Isuzu N-Series. Manual - part 497

Engine Mechanical (4HK1-TC)   6A-93

• Install the cylinder head gasket.
• Install the cylinder head gasket with the parts

number upside, along with the cylinder head
rear gear case and dowel.

2. Install the cylinder head assembly.

• Install the cylinder head, adjusting the dowel of

the cylinder block.

Caution:
Be sure not to damage the head gasket when installing
it.

• Apply molybdenum disulfide on the thread and

setting face of the head bolt of M14, and apply
engine oil on the thread and setting face of the
head bolt of M10.

• Use a torque wrench and angle gauge to

tighten the head bolts in the order described in
the drawing.

Tighten:
M14 bolts (1 – 18) to
1st step: 98 N

⋅m (10.0 kg⋅m/72 lb⋅ft)

2nd step: 147 N

⋅m (15.0 kg⋅m/108 lb⋅ft)

3rd step: 30

° – 60° (degrees)

M10 bolts (19, 20) to
4th step: 38 N

⋅m (3.9 kg⋅m/28 lb⋅ft)

• Tighten bolts from 1-18 (M14) and confirm that

they are tightened to a torque of 167 N

⋅m (17.0

kg

⋅m/123 lb⋅ft) or more.

Special tool
Angle gauge: 5-8840-0266-0 (J-45059)

3. Install the fuel injector on the cylinder head.
4. Apply molybdenum disulfide on the thread and

setting face of the fuel injector tighten bolt and
tighten it tentatively.

Important:
Reinstall each fuel injector to the original cylinder from
which it was removed during the disassembly
procedure.

N6A6175E

N6A6176E

N6A6177E

6A-94   Engine Mechanical (4HK1-TC)

Legend

1. Fuel Injector Assembly
2. Fuel Injector Tighten Bolt

 

5. Install the fuel rail.

Tighten:
Fuel rail to 19 N

⋅m (1.9 kg⋅m/14 lb⋅ft)

• Install the fuel rail pressure sensor.

6. Install the injection pipe.

• Apply a thin coat of engine oil on the outer

diameter of the sleeve nut on the side of the
fuel injector and install the injection pipe.

• Use a spanner to tighten the sleeve nut until it

completely contacts both on the fuel injector
and fuel rail.

• Tighten the injection pipe clip with the

designated torque.

Tighten:
Clip to 6 N

⋅m (0.6 kg⋅m/52 lb⋅in)

Legend

1. Fuel Injection Pipe
2. Fuel Injection Pipe Clip

 

7. Final tighten the injection clamp bolts to the

specified torque.

Tighten:
Bolts to 30 N

⋅m (3.0 kg⋅m/22 lb⋅ft)

8. Tighten the injection pipes to the specified torque.

Tighten:
Nuts to 44 N

⋅m (4.5 kg⋅m/33 lb⋅ft)

N6A6178E

N6A6128E

Engine Mechanical (4HK1-TC)   6A-95

Legend

1. Injection Clamp Bolt
2. Injection Pipe Sleeve Nut

 

9. Install the glow plug.

Tighten:
Glow plug to 20 N

⋅m (2.0 kg⋅m/15 lb⋅ft)

10. Install and tighten the glow connector with the

designated torque.

Tighten:
Glow connector to 1.2 N

⋅m (0.1 kg⋅m/10.5 lb⋅in)

11. Apply engine oil on the bridge, install it.

Caution:
Move it up and down to confirm that it moves smoothly.

12. Apply a thin coat of engine oil inside the bridge

cap, install it.

Legend

1. Bridge Cap
2. Bridge

 

13. Install the camshaft assembly.

Refer to “Camshaft Assembly”.

14. Install the rocker arm shaft assembly.

Refer to “Rocker Arm Shaft Assembly”.

15. Install and tighten the camshaft position sensor

with the designated torque.

Tighten:
Bolt to 8 N

⋅m (0.8 kg⋅m/69 lb⋅in)

16. Install the water bypass hose.
17. Install the engine coolant temperature sensor on

the thermostat housing.

Tighten:
Engine coolant temperature sensor to 25 N

⋅m (2.5 kg⋅m/

18.4 lb

⋅ft)

18. Install the leak-off pipe.

Tighten:
Leak-off pipe to 12 N

⋅m (1.2 kg⋅m/104 lb⋅in)

19. Install the fuel leak-off hose.
20. Clip a new gasket to the fuel nozzle leak-off pipe

and install the fuel leak-off pipe.

Tighten:
Nozzle leak-off pipe (injector to cylinder head) to 12 N

⋅m

(1.2 kg

⋅m/104 lb⋅in)

Fuel leak-off pipe (cylinder head side) 12 N

⋅m (1.2 kg⋅m/

104 lb

⋅in)

Fuel leak-off pipe (supply pump side) 18 N

⋅m (1.8 kg⋅m/

13.3 lb

⋅ft)

Caution:
Use new gaskets.

N6A6179E

N6A6093E

N6A6180E

6A-96   Engine Mechanical (4HK1-TC)

21. Install the fuel injector harness connectors.
22. Install the harness bracket and tighten the bolts to

the specified torque.

Tighten:
Bolt to 48 N

⋅m (4.9 kg⋅m/35 lb⋅ft)

23. Install the terminal nuts on the fuel injector.

Tighten:
Terminal nuts to 2 N

⋅m (0.2 kg⋅m/17 lb⋅in)

Caution:

• Do not over tighten the nuts. Damage to the terminal

studs will result.

• The terminal nut with two wires is engine front side.

Legend

1. Fuel Injector
2. Fuel Injector Harness
3. Fuel Injector Terminal Nut

 

24. Install the cylinder head cover.

Refer to “Cylinder Head Cover”.

25. Install the radiator upper hose.
26. Install the A/C compressor.

• Install the A/C compressor bracket on the A/C

compressor and tighten it with the designated
torque.

Tighten:
Bolt to 24 N

⋅m (2.4 kg⋅m/18 lb⋅ft)

• Install the A/C compressor harness connector.

27. Install the A/C compressor drive belt.

• Place the drive belt and adjust its tension with

the adjust bolt of the tension pulley.

N6A6181E

N6A6182E

2

1

3

N6A6627E

N6A6123E