Isuzu engine 4j series. Manual - part 57

6A1 – 96  4JB1/4JB1T/4JB1TC/4JG2 - ENGINE

ENGINE ASSEMBLY

REMOVAL

Preparation:

•

Disconnect Battery Ground Cable

•

Drain Coolant

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Removal steps

1.  Transmission and clutch Assembly
2. Radiator Assembly
3.  Intake air duct
4. Heater hose
5.  Engine control cable
6.  Glow plug harness
7. Fuel hose
8.  Oil pressure switch harness
9.  A/C Compressor Assembly.
    (A/C model)
10. Power steering pump & bracket

Assembly

      (Power steering model)
11. Actuator vacuum hose
      (Exhaust brake model)
12. Vacuum pump hose
13. Front exhaust pipe
14. Support rubber
15. Engine Assembly

Installation steps

To install, follow the removal steps in
the reverse order.

4JB1/4JB1T/4JB1TC/4JG2 – ENGINE  6A1 – 97

1. Transmission and Clutch Assembly

•

Raise vehicle and support with suitable safely.

1) Transmission

!

Propeller Shaft

•

Reference mark the flange yoke to the parking brake
drum.

•

Disconnect the propeller shaft at flange yoke.

•

Put aside the propeller shaft and tie it to the frame so
that it does not interface with servicing work.

"

Parking Brake Cable

•

Move the joint cover.

•

Disconnect the joint bolt.

•

Remove the clip then disconnect the cable from the
bracket.

#

Wiring Connector

•

Disconnect the wiring connectors from the car speed
sensor, the neutral switch and the back-up light switch.

$

Shift Cable and Select Cable

•

Disconnect the shift cable and select cable on the
transmission side.

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6A1 – 98  4JB1/4JB1T/4JB1TC/4JG2 - ENGINE

%

Clutch Slave Cylinder

•

Remove the clutch pipe fixing clips and the clip
bracket (Right hand drive models only).

•

Remove the slave cylinder assembly with the flexible
hose attached, and then tie it to the frame so that it
does not interface with servicing work.

&

Exhaust Brake Assembly

'

Front Exhaust Pipe

(

Transmission Assembly

NOTE:

The exhaust pipe bracket, the gear control bracket
and the clips are sometimes installed in the wrong
position or direction confusedly. To prevent incorrect
installation of these parts, put a correct installation
mark on them.
•

Support the transmission with mission jack.

CAUTION:

To prevent the falling of the transmission, tie it firmly
to the jack with a chain or belt.

Do not allow transmission to hang unsupported from
clutch. Damage to the clutch assembly will result.

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4JB1/4JB1T/4JB1TC/4JG2 – ENGINE  6A1 – 99

•

Remove the nuts of the transmission mounting bracket
on the crossmember side.

•

Engine and transmission angles may need to be
adjusted for removal.

•

Hold the rear section of the engine by the jack or hoist.

CAUTION:

When lifting the engine by the jack, use wood blocks
to prevent any possible damage to the oil pan.
•

Remove transmission fastening bolts.

•

Pull out the transmission assembly rearward.

)

Mounting Bracket

2) Clutch
•

Raise vehicle and support with suitable safety stands.

CAUTION:

Do not let clutch fluid remain on a painted surface,
Wash it off immediately.

!

Pressure Plate Assembly

"

Driven Plate Assembly

•

Use the pilot aligner to prevent the driven plate
assembly from falling free.
Pilot Aligner: 5-5825-3001-0

•

Mark the flywheel and pressure plate lug for alignment
when installing.

•

Loosen the pressure plate assembly fixing bolts.

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