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manual for operation of the 4jx1 - Assistance to the Aviation Industry

1. M 56 14 ORPS Oil Rail Pressure Sensor e eeeeeeeeee eee eee eene nnn nnne eet naa asses esee esten asas sss enn 57 Calibration ORPS 60 Rail Pressure Control Valve RPCV eee eee eese esses tenete senate seen atus ess tns es sens tns e sss ta sense ens tn seo 61 Cleaning the RCDVSsins s saoD uM Ea ILL EE Sn I 62 ECM Engine Control Module eee crece eee eese eene esee sees sete sas e seas ete sn ete sa sese sos seas seas esas see 62 ECU Electronic Control Unit 4 eee esee eese esee e eene ent tnetn atn s tensa sense sata sess en senses stas essa sense 65 High pressure PUMP T Ssss 65 TIMING High pressure Pump Replacement Timing Belts scscssssssssssssssssesessssscesesseessees 65 PEN LE oo ecce 68 ENLAI E EAA 68 Oil Rail Pressure Meter 68 Starting after replacing injector O rings eee eee eese eese etes eene sense ens etna etae tta stas esses ste se seno sta 70 Fuel leak diagrams sleeves o rings eeeeeseseeseeeeeneeeenee nennen nennen ee nnennreten eter etnreteee teet nnen nee 71 I6 Sump atid Engine Prohl end oiouessniissesbroei iex vo CORAN HEU rb ROI Sorena seess riis 72 High pressure Pump Harmonic Balancer and O rings s sessessssesoeseseecesoeoesoesesoesosoe
2. S 115 Ds POLS D m 116 Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 5 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 1 Overall operation of the 4JX1 Engine Suggested Actions for Owners Injector Article written by Red one e Ensure the correct type and grade of oil is being used in the engine Correct operation of every part of the injector oil circuit is critical to the successful operation of this engine The piston within the injector has to move exactly the correct distance to deliver the correct quantity of fuel and operate at exactly the right moment in the engine cycle for the engine to run correctly Selection of a good quality oil of suitable viscosity clearly plays a vital part in this e Check sump oil level regularly at least once per week and be aware that a rising oil level could be the start of other problems e Keep a wary eye open for fluid loss or leaks such as oil leaks from engine seals or the smell of diesel in the coolant e Holden Jackaroo owners contact Holden and enquire whether the Campaign 03 H 03 has been done on your vehicle Note this Campaign relates to the injector sleeve sealing O rings which according Holden can deteriorate and cause fuel to leak into the crankcase If not book it in Holden should do this free of charge e At each 80 k kms service interval re
3. Apparently you undo the clip with a pair of pliers and poke an object in there like a Phillips head screwdriver to break the carbon and sludge that has accumulated there When the mechanic first put the engine onto the electronic management system he found no vacuum whatsoever so he went straight to that and found it blocked which is a common problem on most engines diesel and petrol with EGR and the like He said the Holden Vectra and Astra s are notorious for this In the 4JX1 engine the manifold gets quite filled or coated sometimes excessively with this sludge oil deposit from the combustion process over time Taking off the manifold is necessary and mechanically cleaning it is the only way but would be expensive and difficult suggest that from experience working with diesel engine operators in trucks ships and mining equipment over half my life that taking the vehicle for a drive under high load conditions of towing a heavy load uphill under extended periods in low gears and RPM s around 3 500 up to 4 000 may remove some of these deposits High RPM s is not enough the engine must be loaded Under these conditions it is normal for the engine to smoke excessively It does them a great deal of good and people are surprised what comes out of the exhaust The problem that causes these deposits in the first place is a combination of the EGR system that blows combustion by products back into the inlet manifold from the exhaust combined with a
4. Cat Toyota and a few other makers have stopped using the EGR system now been having way too many problems Benefits are e More power e Better fuel economy e MAP sensor will work better e intake manifold will stay clean and intake ports will not get smaller in size But don t tell too many people what you done just keeping amongst us 4JX1 nuts HEHH HHHH HH HEH HEHH EHE EHE EE EHE HERE EE EHE EHE HERE EHE E EHE EE EHE HERE HERE tH HE EE HERR HE HER RR RR Posted 13 August 2013 01 36 AM You can disable the EGR by unplugging the hose at the bottom of the valve Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 86 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Follow that hose back to the T piece unplug all of the hoses and then push the two remaining hoses together one is smaller than the other You should be left with a short length of hose and a T piece It doesn t completely stop the EGR but it does make a difference It increased my cold engine performance significantly No more gutless slow diesel until it warms up Thanks to Pete88 on Club Isuzu HE HHEHEHHEHEHEHEHEH HE RHET EFEET EET EHHH EEH HHH FETE E EET HR Ett ttt ttt ttt ttt tet ttt Posted 21 July 2011 11 06 PM Just reading this with interest blocked off my EGR some time back after reading this on an another forum Since blocking the valve my motor seems to be runni
5. g Every size water hose you can find h Oneofthe most important things to put on board is your tool box If you re not a tool type person it s still imperative that you carry some tools The problem always is the tool you need is the one you don t have So what are the basics i Phillips amp a flat blade screw driver preferably a mixed set j Two 10 inch and two 8 inch shifting spanners much rather a GOOD mixed set of metric and or imperial spanners k Apair of pliers a wire stripper and Side cutters l Ahammer Spare Parts m Arange of globes for both car and van n Spare A C and fan belts o Top and bottom radiator hoses and a length of heater hose this can be cut to suit p recommend you replace your belts and hoses before your trip and keep the old ones for spares q Extra engine oil and extra coolant water can always be used in an emergency r A full size spade a small camp spade an axe and a tomahawk are always handy assets even if you don t plan on leaving the black top Cheers Sergey Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 22 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Battery Alternate Delkor M27 marine battery Century N70ZZ 4WD battery has 700CCA and 145RC Supercharge Calcium calcium 720cca amp 160 Min reserve I run a 650CCA RHS and a 550CCA LHS from Marshals Century N70ZZ4WD 700CCA battery 1OOOCCA
6. 755 37 EGRE RvGisukOpenShat maps 5 ___ EGR Ressure Sensor Hgh Wiage OW P018 POIs P019 P019 P11 P11 P11 P11 P019 P019 j c co c2 P020 P020 P020 53 4 22 36 Ch P1217 P0218 P0336 Lus a are 15 mu e mu e Pores e 8 T 58 FW 8 re 8 ene Gm es e 85 15 mm 5 Wu 9 mms 9 7894 54 LAND X mm 3 mm e me e mor 5 R54 a Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 17 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 4 J41 TC ENGINE ORIVEABILITY AND EMISSIONS amp E 55 HER rmm using a Tech Z BIN ERN wVOmutpenSar rss n Opes L FE 74 tae Thetis Poston eror o ag DR WEE 74 __ Take Thole Postion Sensor righ Wage YON MET 73 take Theta Seem Gra Openhot ON es 72 Itake Thrtle MetorConirol Grou Signa Gp 555 7 54 ice Speed Sensor fe Sm 9 m8 75 eSiWheiincion dpen mut DR su 75 MesWkancoShonUmu YON mm 3 SmemWaw Too Tow LL L555 55 SrsemVifageTolowstm ng L reer rate Seinen B LL Tm
7. A leaking o ring on the oil pickup pipe in the sump the long one sometimes causes inconsistent oil pressure Check the short one as well when you take the sump off as all except the very latest design Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 33 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 had a tendency to break off and stop the injection system from working if it s on the way it may contribute to difficult starting As always if you find a cure let the forum know REEEEEKE think Im dreaming After checking what could I ve changed oil and filter Used Castrol Magnetec The hot starting problem and oil pressure fluctuations have gone have just traveled 1100 kms with no problems at all Holden dealer using Mobil 4X4 oil did previous oil change Can it be this simple Hot starting problems The oil pressure gauge is that of engine lubrication only not fuel injection pressure system a Check the intake butterfly and sensor as that could be a starting point b What is the rail pressure sensor like c What is the rail temp sensor like d is there oil in the injector harness is it sucking air in the fuel system is there a carbon build up in the map sensor e Has your thrust bearing worn out pulling the fly wheel away from the crank angle sensor f isthe cam sensor open circuiting do you have a trailer plug that is shorting the ecu um
8. BseSWiainand N me 8 EekamEm LL em 55 obier iga 9N esr 56 mmeierWengSgri ON Tig 55 NeSemiytdeEte DN i 5 imebierFnionmiPmganmed YON mem 77 ChekEelamp rut pwut 79654 3r lemomeer raR Open 5655 7 17 Theme FeimyCieut OpeniShat esr 76 EM Relay Gru Openshaw Ti sr TenMessWtmutOpenthat Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 18 Page Manual Jackaroo 4JX1 Engine March 2014 Service Intervals found by 4JX1 users Monday March 31 2014 Item Distance Change Best Use Notes INJECTOR SEALS 100 000 Yes 140000 km CAT HEUI injectors for 100 000 Yes internal seal replacement 150 000 Cil Changes 5000 to 10000 Yes Penrite HPR Diesel 5 or Mobil km Delvac1 Castrol R synth 5W 30 Mobil 1 5w50 ORPS 50000 70000 Yes km Throttle body position 50000 70000 Yes sensor km ORPCV 50000 km Clean Replace when necessary Injector CAT HUEI 100 000km Overhaul CAT Kit sells for about AS65 overhaul set 85 injector must change Cu washer Wiring harness At 240 000 km clean Gidday to all intervals HARNEX in Brisbane can re manufacture the entire harness f
9. Cheers Rich G day Rich My jack idled erratically a few years ago Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 109 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 The flapper valve in the head of the fuel filter had pieces of rust and paint which prevented it closing efficiently From what I remember it ran reasonably well when cruising but difficult to drive smoothly at low speed in the lower gears ie jerky throttle Had to ride the clutch a bit to keep it smooth The car went well for about 5000km before the uneven idle returned As before economy remained good no loss of power and above 1000rpm everything seems fine The oil pressure started dropping a bit low on occasion but only when coasting with the throttle closed Blip the throttle pressure immediately returned to normal which is about 500KPa on the gauge The oil pressure thing seemed more like a sticky relief valve than anything else a complete pain to fix if that s the case it may not be a real problem anyway see below Anyway off to the mechanic who agreed to drop the sump and check the oil pickups before doing anything more serious The pickup seals were extremely hard and cracked in a few places but it didn t seem there was any major problem yet The mechanic checked everything with his scan tool no codes and the oil pressure sensor is not registering the low pressure that shows on th
10. I was shocked at the amount of oil in the connector itself Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 45 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Glow plugs Cleaning intake manifold Glow Plugs Anyone bought glow plugs from these guys www dencodiesel com 85 80 for a set of 4 Much better than most stores Matt Glow plugs Australia I have asked him the question we all want to know the answer to why are they so much cheaper then elsewhere they seem to be the same product HKT PI 172 I finally bought some HKT plugs from the ebay guy who is actually www sundiesel com au The electrode tip came loose as I tightened the nut on the bus bar it turned the nut at the top of the electrode and pulled the electrode loose the tip and electrode is one piece One the body came out without the tip the tip was being held in by all of the carbon build up on it due I think to the plugs not heating I squirted some carby cleaner on it and gave it a wiggle and it came out thank god I have one original plug that is stuck broken in the head and it s staying there for now I seem to have a lot of carbon build up in my inlet manifold I believe this is due to the oil coming through from the tappet breather tube what can I do about it do I need to do anything about it I ve just put Bosch GPI 026 glow plugs in the jack no problems removing the plugs jus
11. Any ideas This problem has only come since i had the recall done by Holden i just looked at the loom they replaced and there is a thin black wire which isn t connected could that be a problem Also while have you reading can someone give me please explain where the white wire is located Hopefully that may fix my rough idle and power loss Cheers Matt Posted 20 February 2013 09 05 PM MattPorter on 18 Feb 2013 10 55 PM said Cheers mate have checked all the contacts wiring and fuses What purpose does the big blue charge relay serve Could that be it will tell you about MYJackaroo but have found that the wiring on Jacks varies that the Australian model differs totally from the overseas models and there are NO wiring diagrams available to the public for under 500 in my search so far Proceed with caution The big blue charge relay is the main conduit for power from the alternator to the battery while the engine is running A faulty relay will inhibit or stop charging of the battery while she is running This may be your problem Also a short circuit in the relay solenoid circuit would possibly connect the battery ve to earth at rest This may also be your problem The cheapest way to test for this fault is to swap it for another relay and see if the fault disappears use the air bag relay to swap for personally The advantage of this is gt if you stick a faulty blue relay in the airbag socket then the
12. From what I have observed while freeway driving around with Tech2 attached is that the stepper motor spends a lot of its time in the middle sectors around 4 7 steps which is exactly where it was giving inconsistent readings So to recap 1 It may be possible to use a multimeter to diagnose a faulty TPS 2 It is possible for a known good TPS to be calibrated to produce the correct voltage at zero steps by using a simple multimeter Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 90 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 3 It is not possible to calibrate the stepper motor without being able to get it to move from zero steps to a 4 known step whether that step be 1 2 or any number up to 10 If the stepper motor is not calibrated then the ECU will not be able to position the throttle blade accurately even though the TPS is correctly calibrated INDUCTION 6J 9 INTAKE THROTTLE VALVE REMOVAL 1 Remove intercooler assembly Refer to Intercooler in this manual 2 Remove harness connector from motor and ITP sensor 3 Loosen the two fixing nuts and remove the throttle valve assembly Legend 1 Motor 25 Intake Throttle Valve 3 ITP sensor INSPECTION AND REPAIR 1 Check for catching somwhere on the throttle valve 2 If some problem is discovered during inspection on the throttle valve the throttle valve must re
13. Hi Suzu The original water pump leaked through the shaft seal When I took it off and turned the shaft the seal squeaked and coolant had been leaking out of the housing drain hole No leak from the pipe you mentioned I could not believe my luck when the replacement pump did the same thing This time it was weird that the coolant also leaked out of the outer bearing also Holden only reimburse the cost if the part is faulty which they did The second replacement has been fine no loss of coolant no leaks at all Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 54 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 ON VEHICLE SERVICE WATER PUMP Legend 1 Fan Pulley 2 Water Pump Assembly REMOVAL 1 Drain coolant 2 AC Generator Drive Belt 1 Loosen AC Generator mounting bolt adjust plate lock bolt and remove the drive belt 3 Cooling Fan Assembly 1 Remove lock nut and take out cooling fan assembly with cooling fan clutch 4 Water Pump Assembly INSPECTION Make necessary repair and parts replacement if excessive wear or damage is found during inspection Should any of the following problems occur the entire water pump assembly must be replaced 1 Cracks in the water pump body 2 Coolant leakage from the seal unit 3 Excessive play in radial direcbon or abnormal noise 4 Excessive play in thrust direction Limit 0 2mm 0 008in or less 5 Cr
