From the cylinder head and timing gear train through the fuel, electrical, turbocharger and preheating systems, this 226-page Isuzu 4LE2 service manual PDF (OEM ID 87495896 NA) walks the diesel engine end to end, including the 4LE2X variant. Wiring diagrams trace the charging and starting circuits through the generator, IC regulator and starter, while the List of Trouble Symptom lets you look up a symptom and its likely causes. Engine mechanical chapters take the rocker arm shaft, pistons and connecting rods, crankshaft and cylinder block through removal, inspection and installation. Check nozzle opening pressure against 13.0 MPa, and keep water pump bearing radial play between 0.008 and 0.010 mm. Perhaps you came for valve clearance adjustment, or for checking a worn cylinder bore against the Repair Standard. Bookmarks for every system and a searchable text layer in this repair manual take you straight to that section. Download it today.
What's Inside This Isuzu 4LE2 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 3-36 | Service Precautions, Reading the Model, Recommended Lubricant, List of Trouble Symptom, Repair Standard |
| 4LE2 Engine Mechanical - General Information and Accessories | 37-52 | Service Precautions, Engine Number, Engine Accessories, Fan Belt, Torque Specifications |
| 4LE2 Engine Mechanical - Exterior Equipment and Rocker Arm Shaft | 53-77 | Engine Exterior Equipment, EGR System, Rocker Arm Shaft, Valve Clearance Adjustment |
| 4LE2 Engine Mechanical - Cylinder Head and Piston/Connecting Rod | 78-100 | Cylinder Head Disassembly, Valve Inspection, Piston Removal, Connecting Rod Inspection |
| 4LE2 Engine Mechanical - Flywheel and Crankshaft | 101-111 | Flywheel Removal, Ring Gear, Crankshaft Front Oil Seal, Crankshaft Rear Oil Seal |
| 4LE2 Engine Mechanical - Timing Gear Train and Camshaft | 112-122 | Timing Gear Train, Idle Gear, Camshaft Inspection, Camshaft Installation |
| 4LE2 Engine Mechanical - Crankshaft and Cylinder Block | 123-134 | Crankshaft Removal, Crankshaft Inspection, Cylinder Block Inspection, Cylinder Bore Measurement |
| Engine - Cooling System | 135-144 | Water Pump, Thermostat, Fan Clutch, Cooling Fan |
| Engine - Fuel System | 145-158 | Fuel System, Governor, Injection Pump, Nozzle Holder, Fuel Filter |
| Engine - Electrical System | 159-196 | Charging System, Generator, Starting System, Starter, IC Regulator |
| Engine - Exhaust System | 197-202 | EGR Control, EGR Controller, Tachosensor, Boost Pressure Sensor, EGR Valve |
| Engine - Lubrication System | 203-208 | Lubrication System, Oil Filter, Oil Pump, Strainer |
| Engine - in Take System | 209-224 | Turbocharger, Turbine Shaft, Compressor Impeller, Bearing Housing |
| Engine - Preheating System | 225-226 | Preheating System, Glow Plug, Glow Plug Timer |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Isuzu standard tightening torque (M10 x 1.5, 4.8 4T, Hexagon head bolt) | 19.6 - 33.3 N·m {2.0 - 3.4 kgf·m} | p. 12 |
| Isuzu standard tightening torque (M12 x 1.25, 4.8 4T, Hexagon head bolt) | 49.0 - 73.5 N·m {5.0 - 7.5 kgf·m} | p. 12 |
| Play of the water pump ball bearing (radius direction) | 0.008 - 0.010 mm | p. 32 |
| Water pump installation torque | 18.6 — 28.4 N·m {1.9 — 2.9 kgf·m/13.7 — 20.9 lb·ft} | p. 66 |
| Nozzle opening pressure | 13.0 MPa | p. 33 |
| Injection pump housing cover installation torque | 7.8 — 11.8 N·m {0.8 — 1.2 kgf·m/5.8 — 8.7 lb·ft} | p. 64 |
| Water outlet pipe installation torque | 18.6 — 28.4 N·m {1.9 — 2.9 kgf·m/13.7 — 20.9 lb·ft} | p. 67 |
| Thermostat valve initial opening temperature | 82 ± 1.5°C {180 ± 34.7°F} | p. 138 |
| Clearance between the pump body and outer circle of the outer rotor | 0.100 - 0.185 mm | p. 207 |
| Axial clearance between the pump cover and the rotor | 0.040 - 0.085 mm | p. 207 |
| Solenoid ASM installation torque | 14.7 — 24.5 N·m {1.5 — 2.5 kgf·m/10.8 — 18.1 lb·ft} | p. 65 |
| Leak-off pipe to nozzle holder tightening torque | 9.8 — 13.7 N·m {1.0 — 1.4 kgf·m/7.2 — 10.1 lb·ft} | p. 65 |
