Isuzu N-Series. Manual - part 493

Engine Mechanical (4HK1-TC)   6A-77

30. Remove the injection pipe clip, and remove the

injection pipes.

Legend

1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip

 

31. Remove the fuel rail.

• Remove the fuel rail pressure sensor

connector.

32. Remove the fuel injector bracket.
33. Loosen the fuel injector clamp fixing bolts and

remove the fuel injectors.

If the fuel injectors are difficult to remove, use the fuel
injector remover. Install the fuel injector remover to the
leak-off pipe attachment part on the fuel injector. Use a
sliding hammer to force the fuel injector clamp off the
fuel injector.

Caution:
Do not remove the fuel injector sleeve.

Special tool
Fuel injector remover: 5-8840-2826-0 (EN-46720)
Sliding hammer: 5-8840-0019-0 (J-23907)

34. Mark each fuel injector with the number of the

cylinder from which it was removed. Store the fuel
injectors in a safe place. Position the fuel injector
so that the nozzle is protected.

Caution:

• Do not tamper with the electromagnetic portion of

the fuel injector. Reduced electromagnetic function
will result in injector failure.

Legend

1. Sliding Hammer
2. Fuel Injector Remover
3. Fuel Injector Assembly

 

Caution:
Attach a cylinder number to the removed fuel injectors
til re-install them.
Be sure not to make the nozzle touch something.

N6A6128E

N6A6129E

6A-78   Engine Mechanical (4HK1-TC)

35. Remove the lower head cover.
36. Remove the cylinder head assembly.

• Loosen the cylinder head bolts in the described

order in the drawing.

Caution:
Be sure not to overlook (1) and (2) because they are
attached with the flywheel housing with M10 bolts.

• Remove the cylinder head gasket.

Caution:
Replace the head gasket with a new one once it was
removed.

Disassembly

1. Remove the throttle assembly.

• Remove the intake throttle valve connector.

2. Remove the inlet cover.

• Remove liquid gasket adherent to the removed

inlet cover.

3. Remove the A/C compressor bracket.
4. Remove the exhaust manifold.

Refer to “Exhaust”.

5. Remove the exhaust gasket.
6. Remove the water outlet pipe.
7. Remove the thermostat.

8. Remove the idle gear C cover.

N6A6130E

N6A6131E

N6A6034E

N6A6132E

Engine Mechanical (4HK1-TC)   6A-79

• Put the edge of a driver on the outer circle of

the sealing cup as shown in the drawing, tap it
lightly, reverse it, then pull it out with pliers or
other equipment.

9. Remove the idle gear C.

Legend

1. Idle Gear C
2. Shaft

 

10. Remove the split collar.

11. Remove the spring upper sheet.

12. Remove the valve spring.

• Use a replacer to compress the valve spring,

then remove the split collar.

Special tool
Valve spring replacer: 5-8840-2621-0 (J-43263)
Pivot: 5-8840-2808-0 (EN-46721)

• Remove the special tool, then remove the

upper sheet and springs.

Sort the removed valve springs by cylinder
number.

13. Remove the intake and exhaust valves.

• Sort the removed valves according to cylinders

by using tags and others.

14. Remove the valve stem oil seals.

N6A6133E

N6A6134E

N6A6113E

N6A6135E

6A-80   Engine Mechanical (4HK1-TC)

• Use pliers to remove the oil seals.

15. Remove the valve guides.

•  Use the valve guide replacer to press out the

valve guides from the bottom side of the
cylinder head.

Special tool
Valve guide replacer: 5-8840-2628-0 (J-43272)

16. Put the nozzle sleeve remover on the nozzle

sleeve from the bottom side of the cylinder head,
then pull out the nozzle sleeve.

Special tool
Nozzle sleeve remover: 5-8840-2623-0 (J-43265)

Caution:

• Be sure not to scratch the bottom side of the

cylinder head.

• Do not reuse the removed nozzle sleeve.
• Carefully remove sawdust in the screw groove.

Legend

1. Nozzle Sleeve

 

17. Remove the bridge guide.

• Electrically weld the nut on the head of the

bridge guide, attach the sliding hammer and
pull it out.

Legend

1. Nut

 

18. Remove the oil seal.

N6A6114E

N6A6136E

N6A6137E

N6A6138E