14. Is the action complete Verify repair 1 1 Raise the vehicle and disconnect the CKP sensor harness 2 Ignition ON 3 With a test light ta ground probe the harness ignition feed terminal Did the light illuminate Goto Step 19 Goto Step 15 Check the ignition feed wire between the sensor and the ECM for a short to ground or open circuit Is the action complete Verify repair Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 14 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 4JX1 TC ENGINE DRIVEABILITY AND EMISSIONS 6E 51 Engine Cranks But Will Not Run Cont d Sw m Vaws Ye 1 Ignition ON 2 At the CKP harness connector connect a test light between the ignition and ground terminals Did the light illuminate Goto Step 21 Goto Sep 20 20 Checkthe sensor ground circuit for an open or shortto voltage Is the action complete Verify repair 21 Check the signal circuit between the sensor and the ECM for a shortto ground short to voltage or an open 22 Replace the CKP sensor p ime seron comer o verge on Sent Reading Flash Diagnostic Trouble Codes DTC Fault Codes The provision for communicating with the Engine Control Module ECM is the Data Link Connector DLC The DLC is located in the front console box It is used in the assembly plant to receive information in checking that the engine is operating prop
15. March 2014 Monday March 31 2014 19 Fuelsupply Tank and initial Fuel Filter This problem started Woodsy when I did the 120000km service and one of the jobs was to replace the fuel filter I noticed a little later a couple of 100 ks that the motor would start OK and a couple of seconds later run rough and then stall To restart I would have to crank it over for about 20 seconds and it would splutter into life After this happened again I checked around under the bonnet and found I could pump the primer on top of the fuel filter several times I opened the bled vent and pumped the air out thinking that would be the end of the problem NO WAY It has continued to happen after about 100 200 kms I replaced the full filter housing containing the priming pump and no more problems Obviously the diaphragm in the pump had a small hole or tear allowing air to be drawn in I had pressure tested the housing before and found no leaks but the pressure must have closed the hole tear Replace Fuel Filter Posted 05 May 2005 10 13 PM I did mine last week after Sal had a starting problem one night just to be safe to get going she hit the priming pump a couple of times and the Jack started Dunno what was wrong Ok assuming you have removed and replaced the filter this can be a challenge Get a 10mm spanner and loosen about a turn the bolt on the pump body at about 9 O clock standing at front of vehicle Press the pump down
16. christd1 on 05 Nov 2009 10 40 PM said CAV fuel filters Gents am thinking of fitting a CAV fuel filter with a glass bowl as a back up for main filter and B to see when I have water in my diesel Has any one fitted one of these fuel filter set up If so were did you mount it Pics would be greatly appreciated Found a supplier for the CAV fuel filters and all their other styles of filters here in Nowra Grimes Diesel Service Lot 1 Meroo Rd Bomoderry NSW PH 02 4421 0791 Most standard fuel filters are 8 10 micron whereas the R2132P filter is a 4micron filter This improved filtration combined with the added bonus of a water and sediment sight bowl result in greater pump amp injector protection The cost of the replacement R2132P filter cartridge can be as little as 1 10th the cost of the factory fuel filter so the assembly often pays for itself in the first few filter changes ignoring the future cost savings related to the extended life of the pump and injectors bought a cav unit from Whitworths Boating chandler for 80 The cartridges are about 12 and real easy to get hold of Cheers Here s a simple solution Go to the filter shop get hold of a new filter for your Jack Then find one with the same size top ring and thread which has a bottom drain Use that instead and you have your water trap Alternatively get a water trap off an older Jack or some other make model and fit before your existing filter What is the nu
17. conditioner pump holder about 100 mm long about 15 18 mm in diameter Reason Due to temperature changes head and metal pipe are expanding and compressing the o ring After cooling down the rubber o ring returns to initial shape By the time rubber becomes like a plastic and water starts leaking out sometimes invisible from outside and the air starts coming in creating an air bubble in the gallery of the head around injectors and sleeves When the engine is started it takes some time to fill up the gallery with coolant and all this time injectors are working heated from combustion chamber Diagnostics At the beginning stage Place the inner car heater temperature handle to max hot Switch off the fan and radio Start the engine and listen to the sounds near glovebox area If you hear sounds like water murmuring that means the air bubble was there Repeat the test next morning At the escalated stage Park a car with a warmed up engine at an angle to the front Front side should be lower than a back in my case 150mm of difference was enough Stop the motor and wait for 2 10 min you will see coolant drops under the car coming out pretty fast Or just do a pressure test How to fix Take out aircon pump aircon pump holder belt tensioner Unbolt L shape pipe and pull it out Replace the O ring App time about 3h cleaning everything under aircon pump included That s what I did yesterday after I got a spot of coolant unde
18. operatng temperature Due to easy accessibility inspecting the MAP sensor for blockage may be easier than diagnosing Trough Tech 2 Typical blockage is shown in Figure Note 1 Inspecting for MAP sensor for blockage does not confirm that the MAP sensor or sensor crcuit are OK This shouki be considered if further diagnostics are required Note 2 MAP sensor blockage can result in driveabdity symptoms Nat could be easily mistaken for a sticking ral pressure control valve RPCV or sticking throttle valve Figure 1 MAP sensor blocked with carbon Euro Ill Sensor Shown CORRECTION Clean the buit up carbon from the MAP sensor breather hole Gently scrape tne carbon busd up from the breather hole while holding the sensor in a position that allows the carbon to fall out of the sensor Avoid pushing carbon into the sensor Refer Figure 2 Note Do not use flammable cleaners on the sensor or in the manifold Figure 2 MAP Sensor After Cleaning changes especially at cylinder 44 As a result We have burned holes in the piston and engine replacement So please be careful while playing with EGR Yes in short term it doesn t matter but for a long time it could have an expensive result Sergey Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 87 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Posted 31 August 2013 06 59 PM Jack on 31 Aug 2
19. think the pneumatic over hydraulic type I have are also about 150 So for 300 and a set of ramps it s quite straight forward If doing this mark all drive shaft locations prior to disassembly since they may have been balanced Clutch Dual mass Clutch original is a dual mass recommended replacement is solid Holden Jackaroo CLUTCH KIT amp FLYWHEEL 3 0 Ltr Turbo Diesel 1998 Onwards EXEDY Price AU 1 499 99 http www exedy com au clutch finder Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 104 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 22 Radio and Installation For future reference to make life a lot easier AEPRO make adapter harnesses for the Jackaroos to suit most common after market brands Should be available from Autobarn or your local AEPRO stockists You can look on their web site for further info www aerpro com au Here is my 05 worth 1999 base model TD Jackaroo Go to Supercheap and buy APP062 harness adapter 16 95 It is listed for Commodore VT onwards You use all of the wires except ILLUM and MUTE Solder all of the wires from the adapter to your head unit and heat shrink them Put a cable tie around the adapter as it doesn t lock in as the original You might want to wrap a bit of foam around the plug as to stop it rattling later Re the antenna control module GM 92029494 remove it open the back cover a
20. using a Tech 2 mor 34 MiesmsriwRa SSCS m5 34 Me SeswrHghiitag 9M og 5 Intake Artem Sensor Low Wage on Les 25 intake Artem Sensor Hoh vitae CON Po 18 Engine Coslart Temp Sensor Low itaq ON PUE i4 Eae Cootart Temp Sensor Hah Vias L ii 5 HeiPosionSensrRabnay O ON mur n e Posion Sensor Low vetas ON 21 Fecal Position Sensor High voltage Fua Temp Sensor Low ditage Fug Temp Sensor High voltage Rai Pressure Sensor Low ltage Rai Pressure Sensor High ditage RP CV Circuit Open Short Rai Pressure System Low voltage Rai Pressure System Hgh vokage Rai Pressure System High Witaming Oil Temp sensor Low ltage Oil Terme sensor Hgh s ltage njector 1 Circuit Fault njector 2 Circuit Fault njector 3 Circuit Fault njector 4 Circuit Fault High Coolant Temp Viaming High Oil Temp Vieming Engine Over Speed Wifaming Crank Position Sensor Qut of Syncro POSS Crank Position Sensor No Signal POS41 Cam Position Sensor Out of Synem mue a CamPesinsensrNogmi UN mus 86 Glow Pelay Grout Operen moss 67 Glow lae Git QpeniShot 4x 3 EsRWVtma 45 tSRBesweSesriw Wage L
21. 100 000 to 120 000 miles Faulty injector pump Dirty air cleaner Turbocharger or intercooler faulty Problems within cylinder head valves clogged up due to faulty EGR exhaust gas recycling unit White Smoke Normally means that the fuel injected into the cylinder is not burning correctly The smoke will burn your eyes Engne pump timing out Fuel starvationto the pump causing the pumps timingnotto operate correctly Low engine compression W erpetral in the fuel Blue Smoke The engine is burning engine oil Worn cylinders or piston rings Faulty valves or valve stem seals Engne over full with engine cil Faulty injector pump lift pump allowing engine oil to be mixed with the diesel Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 12 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 6 Diagnostics Non Starting Engine 4JX1 TC ENGINE DRIVEABILIT Y AND EMISSIONS 6E 49 Engine Cranks But Will Not Run Circuit Description In thistype of injector system the Engine Control Module ECM triggers the correct driver inside the injector which then triggers the correct injector based on the 57X signal received from the crankshaft position sensor CKP During crank the ECM monitors the CKP 57 X signal The CKP signal is used to determine which cylinder will fire first After the CKP 57X signalhasbeen processed by the ECM it will
22. 25 Alternator Specifications ce ete P PD e SEEDS ER EORR HE e FISU TF ED r E e E EE ansans 26 Regulator Problems Alternator eee eee e ee eee ee eate seen seta ane seta sete ao sesta setas ete aa setas ste an osea se eaa 27 Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 2 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 9 Fuel SUID E E TEKER 29 Fuel Filter ARR 29 CAV dubi le n 29 MatercamEllter ctore teneur at II AU M NEUE uM LN 30 luu 31 10 D1L CHANGES ssisicsinienniiinimnniianuniacnicanananciannianiennnens 31 Notes on Oil related matters ssccsscssssesssssccscessscscessssssssssssesesssssssssessssessssnsssessossscssessssssesssesess 31 COI E EAE occ 31 COSIN aTe AEN H 32 Injector Harness Seals ssciucisceitasesobens M 34 Catch CAM me 35 ENDS SIS c X 35 urne m 35 Gaskets and seals needed to change the injector eere Lees eee ee eee eee eee ee sete e setae etas eeas 36 I
23. 3 manifold turbo nuts Matt H on 30 May 2009 08 03 PM said 25 Remove the four m12 nuts which secure the long exhaust section to the main body of the turbo These are very tight due to the effects of heat You need to remove these studs as the new turbo does not come with them Turbo Aust advise that if you break one do yourself a favour and just go to Holden and get some for the new turbo as it is far easier than trying to find the right parts elsewhere and for one they aren t that dear Matt H on 30 May 2009 08 03 PM said 35 Using a 10mm socket at the exhaust end and an 8mm socket and the intake end remove the nut which secures the compressor fan to the shaft Its left handed or the opposite to what you would expect The odds of stuffing the thread are extremely high 36 Once the nut is off you can remove the compressor fan Four more star head bolts secure the opposite half of the aluminium intake housing to the bearing housing section A gentle tap with a screwdriver will remove this aluminium section Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 81 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 The compressor to shaft alignment should be noted scribe mark etc before removal if you plan on putting it back together The assembly is precision balanced and should be re assembled in exactly the same position Matt H on 30 May 2009 08 03
24. Catapillar Battery Battery Isolators Charge Protectors http www traxide com au isolators sc80 90 amps standard html This is the STANDARD SC80 The SC80 has been in production for more than 20 years since it is was first introduced and it still has features that make it far more versatile than any other other isolators The Standard SC80 is available in 12 volt and 24 volt on request The SC80 s first and most important objective is to protect the vehicle s main battery against being discharged bellow a point at which the battery would not be able to start the vehicle The Standard SC80 has a PRIMARY and a SECONDARY circuit These circuits can be joined together and operated as a single 90 amp auxiliary battery charger connecting the main battery to 1 auxiliary battery The Standard SC80 can be used to charge 2 auxiliary batteries via separate 45 amp circuits So if there is one auxiliary battery under the bonnet of a vehicle and another in a caravan being towed by the vehicle the SC80 will charge both batteries while the voltage at the main battery is at a high enough level After the vehicle motor is stopped all the batteries to extend the operating time of the auxiliary batteries can share the power But once the voltage at the main battery drops to the cut out level all the batteries will be isolated from each other Dual Battery This is how I have done mine along with a bezel light from dick smiths and a momenta
25. However combined front and rear axle load should not exceed maximum G V M 2500 2600kg Remember to take the tow bar ball weight into account when determining the rear axle load So my 2002 Equipe LWB auto petrol dual fuel has the following figures factoring in loaded Heaslip camper with overrun brakes GVM 2600kg Curb mass 1885kg 715kg for passengers luggage and modifications equipment including net increase for dual fuel system GCM CVM 2600 Heaslip camper 1000kg 3600kg Front axle load aim at 1200kg with alloy bull bar and dual battery no winch Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 113 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Rear axle load aim at 1400 kg i e 1300kg with rear shelving system PLUS 100kg tow ball weight i e 1096 of 1000kg trailer So System Weight Dual fuel system 80kg Alloy Bull Bar 50kg Driver amp Navigator 200kg Rear racks amp shelves 50 kg Alloy roof rack 20kg Full fridge 100kg Mallee tracks 20 kg Tools 20 kg Recovery Gear 30kg compressor etc Food etc 60kg Water 40kg 4 x 10 litre half Jerry cans 40kg TOTAL 710kg The above figures tow ball weight excepted would apply to travelling bob tailed i e no trailer Additional food water gear etc could be carried in trailer weight limits permitting Axle is rated
26. SAVE Image 2 of CLOSE X SAVE CLOSE X IMG_1980 3PG Size 90 68KB SAVE Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 74 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 CPS Crank Position Sensor Jack would just die no running rough coughing farting nothing Just cut out intermittently I d had a check engine light for some time with no associated code on the scan gauge didn t seem to affect the running so ignored it The lack of motive power forced me to look into things a little more and after shorting the ODBC pins I got the code for the throttle position sensor No problems quick call to Kumbak and the new to me sensor is fitted code gone and a quick spin down the back paddock proves it s all fixed Not Thinking all was good I headed into town to pick the kids up from school I made it half way before she stopped again Towed home behind the wife s Dunny door not real embarrassing About another week of diagnosing the problem ruling out all the usual suspects and I finally happened on a tip on the UK Isuzu website which mentioned the crank position sensor I pulled the sensor and what do you know it was covered in mud and crap Surely it can t be this simple Cleaned the sensor and reinstalled it The workshop manual mentions an o ring which there was no sign of when I removed the sensor I found one roughly the right si
