How to Remove 4JJ1 Engine from ISUZU N-Series Truck

This instruction show you guide on how to remove 4JJ1 engine from ISUZU N-series truck.For more guide about ISUZU,please refer to:ISUZU Trouble Repair.

Precautions when installing or removing the engine

Always apply chock blocks to the vehicle wheels.

Select an engine hoist that is able to withstand the weight of the engine.

Do not get under the engine while it is hoisted.

Never put your hands where they can get easily caught.

Procedures:

1.Disconnect the battery cable negative terminal.

2.Drain the engine coolant.

3.Remove the starter.

Refer to “Starter Motor”in Section 1E, Engine Electrical.

4.Remove the front exhaust pipe and exhaust brake.

Refer to “Exhaust Pipe”and “Exhaust Brake”in Section 1G, Engine Exhaust.

5.Remove the transmission.

Refer to “Smoother Transmission Assembly”in Section 5B, Automatic Transmission (Smoother)

for details on the Smoother vehicles.

Refer to “Transmission Assembly”in Section 5C, Manual Transmission, for details on M/T vehicles.

6.Remove the air intake pipe and hose.

Remove the hose on the intercooler side.

Remove the pipe from the turbocharger with the hose attached.

8.Disconnect the boost sensor connector(1) and harness clip.

9.Disconnect the ECM connector and clip.

10.Remove the air intake duct and hose.

Remove the duct on the intercooler side.

Remove the duct from the intake throttle valve with the hose attached.

11.Remove the radiator upper hose.

12.Remove the A/C compressor.

Remove the A/C compressor drive belt.

Remove the compressor from the A/C compressor bracket.Fasten to any suitable position with a wire along with the hoses.

13.Remove the engine ground cable from the frame.

14.Remove the vacuum hose(1) from the vacuum pump(2).

15.Remove the radiator lower hose at the engine side.

16.Remove the fan guide.

Refer to “Water Pump”in Section 1C Engine Cooling.

17.Remove the cooling fan assembly.

18.Remove the power steering pump.

Remove the power steering pump at the engine side with the hose attached.

Fasten the power steering pump with hose attached to any suitable position with a wire.

19.Disconnect the heater hose (2) from the heater pipe(1).

20.Install the engine hanger.

Remove the EGR valve harness clip(1).

Install the engine hanger to the rear left side of the engine.

Special Tool Engine hanger:5-8840-2861-0

21.Remove the fuel hose.

Drain the fuel from the fuel filter.

Remove the hose at the fuel filter side.

22.Remove the mounting bolts on the chassis frame side of the engine mount.

Before removing the engine mount, use the hoist to suspend the engine.

Legend

1.Leaf rigid suspension

2.Wishbone suspension

23.Remove the engine assembly.

Slowly operate the hoist to raise the engine to the top surface of the chassis frame.

Turn the engine 90 and move it from the chassis frame top surface to remove the engine assembly.