Isuzu N-Series. Manual - part 597

6A1-76 4JB1/4JB1-TC/4JG2/4JH1-TC - ENGINE

4) Shift Cable and Select Cable

• Disconnect the shift cable and select cable on

the transmission side.

5) 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.

6) Exhaust Brake Assembly
7) Front Exhaust Pipe

8) Transmission Assembly

Notice:
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.

Legend

1. Shift cable
2. Clip
3. Select cable
4. Snap pin
5. Snap pin

Legend

1. Flexible hose
2. Clutch pipe

N6A3334E

N6A3335E

N6A3336E

N6A3337E

4JB1/4JB1-TC/4JG2/4JH1-TC - ENGINE 6A1-77

• 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.

9) Mounting Bracket

• Raise vehicle and support with suitable safety

stands.

Caution:
Do not let clutch fluid remain on a painted surface, wash
it off immediately.

10) Pressure Plate Assembly
11) 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.

2. Flywheel
3. Rear Oil Seal

• With the oil seal pushed in deep, install the special

tool as shown in the illustration to remove the oil
seal.

• Rear oil seal Remove: 5-8840-2360-0

Notice:
Take care not to damage the crankshaft or oil seal re-
tainer when removing oil seal.

Installation

1. Rear Oil Seal

• Use the oil seal installer the oil seal to the cylinder

body.
Rear oil seal Install: 5-8840-2359-0

N6A3338E

N6A3339E

N6A3129E

6A1-78 4JB1/4JB1-TC/4JG2/4JH1-TC - ENGINE

Notice:
Wipe off rust and scraps clean from the press-in portion
of the oil seal.

1) Take note of the press-in direction of the oil

seal.

2) Install the adapter of the special tool to the rear

end of the crankshaft with two bolts.

3) Install the oil seal to the outer circumference of

the adapter.

4) Insert the sleeve into the adapter portion, and

tighten it in with the bolt (M12 

× 1.75L = 70) until

the adapter section hits the sleeve.

5) Remove the adapter and the sleeve.
6) After installing the oil seal, check the measure-

ment of the oil seal.

2. Flywheel

• Apply engine oil to fixing bolts.
• Tighten the flywheel bolts to the specified torque in

two steps using the Angular Tightening Method.
Follow the numerical order shown in the illustra-
tion.

Tighten:

• Flywheel bolt to

1st step: 59 N

⋅m (6.0 kg⋅m / 43 lb⋅ft)

2nd step: 60

° — 90°

3. Transmission and Clutch Assembly

1) Driven Plate Assembly

• Apply multi-purpose with MOS2 type grease to

the driven plate hub spline.

• Use the pilot aligner to install the driven plate

assembly.
Pilot Aligner: 5-5825-3001-0

2) Pressure Plate Assembly

• Tighten pressure plate assembly fixing bolts in

numerical order.

Tighten:

• Pressure plate fixing bolt to 18 N

⋅m (1.3 kg⋅m / 13

lb

⋅ft)

Standard

mm (in)

12.2 — 12.8 (0.48 — 0.50)

N6A3340E

N6A3112E

N6A3339E

4JB1/4JB1-TC/4JG2/4JH1-TC - ENGINE 6A1-79

• Remove the pilot aligner.

Notice:
In case a new pressure plate assembly is mounted, after
tightening a pressure plate at the specified torque, be
sure to remove the wiring for protection of a diaphragm
spring.

3) Mounting Bracket

Tighten:

• Mounting bracket nuts to 69 N

⋅m (7.0 kg⋅m / 51 lb⋅ft)

4) Transmission Assembly

• Support the transmission with mission jack.

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

• Shift transmission into high gear.
• Align transmission with engine slope.
• Turn output parking brake drum to aid clutch

spring engagement.

Tighten:

• Clutch housing to flywheel hosing bolts to

M10: 46 N

⋅m (4.7 kg⋅m / 34 lb⋅ft)

M12: 91 N

⋅m (9.3 kg⋅m / 67 lb⋅ft)

• Raise engine and transmission up into rear

transmission mount.

Tighten:

• Engine rear mounting nuts and bolts to

M10: 40 N

⋅m (4.1 kg⋅m / 30 lb⋅ft)

M12: 69 N

⋅m (7.0 kg⋅m / 51 lb⋅ft)

5) Front Exhaust Pipe

Tighten:

• Front exhaust pipe bolts to 37 N

⋅m (3.8 kg⋅m / 27 lb⋅ft)

6) Exhaust Brake Assembly

Tighten:

• Exhaust brake bolts to 17 N

⋅m (1.8 kg⋅m / 12 lb⋅ft)

7) Clutch Slave Cylinder

Tighten:

• Slave cylinder bolts to 19 N

⋅m (1.9 kg⋅m / 14 lb⋅ft)

• Perform slave cylinder adjustment before in-

stallation of the return spring.
a. Loosen the lock nut of the push rod.
b. Turn the adjust nut until it reaches the shift

fork.

c. Back off the adjust nut 1.5 turns. (shift fork

free play Approximately 2 mm / 0.1 in).

d. Tighten the lock nut.

Tighten:

• Push rod lock nut to 16 N

⋅m (1.6 kg⋅m / 12 lb⋅ft)

8) Shift Cable and Select Cable
9) Wiring Connector

• Color of Connector

Back-up Light Switch: Brown
Neutral Switch: Gray

N6A3341E

N6A3338E

N6A3343E