27. Type suitable Yes I just rang Gary Butterworth from MTQ in Melbourne 03 9315 1633 and he confirmed the VIDS model supersedes the previous VICF with the main difference being the larger 40mm inlet wheel so more air will be pumped into the engine I would guess Shaft size is the same And he has these in stock so I will get this next week OTHERS Hi Arno I dont know what caused your turbo to sieze up but I do know there supposed to be free anyway you can get a turbo cartridge from E bay for about 220 delivered in 4 days TNT the one I bought was identical to the one I took off and they are a piece of cake to change Little tip just buy the cartridge and not the full turbo housing Below is where I bought mine from and I thought that was reasonable good luck Devon www ebay com au and search for RHF5 Turbo Cartridge Chra Jackaroo Trooper 4JX1T TURBO Removal and replacement Matt H on 30 May 2009 08 03 PM said 6 Remove the air intake pipe which connects the air filter chamber to the turbo inlet 7 Remove the intercooler 11 Remove the two brackets which support the intercooler forward and aft of the turbo 12 Remove the four bolts which hold the heat shield around the turbo There is one down the back which is a bit of struggle Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 80 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 13 Remove the
28. a crystal The oil pressure pressing against it will cause a very small voltage which is actually a pulsed signal That signal is sent to the management computer and controls the solid state switch which allows the circuit for the injectors to become active Remember the battery If the battery is not able to turn the engine at what you ll hear as a normal speed the oil pressure will not be enough to send the signal which opens the injectors The ORPS Oil Rail Pressure Sensor cost s about two hundred and twenty USS and if you do the job yourself your probably save a similar amount on labor charges The engine oil is also critical Only use the recommended oil If that has not been used Buy double the amount of the correct oil and two of each filter Drain what s there and then refill with the recommended oil once vehicle is up and running run the engine for thirty minutes or so pref on the road and then re drain and again fit the other set of filters and refill We don t like the chemical engine flush additives too dangerous especially in a diesel engine Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 101 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 21 Clutch The clutch on my Jackaroo has stopped working The pedal went down without disengaging the clutch and having pulled the pedal back up it will no longer go down Master cylinder
29. air con belt adjuster roller bearing is NSK 6203DUL 1 had to take it off to get access to the timing belt cover Timing belt was Gates T312 at 45 Posted 19 April 2013 04 07 PM Astiming belts go this is 1 of the easiest Remove air intake pipe alt amp a c belts wire 4 cam angle sensor plastic timing belt cover If you re replacing the oil seals behind the pulleys loosen the retaining bolts now With a socket on the front pulley nut turn engine over until timing mark on top timing belt pulley lines up Check timing mark on crankshaft pulley should be lined up on tdc Remove the timing belt tensioner Once you get the cover off it s all pretty obvious anyway Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 66 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 When you ve replaced the belt amp fitted the tensioner it s spring loaded but I usually give it a bit more tension while tightening it up Once your done recheck timing marks then turn engine over 2 revolutions with spanner this makes sure it s all good amp valves aren t hitting recheck belt tension Done this from memory so hope I haven t forgotten anything Cheers Graham Posted 20 April 2013 12 18 PM Did mine a few months ago and the only problem had was seeing the timing mark on the crankshaft pulley Couldn t see it at all from above Climbed under the car and could see it ok from underneath so e
30. and the throttle cable is properly adjusted install a new ITP sensor Installation Procedure the ITP sensor on the throttle body with the ts 3 Remove the bolis and the left side bracket to the ntercookr 4 Remove the air duct with bracket from the intercceler 5 Remove the throttle body from the intake rmanilok 6 Disconnect the ITP sensor electrical connector and throttle motor control connector 2 Install the throttle body to the intake manifold and the 7 Remove the belts and the ITP sensor from the throttle air duct with bracket between throttle body and body intercooler Torque 20 N m 14 Ib ft NOTE Do net clean the ITP sensor by soaking it in solvent The sensor wil be damaged as a result 3 Connect the ITP sensor electrical connector and throttle motor control connector Function Check 4 Install the bracket to the infercocler Use a Tech 2 to check the ITP sensor output voltage at 5 Install the cover af intercooler closed throttle 6 Install the negative battery cable The volkage should be under 0 85 volt If the reading is greater than 0 85 vol check the throtile shalt to see d itis binding DTC 74 is our old pal the TPS which again might NOT be faulty Whether with a new TPS or an old one the output voltage seen by the ECM measured at J1 18 varies with the MOUNTING ANGLE of the TPS on the side of the Throttle Body So loosen the 2 mounting bolts set up the Voltmeter between
31. bottom pipe and blow down it and you should hear the sound of air in side of engine If you have oil going in top and clear bottom pipe then you haven t any problems the turbo was no good but change oil to 20w 50 IF YOU hadn t any oil pressure then the engine would have blown up at about 1mile from the start Turbo was no good to start with White smoke and pressure in radiator My 1998 3 0 DOHC 4jx1 engine started pumping out white smoke Before this happened the check engine light was coming on intermittently On further investigation noticed that there was coolant blowing out of the breather tube on top of the radiator expansion tank When took off the radiator cap there was coolant blowing out of the radiator with some force and I assume in time with the compression stroke of one of the pistons A mechanic friend of mine says that the engine is not worth trying to repair and that these engines are notorious for this type of problem He said that it could be the cylinder head gasket or the head but he suspects that the engine block itself has fractured due to the force that the coolant is coming out of the radiator Just before this all happened I noticed that the heater would go cold and the temperature gauge would go to the cold side of the scale then go back to normal but it never indicated any temperature higher than normal Any Any sign of diesel in the water Sounds like head gasket to me the engine will rebuild ok but have the
32. easy to fit onto the oil cooler but could not get the fixing clip onto the engine block end took of the intercooler and intake pipe turbo shroud and battery then I could just about get to it http forum australia4wd com index php topic 27763 nb one more very important o ring to check and fix Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 53 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Water pump The water pump went a couple of years later at around 215 000km That cost me 246 50 from SMS Diesel Spares here in Sydney suzu on 22 Jan 2008 08 21 AM said Are they sure it s the water pump Reason is I have never had to change one yet in 10 yrs of working on them the common mistake over here is people think it s leaking when in fact it s the small gold coloured bypass pipe just to left of it It seals in the head with nothing more than an o ring which has a tendency to go hard and then leak and because it s surrounded by the sound deadening this soaks it up so you can t really see where it s coming from Is this the pipe below the A C compressor It is just under the air conditioner bracket the bottom bolts on just above the adjuster rail for the alternator and the top goes in to the corner of the head I ve replaced these o rings twice actually last time I just got a pack of o rings found 2 that fitted nice and tight and silicone it in
33. else inside because if you completely block the ventilation these gases could find another way to go by pressing out some seals Just imagine that this could be a crankshaft seal at the back near gearbox and get the price of fixing these tuning results WBR Sergey Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 8 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 2 How the 4JX1 System Works A close look at the HEUI System The HEUI fuel system consists of four basic components 1 HEUI Injector Uses hydraulic enerey as opposed to mechanical energy from the engine camshaft from pressurized engine lube oil for injection The pressure of the incoming oil 800 to 3300 psi controls the rate of injection while the amount of fuel injected is determined by the ECM 2 Electronic Control Module ECM This sophisticated on board computer precisely manages fuel injection and other engine systems The HEUI injector solenoid is energized by an electronic signal generated in the ECM Using input from multiple sensors the ECM s dual microprocessors use proprietary software and customer supplied performance parameters to produce maximum engine performance under any conditions Jill 3 High Pressure Oil Pump The variable displacement axial pump features a built in reservoir to immediately supply oil at cold starts 4 Injector Actuation Pressure C
34. from the turbo back with new flexible joint and flow through muffler for under 400 if that helps you in your decision Give the genuine one a miss Cheers My Roo Hi Jack have recently had a new exhaust system fitted to my diesel Jackaroo 2000 SE 4JX1 It is mild steel pressed bend 2 5 system from the dump pipe back with a straight through glass packed muffler and resonator just aft of it Total cost was 360 fitted The catalytic converter was removed The new exhaust has been routed the same as standard It s O K except the increase in pipe diameter has reduced ground clearance a little would recommend following along the right torsion bar and crossing over to left side of vehicle some where aft of the gearbox auto transmission to maintain good ground clearance As for the muffler it was a bit loud and have installed a much larger one twice the size with heaps more glass material inside it to absorb the noise It s still straight through but unfortunately it cost me another 120 though angry One other thing make sure a flexible joint is used some where in the system This takes out engine vibration They didn t fit one to mine initially and the vibrations were excessive could feel them through the footrest and my seat back Overall performance has increased The engine feels more responsive under acceleration and it holds a higher gear when overtaking on the highway and going up hills The only down side is tha
35. has correct level of fluid no detectable leaks l ve removed the inspection cover where the slave cylinder goes into the bell housing The fork on the outside is against the pressure plate It clearly isn t pulling against anything in the centre of the clutch The fork is pivoting normally on its pivot pin Having looked at the workshop manual it appears the clutch is disengaged by the release bearing pulling the cover plate diaphragm spring It seems that there is a breakage in whatever connects the release bearing to the diaphragm spring Am on the right track If so can this be fixed without taking the pressure plate off can t work out what connects the release bearing to the diaphragm spring The clutch pulls at the centre of the pressure plate instead of pushing Thrust bearing is held into centre by clip Is clutch engaged do you have drive Some things tom try are e Open bleeder valve on slave and see if you can push pedal to floor and if this allows any movement at clutch fork e Alsotry removing slave from gearbox and see what moves You will not get much movement at fork by hand AJ The hydraulics are all working fine The problem is the fork is not connected to anything in the centre of the clutch If push back the slave cylinder rod after removing at the inspection cover can move the fork back and forth quite freely The thrust bearing seems to have become disconnected from the pressure plate so it no l
36. injector is a direct scaled down copy of a CAT injector Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 44 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Hi Glenos After seeing it done first hand I would attempt it myself from now on If you have ever taken off the intercooler and cylinder head cover insulator to get to the rocker cover your basically there This involves a couple of steps including the removal of the throttle body flange plus the air intake duct from the air cleaner box through to the turbo and the removal of a hose at the rear of the engine You can then remove the engine insulation cover and foam from the cylinder head cover and inlet manifold This will then allow you access to the glow plugs A narrow metal runner is bolted to the top of each glow plug which needs to be removed first Then you can remove each glow plug Mine came out quite easily but the mechanic was very surprised and was expecting it to be a little harder It is important the right tools are used here as the glow plugs are at an angle A cheap socket set will not suffice you need a higher quality socket set which allows you to remove the plug at an angle They also took the time to inspect the wiring loom near the throttle body and give it a good clean out They re attached it with a cable tie at an angle so the oil would no longer run down the wiring loom into the connector
37. problem is most likely associated with other ECU inputs e Cam angle sensor e Crank angle sensor e Fuel pressure switch and or e Other electronics CTIs Oil Rail Pressure Meter can also be used as an economy fuel gauge for Isuzu 4JX1 engines by driving with oil pressure readings below 2 5 I think buying a Tech2 and reading the Isuzu manual is the correct translation There are so many hoping to cash in on the fear of the 4JX1 It s a simple system The oil that drives the injectors is held at the right pressure by the ORPS and the RPCV The Oil Temp sensor is a bit of a fine tune for oil viscosity The wiring harness needs a clean at 240 00km intervals After that the ECM does all the work Period Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 69 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Change the sleeve seals and copper washers at the same intervals as a CAT diesel 100 000km Buy a Tech2 for 400 lousy bucks and learn to read it Then be assured you have the same super reliable super economical super long lived Isuzu diesel as in all the trucks I ve owned Starting after replacing injector O rings You need a fully charged battery to get oil up into the common rail and at 400psi all the air out of the fuel lines The Isuzu manual tells you straight that it will take a lot to start it if the oil rail isn t primed with 300cc of oil When the die
38. rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 37 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 VALVE CLEARANCE ADJUSTMENT NOTE 1 Valve clearance should be inspected and adjusted while the engine is cool 2 A ME M D ANTO MA an INSPECTION 1 Remove cylinder head noise insulator cover and cylinder head cover Refer to Cylinder Head in this manual 2 Disconnect ail hamess connecters of the injector and remove hamess assembly 3 Drain oil from oil rail assembly 4 out injector assembly 5 Loosen oi rail bolts remove oil rail assembly 6 Set cylinder No 1 to the TDC at the compression stroke Make sure that there is play in cylinder No 1 tappets on inlet and exhaust sides and that there is no play in cylinder No 4 tappets 7 Measure valve clearance at No 1 TDC Refer to the black circles indicated in the illustration Standard Valve clearance Intake valve 0 15 mm 0 0059 in 0 05 mm 0 0020 in Exhaust valve 0 25 mm 0 0098 in 0 05 mm 0 0020 in oo 00 lt No l No 2 No 3 No 4 ee ee o0000p 8 Tum the crankshaft one tum to set No 4 cylinder TDC at the compression stroke 9 Measure valve clearance at No 4 TDC Refer to the black circles indicated in the illustration Standard Valve clearance Intake valve 0 15 mm 0 0059 in 0 05 mm 0 0020 in Exhaust valve 0 25 mm 0 0098 in 0 05 mm 0 0020 in ENGIN
