valve using the red lead primer.

  24. 1B-22 Mechanical (4HK1) Note： ・ Inspect the contact surface of the inlet valve and valve seat. specified value： 2.7 mm { 0.1063 in } Contact width limit： 3.0 mm { 0.1181 in } Contact width Caution： ・ If the measured value exceeds the limit value, fix the contact surface of the valve seat using a sheet cutter. ・ If the contact position is not in the center of the valve seat, fix the contact surface of the valve seat using a sheet cutter. ・ If the contact surface is not smooth, fix the contact surface of the valve seat using a sheet cutter. 7. Apply the compound to the valve seat. 8. Install the inlet valve to the valve guide. 9. Adjust contact surface to the specified value using the valve lapper. Note： ・ Lightly tap the inlet valve on the valve seat while turning it. 6. Adjust the valve seat. Caution： ・ Use a seat cutter suitable for the valve seat angle and valve stem diameter. valve seat angle： 30 ° external diameter of the valve stem： 8.0 mm { 0.3150 in } Diameter Caution： ・ After fixing the valve, remove all compounds. 10. Check the sinking amount of the inlet valve. specified value： 0.80 to 1.03 mm { 0.0315 to 0.0406 in } limit： 2.3 mm { 0.0906 in }

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