service repair manual

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

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

3. 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. Ventilation hose
2. 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. Cylinder head cover
2. Gasket
3. Lower cover
1B-2 Mechanical (4HK1)

4. installation
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. Cylinder head cover
2. Gasket
3. Lower cover
3. Connect the ventilation hose to the air breather.
4. Connect the oil level gauge guide tube to the
cylinder head cover.
tightening torque： 19 N・m { 1.9 kgf・m / 14 lb・ft }
1. Ventilation hose
2. Oil level gauge guide tube
Mechanical (4HK1) 1B-3

5. 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.
Note：
・ Remove the clip.
5. Remove the oil feed pipe from the oil port cover.
Note：
・ Remove the clip.
6. Disconnect the oil return pipe from the turbocharger
assembly.
7. Remove the oil return pipe from the cylinder block.
1. Turbocharger assembly
2. Oil feed pipe
3. Oil return pipe
8. Disconnect the water return pipe from the
turbocharger assembly.
9. Remove the water return pipe from the water pump
assembly.
10. Disconnect the water feed pipe from the
turbocharger assembly.
Note：
・ Remove the clip.
11. Remove the water feed pipe from the cylinder block.
Note：
・ Remove the clip.
1B-4 Mechanical (4HK1)

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

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

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

9. Note：
・ Remove the EGR cooler water feed pipe and
EGR cooler water return pipe.
1. EGR cooler water feed pipe
2. 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. Lock operation section
2. Lock release
3. Lock
3. Remove the intake throttle valve from the inlet pipe.
1. Boost temperature sensor
2. Boost sensor
3. Inlet pipe
4. Gasket
5. 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.
1B-8 Mechanical (4HK1)

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

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

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

13. 1. Sliding hammer
2. Fuel injector remover
3. 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.
20. Rocker arm shaft removal
1. Loosen the adjust screw using the wrench.
Note：
・ Loosen all valve clearance adjustment screws.
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.
1B-12 Mechanical (4HK1)

14. 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.
Note：
・ Temporarily assemble the removed caps and
bearings in the original position to avoid a mix-
up after the bearings have been inspected.
22. Bridge removal
1. Remove the bridge cap from the bridge.
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.
1. Bridge cap
2. Bridge
23. Cylinder head assembly removal
1. Remove the cylinder head assembly from the
cylinder block.
Note：
・ Loosening order of the head bolts
Mechanical (4HK1) 1B-13

15. 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.
1B-14 Mechanical (4HK1)

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

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

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

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

20. 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.
Note：
・ Attach a rod from the inner surface of the
cylinder head, and tap it to remove it to the
outer side.
Mechanical (4HK1) 1B-19

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22. 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.
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. Bridge
2. 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 }
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
1B-20 Mechanical (4HK1)

23. 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.
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 }
1. Valve
2. The position 10 mm under the valve guide head
3. 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 }
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.
Mechanical (4HK1) 1B-21

24. 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.
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
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.
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 }
1B-22 Mechanical (4HK1)