39. t change 2 Select zero steps unscrew the allen head screw then push the throttle blade until it contacts the throttle body Next screw in the allen head screw until the throttle blade starts to move away from the throttle body Note the voltage on the Tech2 it should be higher than was achieved at step 10 When shutting down the engine the ECU commands to stepper motor to step 11 which I presume is to fully close the air intake to gently stop the engine 22 Retighten the jam nut and recheck that the TPS voltage at 10 steps has not changed 23 Power off the Tech2 and turn off the ignition 24 Disconnect the stepper motor and TPS wiring and reinstall the throttle body using new gaskets 25 Reconnect the stepper motor and TPS wiring Retighten the stepper motor and TPS mounting screws 26 Reinstall the intercooler bracket that bolts to the throttle body 27 Reinstall the pressure hose between the intercooler and the throttle body 28 Tighten the intercooler mounting bolts 29 Tighten the clamps on the pressure hose between the intercooler and the throttle body 30 Replace intercooler cover 31 Reconnect the glow plug wiring 32 Start the engine and re run the Throttle Position Motor test on the Tech2 as a final confirmation ECU and calibration of TPS When I replaced my first TPS I checked it out with a multimeter and found that it gave correct values at either end of its travel but gave inconsistent readings in the middle of its travel
40. the ECM connector J1 pin J1 18 and Battery and turn the TPS until the voltage is about 0 85V that s with the Ignition ON and the Engine OFF It does NOT require a Tech2 as the voltage can be read directly from the ECM connectors Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 83 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 ITP Intake Throttle Position sensor Error DTC 74 think what Browndoff means to say is use a Tech 2 Then using the Throttle Position Motor program check the TPS voltages at each step against the chart below The TPS might be OK but just way out of alignment or in need of a clean with some contact cleaner removed the TPS and cleaned it with contact cleaner This made no difference whatsoever purchased a new TPS Holden part number 8973728510 which cost 108 Fitting this seems to have cured the problem I haven t driven far yet but the check engine light has not come on disassembled the old TPS which is basically a carbon film potentiometer variable resistor The carbon film was badly worn see picture by the sweeper and presumably the film was completely worn through in places giving the occasional open circuit which would cause the check engine light to come on There was no oil inside the TPS Two points which may be helpful to others 1 There is no need to take off the throttle assembly to replace the TPS i
41. the black wire between the sender and the plug and soldered a wire to this and the switch terminal There is a picture in my gallery of the assembly The sender now operates the oil pressure gauge and the new switch operates the oil warning light If the light stays on and the gauge stays at nil I know I have a problem with oil pressure If the light goes out and the gauge stays at nil I know there is a fault with the sender Better still nothing odd happens again The parts cost 27 but it was a bit fiddly as the thread on the switch and the adapter both had to be shortened so that they sealed properly Just for the record the thread on the sender is 1 8 BSPT Thanks to Husky and Suzu for help along the way Cam sensor My Gates alternator belt broke today and ripped out my cam sensor Car won t start now but kept running when it happened Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 73 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Not available at SMS diesel spares Repco don t have a supplier Bursons do but the price comes in around 150 Genuine from Holden 128 No warning lights came up when sensor was destroyed but vehicle continued to run Only one of the alternator belts broke so no alternator light came on as it continued to run on one belt It was only when stopped that it wouldn t restart I am unsure when the belt broke on my journey but I do
42. the last person to have it off The underside of the flexible end that attaches to the turbo was folded under the clamp which not only allowed intake oil contamination to leak out but also most disturbingly allows air dirt etc to be drawn straight into the compressor If you haven t had yours off it would be worth checking as replacing a turbo is something all of us want to avoid I don t know whether it is directly related but I also checked the turbo bearing free play and it is well beyond the allowable max of 0 14mm Looks like I have another warranty claim to make Cheers Andy Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 79 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Turbo Timers Holden Jackaroo L2 Series Turbo amp Rodeo R7 R9 Turbo Including 3 0 Litre Product Code 724 R7 The most popular and foolproof method of guaranteeing that the engine manufacturer s recommendation is carried out every time you switch off is to fita BOGAARD Turbo Timer Many thousands are fitted to vehicles as diverse as Subarus Land Cruisers and Kenworth trucks Some of Australia s largest and most respected truck manufacturers fit BOGAARD Turbo Timers on their assembly lines BOGAARD Turbo Timers are inexpensive foolproof amp fail safe They are easy to fit with plug in models for many popular passenger amp off road vehicles 271 04 inc GST Turbo Changes
43. working ok So left it as is Starts ok 11 and now will check that had not missed something Posted 27 December 2012 08 12 PM An engine with good compression not only compresses well it also sucks very well on the intake stroke Fluids may be drawn into the engine including 1 engine coolant water white smoke usually 2 excess amp unburnt diesel white smoke usually 3 engine oil blue smoke usually The HEUI injector system can produce nozzle tip pressures approaching 30 000psi This means that a faulty fuel injector control system can put too much fuel into the engine There is a fixed amount of oxygen so part of the fuel wouldn t burn in that case You will then get white smoke smelling of diesel acrid i e unburnt diesel hence white smoke can come from sources other than a loss of compression a faulty injection Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 20 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 b Fuel leaking past seals under partial vacuum into the combustion chamber White smoke may also come from water leaking past the injector seals which is common in this engine Therefore check for error codes from the ECM If there are none the problem is likely injector seals not faulty fuel injectors If there are error codes indicating injector failure that section of the engine should be checked first In my case ther
44. 013 12 14 PM said There are many other types of Diesels with EGRs that have the EGR system blanked off with no apparent ill effects Some have to have a small hole in the blanking plate to prevent a fault code and subsequent limp mode but that s it Yes it s tempting to just block the EGR thing off and have a clean intake manifold But it seems that Isuzu fitted a throttle plate mainly for the EGR which means that throttle plate openings are timed to suit the EGR manifold vacuum requirement so the system is well embedded in the ECM s programming would say that Isuzu used the legislated compulsory EGR requirement and the accompanying throttle plate gizmo to control a few other things as well Such as the mass of air coming into the cylinders air fuel ratio and turbo spool down times and thus engine braking This seems to effect idle running and god knows what else It would be rather handy if the Isuzu manual started every chapter with and we did this because HEHEHEHEH HEHHEHE H H H HHHH H H H H HHH HHHH HERE H H H H H EPEPTEPEPEEEEPEPTEPEPTEPEPEE PEP ET Calibrating the TPS Throttle Position Sensor http forum australia4wd com index php topic 28024 tps adjustment procedure p 196608 for full description and comprehensive images I ve had the throttle body off a few times for various reasons and I thought I d share with you my procedure for calibrating the TPS As SergAnt and other gurus will tell you it s
45. 14 Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 117 Page
46. 407 970 9724 0797 9095 661 190 jector sleeve bottom O ring x4 0956 6119 9401 1699 8971 9720 4076 8971 378 200 9713 7820 eee abe e M See ae injector 8971 925 963 njector to oil rail O ring x4 njector sleeve top O ring x4 njector sleeves Throttle Body gasket Injector wiring harness 8971 463 368 Rocker Cover Gasket 9716 0672 Oil Rail control amp sensor 8971 370 421 Oil Rail Pressure Sensor ORPS 9713 7042 O ring 8971 865 720 Rail Pressure Control Valve RPCV 8971 748 720 njector wiring harness 8971 463 368 8 97146336 O D U o OJOO zjzjz 0 ront Axle ront axle oil seal 8980 365 940 ront axle bearing lock screw x3 8978 101 070 mmm OJO Ex Rear brakes Rear brake guide pin type A GM 8943 628 210 Rear brake guide pin type B GM 8974 160 210 Rear brake guide pin boot GM 8943 628 230 Read brake pads Bendix DB1280 arking brake shoe Beck Arnle 081 3237 Mainifold Air Temperature sensor MAT GM 8121 468 830 Manifold Air Pressure sensor MAP GM Intake Throttle Position Sensor ITPS GM 8973 728 510 low plugs x4 Glow Plugs Aust CPI 026 SMS Diesel PI 172 BOSCH GP1026 HOLDEN ISUZU 8 97143674 1 teering idler arm Pedders PSX9710 Alternator Drive belt x2 BOSCH 11A1005 earing BEX4000 earing 6303 Mid Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 116 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 20
47. 5 30 OR 5 40 FOR THIS ENGINE REASON BEING IS THAT THE OTHER GRADE DOESNT CREATE THE SAME OIL PRESSURE AND IF THE OIL PRESSURE IS NOT CORRECT THESE ENGINES WILL NOT RUN BEEN THERE DONE THAT have a Isuzu Bighorn 4jx1 but is hard starting When it cranks the engine on but but does not pick up speed or it starts like it was out of fuel Can you advice on what to do Try slightly over filling oil level if engine starts and runs for a minute or two then dies the oil pick up in sump has fallen out cracked mounting bracket or sucking air instead of oil you can remove small tin engine sump after draining to check oil pick ups after confirming it runs ok for a little while once over filling oil level in engine Another thing that goes is the rail oil pressure sensor which reads incorrectly and a tell tale sign this is broken is the injector loom connector is full of engine oil when disconnected this is near engine oil level dip stick wiring loom coming out of rocker cover The sensors reading can be checked with scan tool before starting with ignition on 0 0 2MP4A it must read if its reading higher with ignition on only motor not running the sensor needs replacing The engine ECU needs to see approx 200MPA when cranking to get injectors to start to work properly and higher when running at idle and beyond up to about 5MPA at higher revs if this is not getting to this or readings are fluctuating badly indicating air in oil the injectors wont su
48. 65071 Doesn t really matter if its at the front or on top the 4x4 has to be moving to get airflow so the fan would only be any good at speeds below approx 20K s is it worth doing Yes but there is a lot more heatsoak for top mounted intercooler s on idle Turbo Sources Yes I just rang Gary Butterworth from MTQ in Melbourne 03 9315 1633 http www mtqes com au products php and he confirmed the VIDS model supersedes the previous VICF with the main difference being the larger 40mm inlet wheel so more air will be pumped into the engine I would guess Shaft size is the same And he has these in stock so I will get this next week And http www dtsturbo com au There are 3 turbos listed as having been fitted or available for fitment to the 4JX1 They are as follows Man Type Model Specs THI RHF5 VICF RHF5 64006P13 5NHBRL382CAZ THI RHF5 VIDF RHF5 64006P13 5NHBRL401CEZ Each of the three share housings and turbines and all have an A R of 13 5 The second and third listed differ from the originals in that they have a 40 1mm intake inducer rather the earlier 38 2mm There is no information relating to shaft diameters or improvements to oil passages Night before was spent in decisions what s better to replace the turbo cartridge or the whole turbo And how to pay the next month bills if so Posted Image Or I should have to look for a new job more actively Quote file d 5 personal rob car jackaroo jackaroo 4jx1 en
49. E MECHANICAL 6A 67 OO e 00 ee amw O0 0000 ee 10 If measured value is outside standard value readjust the valve clearance ADJUSTMENT For valve clearance adjustment follow the procedure given below 1 Set cylinder No 1 or No 4 to the TDC at the Set the valve clearance adjusting tool on the tappet requiring adjustment After making sure of the correct setting of the special tool depress the tappet by tuming the bolt Valve Clearance Adjusting Tool 5 8840 2590 0 NOTE Before depressing the tappet set the tappet notch in the direction where adjuster can be easily taken out 2 Take out the adjuster using a small screw driver and finger magnet Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Exhaust I decided on 2 5in tube from the turbo back Originally went with no muffler or cat and fuel economy was improved as was the power Noise wasn t a real issue as the turbo s keep the noise down to almost legal limits just don t flog it around town The problem that developed was there was not enough backpressure on the engine so no engine braking or very little and the turbo didn t enjoy the experience either Installed a 2 5in straight through muffler and no more turbo problems but a little more fuel usage and less power but more than factory The whole system in mild steel including muffler was 250 installed at Dandy Exhausts in Melbourne had a new mandrel bent 2 5in system installed
50. EXHAUST Adjustment is by the standard method on OHC engines of putting different thickness shims in The standard shim is 2 8mm You will note in the manual that valve gaps are checked when cylinder 1 is at TDC and then when cylinder 4 is at TDC one 360 degree rotation of teh crank later Which valves to check when are in the manual There is nothing in the manual to suggest that the inlet and exhaust cams are interchangeable The diagrams show which valves are closed through one 360 degree rotation You will note that through the 360 degree rotation the two adjacent cylinder pairs 1 2 then 3 4 close on the inlets But during the same rotation consecutive cylinder pairs 1 3 then 2 4 close on the exhaust The whole valve closing sequence is not shown of course but this suggests that even if the camshafts are located differently on the main drive gear in from the cam timing belt one set of lobes is different to the other Personally always put them back the way they came out and hadn t checked to see if they re identical Gasket arrangements change during the model progression Generally a later set suits all wouldn t have thought they would be interchangeable either suspect it will need to be re setup Being sent back down As for the gaskets or head set the mechanic is just concerned that there wasn t much in the way of other little bits I m running blind here so just trying to gather info Quote file d 5 personal
51. Holden dealer network There has been a single campaign to replace injector sleeve sealing O rings but no indication of replacing the injectors themselves The relevant Campaign Notice is available at the Product Recalls Australia website http www recalls gov au view recall detail php Recall ID Autoz13023 Early injectors up to Serial No 519266 used a rubber O ring material green colour probably Viton but later ones were fitted with ceramic seals instead Whenever owners are having injectors replaced they should ensure only later model injectors ie after 519266 are fitted as these will have the most recent ceramic seals Based on extensive experience in the UK my overseas contact advised that all injectors fitted to early vehicles up to about 2001 ie those fitted with rubber O rings prior to later ceramic seals are likely to have a problem at some point and would need to be replaced From 2001 onwards it seems if they are going to go they fail early say approx 30 k kms Failure of the later model injectors ceramic seals appear to be very rare Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 35 Page Manual Jackaroo 4JX1 Engine March 2014 Gaskets and seals needed to change the injectors Monday March 31 2014 Item Holden part numbers Number Notes gasket nozzle GM 8972407980 4 washers o rings and seals gasket injector nozzle GM 8971757830 4 4 gask
52. Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 MANUAL FOR OPERATION OF THE 4JX1 DiEseL UBS 73 VERSION 3 0 31 MARCH 2014 UBS69 3 1 turbo diesel motor 4JG2 Trooper Bighorn Jackaroo UBS73 3 turbo diesel motor 4JX1 Trooper Bighorn Jackaroo 4JB1 T engine will replace 4JX1 Manual whole ca rhttp www clubisuzu com http vocasupport com 4jx1 engine for download General The 4JX1 is a CAT engine licenced engine to IZUSU Mechanics that work on the 4JX1 Mechanical World on Edward St Wagga South Coast 4wd in Wollongong http www jcdiesel com au http www smsdiesel com au contact pages Melbourne contact html SMS Diesel spares 133767 http eng tek com au Engine performance Disclaimer Any brand posters or other names mentioned are purely for general information and are not endorsed by the author s The written material largely comes from http forum australia4wd com index php forum 60 4jx1 30 ost amp topicfilter all Not all contributors are noted eee cd Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 1 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 INDEX FOR 4JX1 1 Overall operation of the 4JX1 Engine eere eee esee esee en eene n eee en netten eset ta seta rne t anas 6 What is a Diesel engine and questions on operations eee ee
