Isuzu 6SD1T Engines Service Manual

TABLE OF CONTENTS

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 21
Engine I (Disassembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 37
Engine II (Inspection and Repair) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 55
Engine Ill (Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chapter 6 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 117
Chapter 7 Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Chapter 8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chapter 9 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Chapter 10 Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Chapter 11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Chapter 12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Chapter 13 Repair Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

How to Use this Manual

This Service Manual has been prepared as a guide for the service and repair of the Model AA-6SD1T diesel engine.
A general table of contents is shown on the following page, and more detailed subsections are listed at the beginning of each respective chapter.
This manual was first prepared in April, 2001, but subsequent changes in design may result in modifications to certain values and other information in this Manual.

1. Find the applicable section by referring to the Table of Contents at the beginning of the Manual.

2. Common technical data such as general maintenance items, service specifications, and tightening torques are included in the General Information section.

3. Each section is into sub-sections dealing with disassembly, inspection and repair, and reassembly. The section ENGINE ASSEMBLY is an exception. This part is divide into three sections to facilitate quick indexing.

4. When the same servicing operation is applicable to several different units, the manual will direct you to the appropriate page.

5. For the sake of brevity, self-explanatory removal and installation procedures are not mention. More complex procedures are covered in detail.