All 332 pages of this Isuzu 4HK1-6HK1 Repair Manual (OEM #Lep 9-44060) focus on one machine: the 4HK1 and 6HK1 diesel engines as installed in CNH, Hitachi, JCB, and Sumitomo equipment. Inside you get the full engine mechanical teardown from cylinder head cover through crankshaft, a complete common rail fuel system section with injector and supply pump procedures, cooling and turbocharger service, EGR system troubleshooting, and wiring diagrams for the charging, starting, and preheating circuits. Torque tables run deep throughout: snug the fuel injector clamp bolt to 30 N·m, the injection pipe to 44 N·m, and the fuel supply pump gear nut to 64 N·m before you button anything up. Your machine is down. Get the factory number on the first try, not a forum estimate. Bookmarked and searchable — pull up any spec on your tablet right at the engine and get back to work.
What's Inside This Isuzu 4HK1-6HK1 Repair Manual
| System | Pages | Key Topics |
|---|
| Introduction | 4 | Units of Measure, International System, Mksa System, Conversion Table |
| General Information | 5-17 | Service Precautions, Liquid Gasket, Plastiguage, Standard Isuzu Tightening Torque, Designations for Isuzu Standard Bolt Heads, Terminology Definitions |
| Engine Mechanical | 18-196 | Cylinder Head Cover, Timing Gear Train, Rocker Arm Shaft Asm, Camshaft Asm, Piston, Connecting Rod, Crankshaft |
| Cooling System | 197-221 | Precautions on Service Work, Function Check, Main Data and Specifications, Water Pump, Thermostat, Drive Belt |
| Fuel System | 222-257 | Precautions on Service Work, Fuel Filter Asm, Fuel Injector, Fuel Supply Pump, Common Rail, Fuel System Diagram |
| Engine Electrical | 258-310 | Service Precautions, Charging System, Generator, Starting System, Starter, Preheating System |
| Exhaust System and Turbocharger | 311-332 | EGR System, EGR Valve and EGR Cooler, Exhaust System, Troubleshooting, Turbocharger, Measurement Tool |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Fuel Injector Clamp Bolt tightening torque | 30 N⋅m (3.0 kg⋅m/22 lb ft) | p. 241 |
| Fuel Injection Pipe tightening torque | 44 N⋅m (4.5 kg⋅m/32 lb ft) | p. 241 |
| EGR valve bolts tightening torque | 24 N⋅m (2.4 kg⋅m/17 lb ft) | p. 314 |
| EGR pipe bolts tightening torque | 28 N⋅m (2.9 kg⋅m/21 lb ft) | p. 314 |
| Fuel supply pump gear nut tightening torque | 64 N⋅m (6.5 kg⋅m/47 lb ft) | p. 245 |
| Fuel supply pump bracket bolts tightening torque | 19 N⋅m (1.9 kg⋅m/14 lb ft) | p. 245 |
| Crankshaft position sensor tightening torque | 8 N⋅m (0.8 kg⋅m/71 lb in) | p. 135 |
| Valve clearance (cold) | Intake 0.4 mm, Exhaust 0.4 mm | p. 23 |
| 4HK1 Volume of lubricating oil | 13.0 – 20.5 L | p. 28 |
| 6HK1 Volume of lubricating oil | 28 – 38 L | p. 29 |
| 4HK1 Volume of coolant | 14 L | p. 200 |
| 6HK1 Volume of coolant | 14.5 L | p. 160 |