53. PM said 42 Conclusion well had finally satisfied my self that the turbo can not be reconditioned by an amateur The journal bearings are pressed into place and would need to be damaged in order to remove Hmm Mine came out as part of disassembly No pressing was required Perhaps that is part of the problem with yours if they have fused into the body Matt H on 30 May 20089 08 03 PM said 43 Come Monday am ringing Turbo Australia for a replacement Not sure how much of the turbo they give you Will update shortly hope this was of some benefit Cheers Matt They give you a complete turbocharger with a new oil outlet gasket They suggested to me that if was careful with removal could re use all other gaskets and copper washers which did but apply a smear of high temp Ultra Copper to the exhaust gaskets upon assembly If did mine again would probably anneal the copper washers before reassembly The other thing they do not come with is the dump pipe studs as mentioned above FEEEFELEELELEEFE ETE ETELEET EEE H HHHH H EEE ETE ETHEL TEEPE EE EEE ETE T EET EE EET Ett tet tet HER ER Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 82 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 18 TPS Throttle Position Sensor 4JX1 TC ENGINE DRIVEABILITY AND EMISSIONS 6E 209 2 Remove the cover of the intercooler Ifthe throttle shaft is not binding
54. Td6 Hyundai Terracan Land Rover Td5 Range Rover Td6 and Holden Jackaroo 3 0L diesel engines Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 31 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Oil Pickup There have been instances of the oil pickup in the engine sump breaking off These are found by topping up oil levels when suspected and then engine starting Pickup pipe on the oil pump been fixed under a recall As recall they were prone to falling off Had mine a 2000 se fixed under warranty whilst had a fault on a pressure relief valve rectified Pipe Oil Strainer GM 8980125320 and Gasket Oil Strainer GM 8971377980 Revised high pressure oil pick up pipe next to the old style the old ones bracket is about 2mm thick and the new one about 7mm This is due to the old one being so thin the vibration and heat of the engine and it has a tendency to warp and even brake the bracket causing the pipe to fall out causing a lot of problems from no start hard start and even stalling Slow rise of Oil pressure on start up also had this problem of oil pressure taking 5 seconds to come up on cold start discovered that the problem was the oil cooler which sits on top of the oil filter housing draining slowly into the sump when the engine was shut down The oil filter housing bolts to the engine block and has an o ring surrounding it which prevents o
55. a down The white is Antenna up The relay box shows 7 wires the pink an the gray go to the antenna and the black to earth Now the blue wire from the pioneer which wire do connect it to Geoff Posted 14 February 2010 08 53 AM Recently replaced my aerial with the Aerpro AP180 genuine no longer available see occasionally they are available on ebay but if need to replace mast can do so with the Aerpro mast AP12 Here is the wiring diagram for the aerial control box located behind the glove box for those who want to keep it You will need to mount a momentary rocker switch available from Jaycar etc to control the manual up or down Cheers FEEEFELEELEFEEFE ETE ET ETHEL EEE H HHHH H EEE ETE HHH PETE ET EET HEHPHEHEHRHEHEHEHREHHERHEHRHRHEHEHHEH HERE HRHRRR Pin number Colour Usage 1 Black Red Down control 12V momentary 2 3 Pink Aerial 12V continuous supply 4 Red 12V continuous supply 5 Black Earth 6 White Up control 12V momentary 7 Grey Aerial 12V switch 8 Green Black Radio 12V switch Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 106 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 23 Cruise Control Jackaroo SE 2000 Model 3L Diesel Cruise Control Installation Command Aire AP 50 available from K Mart Provided by Trevor Mills 24 Tyres 265 75 R16 is about as big as you can go a
56. acks or corrosion in the impeller INSTALLATION 1 Gasket 1 Set gasket to gear case 2 Water Pump Assembly 1 Instal water pump assembly and tighten to specified torque Torque 20 N m 2 0 kg m 14 5 Ib ft 3 Cooling Fan Assembly 1 Install cooling fan assembly and tighten to specified torque Torque 8 N m 0 8 kg m 5 8 Ib ft 4 AC Generator Drive Belt 1 install AC Generator drive belt and adjust belt tension Torque 40 N m 4 1 kg m 29 7 Ib ft For ACG to bracket 20 N m 2 0 kg m 14 5 Ib ft For ACG to adjust plate 5 Fill coolant to specified capacity Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 55 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 13 Sensors and Returns Ok after cutting THE white wire codes are Fault Type Codes Inj 1 fault 51 Inj 2 fault 52 inj 3 fault 53 Inj 4 fault 54 ORP High Voltage 62 DTC P1196 Rail pressure system high warning Oil system high warning P0192 Flash 63 Rail Pressure Sensor Low Voltage P0193 Flash 63 Rail Pressure Sensor High Voltage Rail Pressure System Low Voltage DTC P1194 Flash 61 Rail Pressure System High Voltage DTC P1195 Flash 61 Multi plug connector When the loom is unplugged oil in the plug means the harness is wicking and the oil creates cross talk too and from the ECM and its only going to get worse I would re
57. all to flush the dirt out In the process of going right through the systems discovered the primer pump wouldn t prime so after scratching my head a lot took the primer pump out benched it and connected 2 hoses with a bottle of diesel at both ends It worked perfectly when pumped it on the bench But noticed one simple problem The mechanic who last worked on it had connected the fuel hoses the wrong way round So this weekend she ll be back in the engine bay and expect the vehicle will run ok now After all engines never run well with any gas And I suspect the flap valves work in reverse if the hoses are back to front and stop fuel flow entirely For future reference l ve put a photo on here of the correct plumbing must say the plumbing is not intuitive so perhaps my pump is from a foreign vehicle so check yours before relying on this photo please The hose fitting closest to the tank is in fact the outlet to the fuel pump My best guess on why this is so is that the Isuzu Trooper was designed as a LHD vehicle so the engine bay would be partly reversed to allow for the steering column Water Scan Filter http forum australia4wd com index php topic 26797 waterscan fuel filter Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 30 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Fuel Pump 10 OIL CHANGES Most likely the wrong g
58. anual 2014 ver 3 0 doc 60 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 1 Connect Tech 2 to vehicle DLC 2 Turn Ignition Switch to the ON position 3 Select DIAGNOSIS from the main menu 4 Select Programming 5 Select Oil Pressure Sensor change 6 Execute Oil Pressure Sensor Program 7 Confirm the completion of Oil Pressure Sensor Program I went through the operation with their technician and the tech 2 had no selection for oil pressure sensor change so what s the real answer here does it need it or not Jeff Rail Pressure Control Valve RPCV JackDriver on 15 Feb 2013 10 57 AM said Hi guys Been playing with my newly acquired Tech2 smile png and noticed that at idle the Rail Oil Pressure fluctuates between 3 9Mpa to 4 5Mpa when the Desired Rail Oil Pressure is 4 0Mpa During this time Rail Pressure Control Valve stays fixed at 19 hmm png I d like to know if anyone else with acess to a Tech2 has seen this fluctuation It it normal or does it indicate a problem like dicky ORPS or sticky RPCV question png I also noticed that when turning the engine off the Rail Oil Pressure drops immediately to 0 5Mpa and then gradually falls lower and lower to be at 0 2Mpa within 30 seconds Again I d like to know if this is normal or whether it indicates leak in the oil rail somehwere like maybe a faulty check valve or failed O ring Any ideas unsure png Cheers JackDriver Oil rail pre
59. aring out There will be a range that the ECM will consider serviceable If the RCPV s response is within tolerance but slowing the ECM will simply pick up the time the Fuel Injector fuel tip is open At some point the RCPV will slow enough to trip an error code It is unlikely that a jerky response at idle would do anything more than produce a less smooth idle As the engine speed increases the ECM will take up any slack This is one advantage of a computer controlled engine it re tunes the engine as it wears for optimum performance Cleaning the RCPV If this phenomenon is of concern the solution is to clean the RCPV It is a delicate device and cleanliness should be observed The device can only be cleaned in an ultrasonic cleaner which will delicately but thoroughly clear all unseen interior passageways as well as those surfaces seen A small ultrasonic cleaner 2L can be purchased on ebay for 75 However if the engine is running smoothly at idle the risk of damaging the RCPV valve during cleaning is too high in my opinion Perhaps the best indicator is fuel consumption Edited by chilby 20 February 2013 10 11 PM EEEEHEHEHEHEHEEHEHEHEHEHEEHEHEHEHE EE HHHH EE EHEHE EE TEHEHE EE EHE EHE EHE HER E P HEHR ER ECM Engine Control Module The ECM is the Engine Control Module which is a fairly robust computer dedicated to managing the timing and length of the injection stroke fuel input and the oil pressure in the Rail hydrau
60. at s my understanding anyway Sump Removal Posted 16 November 2009 11 13 AM Hi lan will need to order a new sump gasket also What sealant is best for the sump and oil pickup if any Thanks 3 Replacement oil pick up post 3 jackezy As we spoke about today there is no gasket just use some Permatex black silicone adhesive sealant Clean the surfaces with kero or thinners and let it evaporate before applying the sealant HERE EHE EE EHE EE E EHE EE EE EHE ERE EEHE IEEE E EHEE EE E EHEEE EE ERE EE ERE EE HHHH EE EHEE EE ERE E E ECRIRE RR E Scrooge Posted 20 April 2006 01 13 PM On a camping trip recently to a fairly remote National Park on starting up one morning to drive home there was no oil pressure on the guage and the oil warning light did not go out Thankfully on the third attempt after running about 30 seconds each time oil pressure came up so we were able to drive home A similar thing happened a few days later I figured the most likely problem was the oil pick up seals so I changed them I have put some pictures in my gallery showing the parts etc A couple of points to note e The cross brace behind the sump needs to be removed to enable the sump to be removed well I m pretty sure it needs to be much easier anyway Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 72 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 e After draining the oi
61. caused a stray electrical path which think effected the wire throttle response As added insurance against the risk of a short circuit also used cable ties to support the connector away from direct contact with metalwork I ve also been concerned about a tight bend in this wiring loom upstream a few inches towards the engine and meant to check it for a while Today pulled the connector apart again lifted the wiring and found the insulation had worn away badly not quite through through contact with a corner of the engine Fortunately there was no exposed copper but there certainly would have been in time carefully cleaned the wiring wrapped with insulation tape and the then spiral wrap also rerouted the wiring slightly to avoid the tight bend Engines now runs as smoothly as ever no hesitation and correct throttle response Thanks Red one checked my plug as soon as i read your post and sure enough full of oil Cleaned it out and she runs better than ever only had her two weeks As for the wiring already done all good E EE Once the wiring insulation is worn through giving a possible earth path any change of direction such as going up or down a hill starting or pulling up eg at traffic lights could cause the wiring to move slightly and in some cases cause intermittent symptoms My theory anyway When had the problem found could make the revs change just by moving the wiring around with my fingers Quot
62. command all four injectors to allow a priming shot of fuel for all the cylinders After the priming the injectors are left OFF during thenext four 57X reference pulses from the CKP This allows each cylinder a chance to use the fuel from the priming shot During this waiting period a camshaft position CMP signal pulse will have been received by the ECM The CMP signal allows the ECM to operate the injectors sequentially based on camshaft position If the camshaft position signal is not present at start up the ECM will begin sequential fuel delivery with a 1 in 4 chance that fuel delivery is correct The engine will run without a CMP signal but will set a DTC code Diagnostic Aids An intermittent problem may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for the following items Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating broken locks improperly formed or damaged terminals poor terminakto wore connection and damaged harness Faulty engine coolant temperature sensor Using a Tech 2 compare engine coolant temperature with manifold airtemperature on a completely cool engine Test Description Number s below refer to the step number s on the Diagnostic Chart 4 An obvious cause of low fuel pressure would be an empty fuel tank 5 The engine will easily start and run if a few injectors are disabled It
63. commend changing the harness as well as the ORP s Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 56 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 14 ORPS Oil Rail Pressure Sensor Some reading http forum australia4wd com index php topic 18628 rail pressure control valve Since the engine will run when the ORPS wire to the ECU is cut and you have replaced the ORPS it would appear that the ORPS is either not getting the correct 5V voltage or GND voltage to it Can you do a flash code test to see if there are any of the following DTCs set DTC P0192 Flash 63 Rail Pressure Sensor Low Voltage DTC P0193 Flash 63 Rail Pressure Sensor High Voltage DTC P1194 Flash 61 Rail Pressure System Low Voltage DTC P1195 Flash 61 Rail Pressure System High Voltage Flash code diagnostics can be used to read active codes and to determine if history codes are present but cannot be used to clear codes or read history codes Flash code diagnostics is enabled by grounding by terminal 4 shorting to terminal 13 of the DLC connector with the ignition switch ON Grounding terminal 4 of the DLC connector see douments below Attached File Reading Flash Diagnostic Trouble Codes pdf 70 49KB 2 downloads Attached File Rail pressure system low or high voltage pdf 89 06KB 1 downloads Attached File Engine cranks but won t run pdf 69 67KB 3 downloads The White Wire ORPS wire to
64. d the injectors to fire if the signal from the ORPS shows too low Oil Pressure Cut the magic white wire and it ll go but very badly cos the REAL pressure is still too low I pulled apart the orpcv it all appears ok gave it a good clean put it back together and still no luck it still runs fine with the orps wire cut When I stop the motor and plug the orps wire together it will try to start and just idle along very slowly with no throttle response When its running I get between 2 7 volts at idle and 2 9 volts at 2000rpm from the white wire so to me it seems like the oil is being controlled fine and I am getting a signal back to the ecm I have 5 volt supply to the orps I will put a test light from the battery and check the earth circuit tomorrow It is a cheap ebay orps as well Would be great if someone could check their voltage at the white orps wire Nathjack Calibration ORPS Posted 05 February 2010 07 14 AM I fitted a new orps to my Jack and took it to a Holden dealer to program the computer for it After going through the tech 2 they told me it wasn t necessary and the tech 2 hadn t a program to do it This is the extract from the service manual which says it must be done and the procedure to follow to do it Rail Pressure Sensor Programming Rail pressure sensor replacement must be programmed This programming needs Tech 2 Programming Procedure Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine m
65. d into the Valve Body until just tight don t get too enthusiastic Slip the Needle into the Needle Valve blunt end facing the Long Pin and screw the Main valve into the Valve Body try NOT to scratch the outside After you ve screwed the whole thing into the HP Oil Pump oil the inside of the Solenoid casing and slip it over the end then the Top Hat and the Nut be SURE to tighten the Nut as much as you think it will take if it gets loose it can fall OFF and the ROPCV will stop working properly cos the Solenoid has no leverage The reason the small hole must face out is that the piston must PUSH on the end of the Long Pin if it were the other way around the Pin might fall inside the Piston Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 96 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 20 Other Solutions Other sources http forum australia4wd com index php topic 27713 a run down of things that have fixed issues with my 4jx1 Shop there had replaced second hand H P pump New injectors and new glow plugs Still failed to get it to run My guys got it running It was driven to us and rode it around for about seven days to make sure everything was ok Parked it on a slope one day and it began to misfire on start up Idled but would not pick up RPM Bled the system and it started up behaved as it should The next few days i
66. day March 31 2014 This will be alien to most normal driving and against normal instincts Failure to stop the engine at this point may lead to a very expensive engine rebuild Staying on a high traction surface eg bitumen would be better than driving onto loose sand spinning wheels would have little braking effect on the engine Do not turn off the ignition before the vehicle comes to rest to avoid locking the steering wheel What is a Diesel engine and questions on operations A diesel alters engine speed by varying the amount of fuel to the injectors Disagree By the amount of fuel and AIR And air is as important as fuel A diesel does not need a throttle plate In fact all it would do is restrict airflow and reduce efficiency Disagree Amount of air coming to intake manifold and staying there prepared to be pushed in the cylinders is calculated and controlled by MAP sensor and Throttle body sensor If we can replace this to by airflow metering sensor like at petrol cars yes we can eliminate the throttle possibly but at our conditions we cannot The size of the pipe x pressure inside amount of flow through Normally fuel injector output by the ECM controls air fuel ratios the Lambda ratio This is by using the data from ALL sensors Fuel temp intake air temp coolant temp MAP TPS Can you feed the EGR system with clean filtered air instead of dirty combusted air This part is easy but how you will heat it to th
67. dealer put in new injector tube sleeves and O seals No electricity from ECM to injector Hi Markq Seems you may have a similar problem on your machine to the one we ve had The 4JX1 has taught us a lot we didn t know before but specifically for this particular engine First I ll advise you check the obvious things Make sure that your battery is charged fully I ll explain why later Next make sure that there s no air in the fuel system On the filter housing you ll see a ten millimeter bolt which should be loosened and once loose push the plunger atop the housing to remove any air Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 100 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 If bubbles come out you ll know that that was the problem or part of it With this particular engine the ORPS sensor gives the type of problems you re talking about The sensor in question is fitted inside the tappet cover into the oil rail which is the cylindrical pipe fitted over the valve assembly It has two sensors one being the ORPS and the other being an oil temperature sensor To get to these it ll mean removing the tappet cover which means first removing the inter cooler then the oil feed pipe which fits into the side of the cover Remove all the screws five each side and three at each end The ORPS is the smaller of the sensors It is a sensor which operates with
68. dy components jpg 90 76KB 1 downloads 8 After cleaning and before reinstalling the stepper motor and TPS ensure that the throttle blade moves freely throughout its entire travel without binding and that the return spring moves the blade back to wide open without hesitation Attached File Maximum blade angle adjustment screw jpg 83 79KB 1 downloads 9 Clean the O rings that seal the stepper motor and TPS with a clean lint free rag then mount the stepper motor and TPS back on the throttle body Nip the mounting screws up just a bit but leave them loose enough so that you can rotate the stepper motor and TPS against the throttle body 10 Loosen the jam nut on the small allen head screw which determines the maximum blade angle and loosen the screw This needs to be loosen to ensure that the stepper can move the throttle blade to its maximum extent Attached File Throttle body components jpg 90 76KB 1 downloads 11 While I ve found that you can adjust the TPS with the throttle body installed on the manifold it s much easier to adjust everything with the throttle body connected but just sitting on the manifold as shown in this image Attached File Testing before reinstalling jpg 75 55KB 3 downloads 12 Disconnect the glow plug wiring harness as shown This will reduce battery drain while you adjust the stepper motor and TPS positions Attached File Disconnect glow plugs jpg 60 03KB 3 downloads 13 Turn on the ignition without engaging the
69. e The jaws should never be hardened since that could scour the sleeve bore Many bugs to fix Keep you posted Edited by chilby 10 January 2013 03 45 PM Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 112 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Vehicle GVM LOADS Re JACKAROO stuff Reply 463 on January 20 2014 05 54 55 PM For those interested in GVM towing capacity of Jackaroo s here is the good oil from my manual and so I can find it when need it Kerb mass The weight of a standard unloaded vehicle with a full tank of fuel D Petrol LWB Manual 1865KG Auto 1885kg Diesel Manual 1995 Auto Auto 2115kg G V M Gross Vehicle Mass G V M is the total weight that a vehicle is allowed to weigh when fully loaded This must include luggage passengers a full tank of fuel and tow bar load The maximum allowable G V M is SWB 2500kg LWB 2600kg Towing capacity State regulations permitting Un braked 750kg Over run trailer brakes 750kg 2000kg Driver actuated with break away capacity 2000 kg 2500kg MAX G C M Gross Combined Weight G C M is the maximum allowable combined weight of vehicle with passengers fuel luggage etc plus the weight of a packed trailer The maximum allowable G C M is SWB 5000kg LWB 5100kg Front and rear axle loads Max allowable front load 1250kg Max allowable rear load 1400kg
70. e Sensor Low Voltage 37 EGR EVRV Circuit Open Short EGR Pressure Sensor High Votiage EN pri Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 64 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 ECU Electronic Control Unit At idle the ECU adjusts the Oil rail pressure control valve until it sees a voltage of approx 1 volt from the ORPS As you crack the throttle open the ECU gives a very short burst of full pressure injection where the ECU wants a voltage of around 4 6 volts until the boost starts to rise and the ECU cuts back the injection pressure to what is needed under its mapping program At a constant 80 km h on flat ground my car shows a voltage of approx 2 4 volts At a constant 100 km h on flat ground it shows approx 3 0 volts Under full throttle the ECU varies the pressure up to approx 4 6 volts depending on current boost etc Boldjack believe you are right about the Brake Lights and the ECU being on the same circuit alas all fuses relays and especially the brake lights were checked very early into this with NFF High pressure Pump Hi Mattsjack Diesels like the 4JX1 do not generate vacuum from the inlet manifold as this is mostly under positive pressure not negative as in a petrol motor Instead a diesel have a dedicated vacuum pump which in the case of the 4JX1 lives under the high pressure oil pump and is driven dir
71. e are no injector error codes Edited by chilby 03 January 2013 01 49 AM steve Like This FEFFEFELELET HEHEHEHEHEHRHEHEHEHEHEHERHE HH HHH H H HHH HHH HHH H H EHE EHE EE HERR HEHEEHEEHEHEEHHEHHEHRER HER HERE HRHEHR HER E Routine Service Things to help Fuel Filter Posted 13 August 2012 09 41 PM How to depressurize the lines How will know when I ve got ALL the air out of the lines afterwards Do need a bung or something when I m doing the small fuel filter back near the tank Tank is full Do fill the fuel filter under the primer Z321 with diesel or will it fill up when pump to prime the lines Do HAVE to take off the Primer to get at the fuel filter or is there a trick to getting the filter off I ve got a 2002 Jackaroo with the dreaded 4JX1 engine So have I Cheers Aaron FEFEFELEELEFE ELE ETE ET ELEET EEE EFEELEFL EEE ETE ET H ETE ET EET ETE T PEPE ttt ttt tb et tet ttt Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 21 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Things for a long trip Posted 07 January 2014 08 58 PM Hi Sam a ORPS with grinded wrench b TPSand multimeter c Camshaft sensor with wiring usually when aircon belt breaks down it cuts off wiring to this sensor d Oiland fuel filter kit e Cable ties big and small few clamps duct tape and f replace a radiator cup with a new genuine one
72. e eee eese eese eene eene etna etas toae 7 Zo How the4JXI System WOPESE Gies READ UERBO niin 9 3 OM Supply Diagram PC M 10 4 Diagnosi gear IBCH IL aos ee i tei sivaedb ransa SEKE sor UREF Ue ERE NER eerie 11 5 Diesel Initial analysis m 12 6 Diagnostics Non Starting Engine cccssccccccsssssccssssssccssssssccsssssscccssssssccsssssssccsssssssesssseees 13 Reading Flash Diagnostic Trouble Codes DTC Fault Codes cce eee eere eere 15 DA E TOF GK cC OS A E A 17 Service Intervals found by 4JX1 users cccssccsssccsssscssssccssscsssscscssscssssssessscsssssssssssssssesssssssssassees 19 General issues and things to look for in your Jackaroo when you first get it esee 20 Routine Service Things to help 4 Leere eese esee esee e seen setas tanen setas etse tastes etse tease ese sese sta 21 USL lir 21 Things tora Tong 1p 5er ERG EU n rtm dro amate epi uie terme 22 lig D M M M 23 Battery Isolators Charge Protectors ee eee eee e eee e eee eee eene ette aeta osten estan set en aset ense teas ee ena seo 23 IUUiPINIPII aT E TETEE E TEE E T E AAE 23 Te VO PP S A E EE A E E 24 DONE Ug E A E EE E E atenaseeaisaeinnien 25 Oled air NETS ne en E a E nIE 25 Belts BQSUESU S H
73. e file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 58 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 KEEFE Ny connector sometimes still gets a little oil in it just clean with electrical contact cleaner but so far haven t needed to replace the loom nor have the funny throttle response symptoms returned My problem is fixed Well after the check engine light was coming on and all and experiencing the same problems as husky the car finally refused to start Luckily had already ordered a RPS so it was waiting at Holden for me 223 Oh yeah no matter how much contact cleaner used it made no difference for me Anyway a few hours of pulling apart reinstalling etc later and at least 1 min of engine cranking to build up pressure in the oil rail it all drained out changing the RPS she fired back into life You could probably do it a bit faster then a few hours but took my time to make sure every little thing was clean and 100 correct Replaced oil pressure sensor injector solenoid wiring harness and sealed the head back First click and it went Its been a week now and is still going strong Hope you get you truck back on the road soon Cheers MMR ORPS Posted 31 May 2008 11 23 PM If the ORPS is faulty believe it will set an error code but only if it has gone belly up If it is on the way out it may not set a code but usi
74. e gauge He did notice the TPS voltage was low at idle That made him suspicious of the input voltage so he checked the alternator output and bingo It dropped from 14 1V at idle to 12 1V and then recovered after a little while The uneven idle started when the voltage dropped and it smoothed out when the voltage went back to 14 1 He adjusted the TPS to give the correct voltage at idle I think he said 4 9V but can t remember for sure and drove it home The idle is still uneven most of the time and the idle speed is slightly lower than before So that s where it stands right now Next week I will get it to an auto electrician to have the alternator checked out Tune in then for the next exciting intallment Cheers Rich Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 110 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Sleeve Puller Tool Chilby Lomm thread mii Tool Top View 2mm deep slit o S w 107 iomm thread is o ET a a n n L x mmdia 1 Locking Pin Re Tool Fabrication Discovery after much research ordinary 1 2 galv water pipe is in fact 21 3mm OD gt a smidge too large However if you get a 1 2 BSP die the tread cuts to 20 955mm OD This gives a 1 8 thousands of an inch clearance fit in a 21mm bore and is the perfect size for the tool body without
75. e groove in which the wedge collar fits was badly worn which I believe would make the new wedge collar fail more quickly Old is on left new on right used an ATV lift which cost 115 plus freight with a wooden platform for the gearbox put a strap around the gearbox and jack to make sure it was safe and it was all very stable Some tips which aren t in the manual in case anyone needs to work on a clutch 1 1took the transfer case off to make the gearbox assembly lighter and less bulky The connecting bolts are 14mm and you can t get a socket onto them so used a ring spanner with the 15mm end cut off and a long tube over it to get more leverage to loosen the bolts Consider getting one of those ratchet spanners the bolts are fiddly and it helps a lot 2 couldn t loosen the nuts on the front prop shaft so split it at the splines after marking both sides so it would be reassembled in the same alignment This worked fine the front half remained in place but didn t get in the way 3 The top bolts holding the gearbox to the engine can be reached from inside the car through the hole the gear change levers go through The gearbox needs to be lowered a little to enable these to be reached Take care not to lower too far or the intercooler will swing back against some pipes running along the bulkhead 4 It took some force to pull the gearbox off the engine used rope and pulleys around the rear axle and gearbox to pull it off 5 The eng
76. e mechanical parts would suffice but my valve had substantial corrosion which prevented smooth operation Speaking to the mechanic who found and cleaned mine said a lot of the problems associated from dirty oil Being either from not changing the small oil filter regularly enough this will cause a blocked filter and the bypass valve will open allowing unfiltered oil into the fuel pump side circuit or letting the oil degrade leaving residual deposits of crud Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 92 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 In my case the previous owner doing too many short trips to get the paper and not getting engine oil to operating temperature to evaporate condensation Preventative maintenance would suggest frequent oil and filter changes including small one a few extra dollars every 5000klIms will save break downs due to bad oil condition FEEEEEHEHHEH HEHEHEEHEEHEHEHEHEHRHEHEHEHEHEEHEHEHEHEHEHRH H H HEHEHEHEHEHEHEHEHRHEHETEHEHEHEHEHRHRHEHEHEHRHRH HEHEHE EEE RPCV on the back of the HP pump FERRE EHE EHE EHE TEE EHE EE HEC EEEHE EE E EE EHE EE EHE EE EE EE EFT To replace or disassemble the control valve DIY 1 Check if you have a selection of 1 1 8 open spanners or tube socket a normal socket won t fit around the flange 2 good idea to check if dirt or sand is in the area because you are going to expose the high pres
77. e same temperature That s a question Another is a pressure of this pre heated air and third is an oxygen concentration as well Recycled air is used to reduce the burning temp in the cylinders by this I assume that oxygen concentration should be lower But it seems that Isuzu fitted a throttle plate mainly for the EGR which means that throttle plate openings are timed to suit the EGR manifold vacuum requirement so the system is well embedded in the ECM s programming EGR system is secondary It uses some data from Temp sensors Pedal sensor TPS and Map and operates controlled by software algorithm limited by EGR pressure sensor as well About the picture of intake pipe and pressure Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 7 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 A thought that a square box marked at the picture is a silencer The surface of air filter is many times higher that a surface of this small hole joining the silencer to the intake pipe Incomparably smaller so no dumping of vacuum Crankcase vapours goes out with a bit of pressure that s the gas coming through the piston rings and accumulating inside the engine That s why all you need guide them into the catch can where they change direction of flow and leave oil particles at the walls of the can Please be careful with putting some membrane or mesh filters or anything
78. e the tap was leaking Some useful tips l ve got after this challenge e ITPS could be replaced without disassembling everything If you cannot find genuine one you can use from Mazda 1998 2000 with B3 engine part ending 13 e Always keep a small magnet in the toolbox When unbolt the throttle 3rd time the nut falls into the intake manifold Very stressful e Bythe time the plastic air duct loses its shape near the turbo and becomes like a funnel think it s better to cut it off a bit because the expanded part prevents proper fitting and tightening e Supporting bolt for a duct over the thermostat is not an option it s a must It prevents the duct from sliding off the turbo and or cracking at the bottom part due to vibration e Application of some silicone at both sides of carton gasket rather than using just a gasket cause a big difference Double check internet before spending money Now the car boosts like a rocket without black smoke behind TPS is not adjusted properly so it is too early to talk about fuel consumption Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 78 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Intercooler Hi all For those who are wondering about the oil in the intercooler it is common normal It comes from the breather pipe on the top of the engine This breather is connected to the air intake for the turbo When the t
79. ectly from the timing gears timing gear jpg ISSUES e Leaking injector tube seals e Faulty ORPS e Wrong engine oil type e Dodgy oil filter for the high pressure supply side TIMING High pressure Pump Replacement Timing Belt The timing of the fuel pump is actually irrelevant since the 4JX1 produce the high fuel pressure in the injector itself by means of a hydraulic piston driven by high pressure oil under the control of the ECU Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 65 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Now it happens that the fuel pump is driven directly from the High Pressure Oil Pump HPOP which is turn is driven directly by timing gears from the crankshaft A pulley on the HPOP then drives the camshafts via the timing belt If the timing gears have never been interfered with then the timing of the HPOP must be correct Unfortunately the timing marks on the HPOP do not align with every rev of the crankshaft and therefore the engine may need to be turned a number of revs before the timing marks on the HPOP are aligned I found this out when I first replaced the timing belt on my Jack However it is true that when the timing marks on the HPOP are aligned the timing marks on the camshaft must also be aligned PROVIDING that 1 cylinder is at TDC To check that 1 cylinder is at TDC you also need to look at the timing marks on the c
80. em appears to be almost identical in marking to the OEM minus the Isuzu branding Contact Neil http www sydneyfilters com au jackaroo He has all the Nippon Max and Wesfil Filters and is cheaper including the freight than what I can buy the lot locally Just tell him you have the 4JX1 Jackaroo Diesel and he will do the rest Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 24 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 8 Air Filters Oiled air filters There is a history of filter oil residue causing problems with the td sensors but if you are getting oil residue downstream of the filter then it is being over oiled which is common and easy to do I think Unifilter do a foam element for the td I prefer the castrol filter oil or silkolene Green Cotton filters They do make one for the 3 0TD and are available from http www greencottonfilters com au The part number for the 3 0TD Jackaroo filter is R252209 and costs 88 plus 7 shipping in Australia SERIE MODEL HP KW ENGINE YEAR SHAPE D1 D2 D3 D4 D5 H FIG PART N PRICE TROOPER II 3 0L TD 159 117 99 gt ROUND 80 116 140 5 R252209 5 Belts and replacement Belt Gates Bosch Alternator belt 7385 11A0980 AirConditioner belt 9490 13A1245 Adjuster pulley Fan Harmonic BSC bearings Davco or Top Cog Balancer bearings OK here is a quick ho
81. erly before it leaves the plant The diagnostic trouble code s DTCs stored in the ECM s memory can be read either through a hand held diagnostic scanner plugged into the DLC or by counting the number of flashes of the Check Engine Malfunction Indicator Lamp MIL when the diagnostic test terminal of the DLC is grounded The DLC terminal 6 diagnostic request is pulled Low grounded by jumpering to DLC terminal 4 which is a ground wire This will signal the ECM that you want to flash DTC s if any are present Once terminals 4 and 6 have been connected the ignition switch must be moved to the ON position with the engine not running The Check Engine MIL will indicate a DTC three times if a DTC is present If more than one DTC has been stored in the ECM s memory the DTC s will be output from the lowest to the highest with each DTC being displayed three times The DTC display will continue as long as the DLC is shorted FEFEEFELEL ET ELELETEEPEPTPEPEPELET ET ETHEL EL EFEEETEEPEPELETETELELETEFET ETE PEEP EP ET ET Ett Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 15 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Fault Codes and Interpretation Posted 22 October 2009 10 05 AM Don t worry about oil in the TPS potentiometer it will be in most Jacks out there as there is no actual seal on the butterfl
82. esesesasssesost scsessvsscosoosese 90 Rail Pressure Control Valve RPCV or Pressure control valve PCV eeeee 92 19 Fuel supply Tank and initial Fuel Filter eee eee e eee eese eee eene en eee nnue 94 Replace Fuel Filter etd ete tede pepe Ribes e ndi ate ee ES eod deed 94 ipt 96 20 Other Solutions Other sources cccccccccccccscssssscsssssssssssssssssscccccccccccscccscccccccsccsscessccsscesees 97 21 Clue RE 102 CWT ad e PTS TREE EEE AEE AAA E AEE EN E E A ASETA 104 Clutch DIETER I 104 22 Radio and Installation cccccccccccccscscscscssssssscsccccccccccccccccccccccccccccccccscccscccsccssccssccsscesssess 105 23 Cr ise CORIF0l iisisiussaica assises eee ek Pak EFe DEENA EEEE EKON ANKETE TAPETE KEENE 107 24 37 TT I S 107 25 BOC RE 108 Reduction of Drap eoe nent ive eee ees Saat kc aes Rn deb dee curre n ue en godes 108 26 CASE STUDY Uneven Idle u csccccsesssssssscssscssssssscssscssscssssssssssssssscssssssssssssssssssssseees 109 Sleeve Puller TO0 CHIDY ge o i nsss 111 Vehicle GVM LOADS cccccssssssssssssssccssccccssssssscesccccecscssssssscccescescssssccscesecescssecccsecesscescssecnccsces 113 Manifold DIOCKEG RE
83. et injector nozzle GM 8971611092 4 4 gasket HP oil pipe GM 8971842160 gasket Throttle Body GM 8971378200 Rocker cover gasket EGR Port gasket GM 97137811 or 8 between exhaust manifold and head 97137811 1 Exhaust manifold gaskets EM3202 ACL Aftermarket Injector Sleeves removal replacement Techniques are replacement In complete form as a step by step above and see end of document for diagram Commercially available Kent Moore EN 49960 Injector Nozzle Sleeve Puller Manifold gaskets Yes you can change the manifold gaskets without removing the turbo or dump pipe and gaskets from the manifold if you want to be tight Just need to undo a 5 exhaust flange gasket under the car and then put a slit in your new gasket for 3 cylinder only The cut needs to go on the LOWER stud hole from lower stud hole in gasket down ways to the OUTSIDE of the gasket This is because it was the only stud that the manifold did not come clear of The cut will allow you to wrap the gasket around the stud Mines not leaking Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 36 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Valve Clearance chilby on 24 Sept 2013 01 57 AM said Note the attached sections from the manual I m not clear on what your question is but the cold valve clearance is 0 15mm INLET 0 25mm
84. et of your part number ALT170760 shows it s a 70 amp model but as to which pin does what sorry can t help there If were you I d get the 90 or 100 amp model provided the connector matches the extra grunt could come in handy on a driving light car fridge equipped glow plugged diesel with possibly long cranking times and possibly short trips Psychster Posted 16 October 2008 11 37 AM For future reference this seems to be a good deal http www jaylec co tins NP4 07 pdf Note the Recitifier Regulator assembly part number 16 3123 was quoted 125 93 GST Freight A much cheaper solution than the 1400 Holden wanted for a new genuine alternator And the following supplier http ishop2 cooldrive com au Code 65 3122 Description ALT HOLDEN RODEO MONTEREY NEW 12V 90A 4JXI 98 04 3 0L Holden Jackaroo Rodeo 3 0Lt 4JX1T 12V 90A Internal Reg Specifications Voltage 12V Amperage 90A Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 26 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Regulator Internal Reg FEFEEFELEL ETL ETE TEELELETEPEPELELELEEEEETEEEEPELETEPETELELEFETET EEE EPEPET HERE RR REP HER E Regulator Problems Alternator Posted 18 February 2013 08 08 PM Hi Just wondering if anyone can help my battery is constantly running flat have replaced my battery and put a new alternator in but it still hasn t fixed the problem
85. f you have the right tools The top bolt can be removed and replaced easily with a 5 16 AF ring or open ended spanner The bottom bolt can be removed and replaced reasonably easily with a 1 4 drive 5 16 AF socket with ratchet driver did need to remove the air pipe between the intercooler and throttle to allow access 2 There seems to be no need for adjustment using the Tech 2 no mention of the need for adjustment is made in the workshop manual It would be great if this could be confirmed by someone who knows Throttle Body and EGR How can the throttle get dirty from oil AND EGR if the EGR is AFTER the throttle plate We have had the discussion about disabling the EGR before and the conclusion is the ECM in the 4JX1 uses the throttle and EGR to increase efficiency not the other way round like most people wrongly believe Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 84 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 The EGR also is used to reduce the combustion temp by about 500 degrees by reducing the amount of oxygen in the air as you said which is a good reason not to disable it This extra 500 could also cause the injector sleeve seals and injector gaskets copper washer under the injector to fail prematurely thus causing more trouble than good Also if you disable the EGR we won t ALL live happily ever after You won t be happy after receiving a fine
86. gine manual 2014 ver 3 0 doc 77 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 At my luck decided to re check everything once again before placing the order for a turbo reassemble throttle body again and made it sterile clean and used red motor grade silicone liquid gasket did a pressure test for the intercooler and air hoses Rubber houses were inspected with magnifying glass as still had a hope that it was not faulty turbo Turbo shaft was checked for touching the body and horizontal play No issues everything OK And then when I started to fit the plastic duct to the turbo inlet hose pressed it a bit stronger and got a suddenly less resistance of material than expected took the duct off took off the metal clamp and started to press at the edges of this plastic Tadammm BINGO The pipe was cracked under the clamp The crack was at the bottom part of fitted duct about 40 45 mm long The last part was easy and simple cut off about 10 12 mm all around neatly fitted the clamp and tightened it saving the money for a future holidays instead of a new turbo The dying kitten Posted Image noise was eliminated with the advice from foreign 4JX1 forums CHECK THE VACUUM DRAIN SILENCER did Not only the silencer but the electric tap as well was clogged by dust Some methanol for the silencer few drops of WD4O for the tap and everything s fine As a bonus l ve got a bit better breaking Looks lik
87. heap Autos that conforms to that specification and also specifically says that it is suitable for diesels so reckon it is the sort of coolant AlexV is referring to ack Ensure you replace the coolant with a Diesel specific coolant preferably based on OAT Organic Acid Technology like most diesel trucks now use like CAT Cummins Mack and other Jap engines use You can buy an Anti Freeze type or basic type but go hunt around for a proper Diesel engine coolant and dilute with water at least 5096 The larger truck parts places or the more reputable car parts joints may have this product Or the truck stops where they sell diesel fuel Castrol BP and other oil companies market it so you can check with their agents It is even sold pre diluted to 5096 bought a 20 litre of SUPER ROO SR400 EXTRA LONG LIFE COOLANT concentrate that is mixed at 5096 with water Product Name SR400 Extra Long Life Coolant Concentrate Description Is a universal ethylene glycol based anti freeze coolant concentrate contains 1060g liter ethylene glycol incorporating an advanced formula technology with virtually non depleting organic acid corrosion inhibitors SR400 is silicate free for improved pump life and contains no harmful nitrates Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 50 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 borates phosphates amines or nitrites SR400 satisfie
88. heat shield 14 Very carefully remove the oil feed pipe connected to the top of the turbo manifold Make sure you don t leave behind the copper washer underneath 15 Leave the oil feed pipe positioned over its original spot You will need to move it slightly to access the two bolts connecting the turbo to the exhaust manifold 16 With a small socket driver set e g 3 8 rather than 1 2 remove the water pipe connected to the underside of the turbo With a combination of spanners remove the two water pipes from the engine side of the turbo 17 Remove the rubber houses connecting this pipe to the side of the engine the oil drain pipe 18 Clear access to the three 12mm nuts securing the turbo to the manifold should now be visible Be very careful attempting to loosen these The heat will have them stuck hard 20 Using a 14mm socket and about 3 or 4 extension get under the car in the same direction the oil filter was removed from and attempt to remove the two nuts which connect the flexible exhaust lline from the cast iron exhaust manifold directly under the turbo had to use an extra long handle to get mine to budge Undo the 4 12mm nuts that secure the dump pipe to the turbo 19 If you haven t removed any skin so far your doing well 22 Up to this stage took me 2 5 hours When I removed mine just recently these were the only steps took Leaving the AC in place probably only cost me 10 minutes or so in extra time to get at the
89. il leaking externally There is no gasket to prevent oil moving between the two ports to the engine block so if the oil filter housing is not tight against the block a slow leak can exist which allows the oil cooler to drain cured the problem by tightening the 4 nuts holding on the oil filter housing would think that the only way this problem could damage the turbo is if the engine is revved up straight away on start up before the oil pressure comes up The owner s manual warns against this If the oil pressure is taking longer than 5 seconds to come up then suspect the oil filter non return valve had a problem with a non lsuzu oil filter which had a faulty non return valve Oil slowly drained from the filter and if the engine wasn t started for a couple of days it took about 15 seconds for the pressure to come up We had a problem with our Oil pickup in April that lead to the turbo destroying itself Turns out that the O ring on the oil pickup failed or was failing and the lubrication oil circuit received no oil This was indicated by the low oil pressure coming on when starting Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 32 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 had an indicated Lubrication oil pressure failure The easiest place to start was the lub oil suction seals did the work myself as was not game to move the vehicle It is no
90. important that the TPS is calibrated correctly otherwise engine power and fuel consumption can be adversely affected Use of Tech2 With this baby you can run a throttle position sensor test where you can step through all the throttle positions from 0 through to 10 and display the TPS voltage TPS A complete instruction and images http forum australia4wd com index php topic 22826 technical article tps replacement The adjustment procedure that I recommend is as follows 1 Remove intercooler cover 2 Loosen the clamps on the pressure hose between the intercooler and the throttle body 3 Remove the intercooler mounting bolts No need to remove all four just the two on the throttle body side will suffice 4 Remove the pressure hose between the intercooler and the throttle body 5 Remove the intercooler bracket that is attached to the throttle body Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 88 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 6 Remove throttle body assembly take off stepper motor and TPS Make sure that you don t lose the small section O ring that seals the TPS to the throttle body 7 Clean the throttle body with good quality carby cleaner It s important that you take the stepper motor and TPS off before you use the carby cleaner as it s an aggressive cleaning agent and could easily damage them Attached File Throttle bo
91. ine needs some support when the gearbox is removed started with a jack under the sump and then put a block of wood between the rear of the engine and the chassis cross beam running under it 6 The pilot bearing is easy to get out with a pull hammer with a hook that fits through the hole in the bearing Definitely worth replacing this as it is so cheap got an NSK one as it is identical to the original but it is a standard bearing so other makes could be used Many thanks to everyone particularly Red One for your help EEH HEHH HEHHEHEHHEHEH HE H HHHH H HHHH H HHHH EEE ETHEL EF EH EET EET ETE T PETE ETT PEt ttt EH HERE RR Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 103 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Clutch Removal Posted 17 November 2013 09 04 PM Hi Tim Drop the back cross members and lower the engine trans about 4 6 pivoting on the engine mounts Best to undo the exhaust at the flange to avoid bending it Watch the fan clearance to the radiator though Then you can get at the bolts ok It s well detailed in the manual Be aware the engine weighs 260kg and the box is about the same solid jack on firm footing eh The clutch has a pull to open release bearing There s a little plate with 2 bolts on the btm side of the bellhousing to stick a long screwdriver up and lever it out of the clutch centre before you drop the box It s
92. ing mine out the engine purrs like a kitten at idling Devon 005 JPG Size 163 49KB SAVE 007 JPG Size 162 15KB SAVE Image 2 of 2 uL Image 1 of 2 wet as Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 95 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 PCV Since it fires with the white wire cut but runs at only 300RPM with no throttle response then it s clear that the cut wire is fooling the ECM into thinking that there s enough Pressure so it fires but very weakly THAT means the pressure is REALLY too low for normal running so the problem lies with the Rail Oil Pressure Control Valve They re awkward to reach but it DOES NOT require you to access it via the wheel arch just move the Fuel Filter and the ECM temporarily In cleaning the ROPCV be careful to ensure that the 4 tiny holes in the little cylindrical needle valve are clear ROPCV Stripped 1 png and that you re assemble with the needle s sharp end pointing INTO the cylinder When clean it SHOULD allow the HP oil into the Rail and it should start properly If you DO have to replace the ROPCV then try http www isuzuauto m Pages gp html The Large Dampening Hole faces the blind end of the Valve Body where the sheet metal Nut attaches then the Long Pin sits on the other end of the Solenoid Moved Piston with the Long Pin inside the Pin Housing itself screwe
93. is not necessary to test all injectors at this time since this step is only a test to verify that all of the injectors have not been disabled by fuel contamination 8 If there is an open or shorted driver circuit DTCs 0201 0204 should be set Engine Cranks But Will Not Run 2 Was the On Board Diagnostic OBD System Check performed Go to Step 2 vduss Ye Ne Goto OBD System Check Check the 15 A injector fuse the 15 A engine device fuse and the 154 ECM fuse Was a fuse blown Go to Step Go to Step 4 3 4 7 Using the Tech 2 system Using the Tech 2 Is DTC P1557 set Check ECM Main rela y Using the Tech 2 Is DTC P0201 P0204 set Check inject circuit fault Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc Check for a short to ground and replace the fuse Is the action complete Is fuel tank empty Is the right engine oil using Is the right fuel using P M Is DTC P0192 or P0193 set Check rail pressure D Verify repair NE Fill the fuel tank Go to Steps Replace the Go to Step amp fuel Replace the Go to Step 7 engine oil Goto DTC 0192 or DTC P0193 Go to DTC P0201 P0204 Go to DTC PI6S7 Go to Steps Go to Step Go to Step 10 13 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 SE 50 4JX1 TC ENGINE DRIVEABILITY AND EMISSIONS Engine Cranks But Will Not Run Cont d pu o
94. l 2014 ver 3 0 doc 59 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Has anyone had their motors nearly run but just wont fire up When I cut the white wire orps it runs fine but as soon as I replace it she wont run just nearly gets there but wont go I have replaces the orps injector seals tps I tried to compression test it and broke 3 glow plugs so I took the head off removed the broken ones and fitted it back up It has very small crack in the glow plug hole of 3 cylinders but I don t know if that would be causing my problem as the compression is fine When it runs I get 2 7 volts at the white wire orps It doesn t blow any smoke Hi Edco You really have to examine CAREFULLY what Nathjack is saying As you quoted When I cut the white wire orps it runs fine but as soon as replace it she wont run just nearly gets there but wont go The phrase nearly gets there but wont go actually points out that it s TRYING TO START and NOT trying to CONTINUE to run In a later comment he wrote It continues to run after plug it the ORPS back in which means the ORPS is OK and ALL would then be well if the ECM could successfully control the pressure in the Oil Rail in proportion to the Pedal position It can t cos the ORPCV is NOT responding Therein lies the BIG DIFFERENCE When actually running it ll plod along with barely enough pressure to fire the injectors but at STARTUP the ECM will forbi
95. l the sump is still not empty there is about 5 litre in there so handle with care e You will need a 3 8 drive 12mm socket for sump and pick up bolts and long extension bar 1 2 drive ones are too bulky e After removing all the sump bolts and the two nuts the sump is stuck to the block by the sealant and has to be prised off with a screwdriver e The pick up seals are quite a loose fit on the pick ups and also in the holes in the engine block so it is best to put some engine silicon sealant I used the gasket stuff see below under the seals so they attach to the pick ups and round the outside before fitting to the engine Why they are loose escapes me e The sump is sealed to the engine with a silicon rubber sealant I used Silastic Black Formed in Place Gasket from Repco but anything like that will do the job Having done all that there was no oil pressure on start up I removed the oil pressure sender to check it out with an ohmmeter and a tyre pump and it seemed to be working properly On replacing it and having one last go the oil pressure gauge came up and the light went out I think there is a reasonable chance that there is an intermittent fault with the oil pressure sender however Holden wanted 274 for a new one I decided therefore to modify the sender I got an adapter which is designed to allow fitting of an after market gauge Speco part number 547 62 and a suitable oil pressure switch VDO part number 231 084 I cut
96. lack box 20cm x 7cm at a guess is a resonator in the air induction A resonator is used also in the air duct between the air cleaner and turbocharger to reduce air intake noise The MAP sensor is mounted on a bracket near the EGR valve it is about 10x3cm at a guess can t see from the manual where there is an air hose connected to it this is mounted with the EGR VSV This sits just near the EGR It is just in the top left corner of AlexV s picture Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 41 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 If you look at the photo took today of where I believe is the sensor port after talking to the mechanic who did the job and he walked me through where on the engine this is In the middle of the picture is a black rubber hose that goes into the aluminium inlet manifold horizontally held in place by a spring hose clamp You cannot miss it as its underneath that round object with the triangle on the outside also fixed to the manifold That hose runs off to the left to underneath the little black box that sits at the front of the inlet manifold behind the radiator hose The black plastic box is the MAP sensor http en wikipedia wiki MAP sensor offers an explanation how these work To take this photo I had to take off the cover that surrounds the fuel filter and this is needed to get better access to this port anyway
97. lic power to the injectors etc Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 62 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 You shouldn t mess with the ECM beyond making sure that all its connectors are clean they can get oil seeping into them and dry and making good solid electrical connections Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 63 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 DTC JPE Em 8 E 8 f oh M Ld t A Per 4 3 a o Accel Position Sensor Rationality a zi 3 8 Accel Position Sensor High Voltage i M 2 8 Fuel Temp Sensor Low Voltage Fuel Temp Sensor High Voltage Rail Pressure Sensor Low Voltage Rail Pressure Sensor High Voltage RPCV Circuit Open Short 3 8 E 8 2 8 1 Ed Rail Pressure System High Voltage 3 li SIE 3 62 Ral Pressure System Hon Waming Oil Temp sensor Low Voltage ON LUN OM oU LUN RECEN m ae OW LiedorWiOmwiFad Injector 4 Circuit Fault 2 ar GamFosmbnSeworNoSQml e GiwReayOmutOpeShod O DELE Circuit Open S pM LION Eel oom ee UM LE 32 ua o 5 EGR VSV ca eS eee V Circuit EGR Pressur
98. lots of times until smooth flow of fuel no bubbles tighten bolt Done If you are having trouble removing the filter I did I resorted to removing the pump body only 2 bolts and 2 hose clamps and attacking the filter with a screwdriver What eventually got it free was using a screwdriver to break the seal of the O ring on the filter Basic steps start to finish 1 Remove shield bracket thing 2 bolts 2 Remove fuel hoses hose clamps 3 Remove pump assembly 2 bolts may not be necessary if you can get the old filter off 4 Attack old filter to get it off Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 94 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 5 Install new filter and reassemble 6 Prime filter by manual pumping To bleed fuel system e Loosen bleed screw on filter housing e Pump until fuel comes out continue pumping until no air bubbles e After bleeding secure bleed screw e Operate primer several more times and you re done Ihave attached a couple of photos of my original diesel filter housing Filter type Z321 If you look at the left hand filter outlet pipe you can see a small circular shape with a notch either side in the housing body this is a small kind of brass gauze filter that is easily over looked when changing the fuel filter from what I have been told this bypass gorse filter is to stop air locks in the filter Since clean
99. lso low RPM or low load use around town This causes a small part of the spent combustion charge to retreat back through the inlet valve into the inlet port and manifold and then stopping when the valve closes and settling onto the surfaces Inlet gas speed is slower and cooler than exhaust gas flow hence these deposits forming have seen the backs of inlet valve completely caked in deposits almost blocking off the inlet port thus affecting performance Sustained high load high RPM operation cures a lot of this if the deposits are soft and oily but have seen them hard carbon and can only be removed through immersion in carbon removing chemicals etc Yes mine is the same misunderstood what was being discussed There is another small pipe behind the TPS which is connected to a PCV valve this is on the pressure side of the turbo Holden left this off when Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 42 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Checked my MAP sensor port on Friday and it was pretty gunky gave it a clean truck seemed to run better but always think that as only drive it on weekends AlexV s description is pretty accurate my apologies for correcting you The MAP sensor is the little black box in the top right corner of Alex s pics there is a pipe that runs from underneath it to just below and right of the EGR Valve As for the pipes
100. ly as has been discovered if the ECU detects that that the boost is rising faster than a standard engine should because you have changed the exhaust then the ECU determnes hat it must be putting in to much fuel and so reduces the fueling untill the engine comes back within spec I have put a restrictor 1 mm hole in the MAP sensor line and increased the volume of hose between the restrictor and the MAP sensor 300 mm length of hose I believe it works as follows Placing a restrictor in the MAP sensor line causes a delay between when boost pressure arrives at the manifold and when that pressure bleeds through the restrictor and is then seen by the MAP sensor Adding volume between the restrictor and the MAP sensor increases this delay You will need to test by trial and error to get the correct amount of delay so that the ECU sees the rise in boost pressure as being normal Eventually the pressure equalises a fraction of a second actually and so the MAP sensor still sees the actual pressure there is however this slight delay tricks the ECU into thinking that the faster boost rise is still normal If you put to much volume between the restrictor and the MAP sensor the horsepower plummets as the ECU then thinks that there is not enough air entering the motor and so cuts the fuel There appears to be a narrow window where acceleration is maximum and the ECU does not try to learn around your new exhaust PS had the same problem with a large exhaust and
101. m M16 threaded rod to the threaded end Then tightened up the dynabolt in the sleeve and and used a 50x50 box section supported by some 4x2 Then used a nut amp washer to screw it all up Have a look through the forums and you will see some that others have done Some say it may score the inner sleeve I did not notice any marks inside although am sure it is not the best method Cylinder 4 took a lot of attempts and it pulled out of the sleeve a few time The removal tool would be the easiest amp safest but there you go Remember to try to fill the oil rail up with oil before installing it back otherwise it takes a while to start Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 43 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 I did the oil rail pressure sensor and wiring loom while I was at it just for piece of mind and you are taking it all apart at the same time Not sure if you know about the dramas with these parts If not search the forum The cost of all the items is not much and as it all came from Dubai the transport costs made it all worthwhile Holden do a service kit think sleeves are 80 each plus o rings Injectors Clicking indicates the solenoids are working How well they re working is normally decided on a test rig Alternatively it s trial and error The injector internal O rings and springs also need to be sound These 3 types of par
102. machining Personally I m circular grinding my tools but the die cut thread should still work a treat l d like mine to be pretty though Further 3 4 BSP water pipe nests over 1 2 and is perfect for the press sleeve It has a 26 9mm OD and an ID bore of 21 7mm perfect for the outer sleeve Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 111 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 All this stuff can be bought at a hardware shop Mind you a lot of the small stores don t stock gal pipe now but you can order it in Since you only need 178mm length overall for the tool you likely have a bit in your metal bin in the shed In the end I m not using pipe sections for my tool however I m welding thickness of MS together then welding and precision grinding The jaws are actually the hard bit to do since they re quite tiny but the shape has to be perfect to the drawing or they either wont lock in the fuel holes of the sleeve properly If not will stick out too far once locked and wreck your aluminium head as you pull the sleeve a very expensive fault might be making 5 of these so be selling 4 once have them working well in case you can t be bothered setting up machinery It occurs to me that the body of the tool may need to be heat treated to retain the ability to spring back to normal shape after having been locked the only way to tell is to make on
103. mber of the filter on a 4JX1 BTW I could check out a filter site that have bookmarked Posted 14 May 2012 08 44 PM You say you have cleaned the little flap valve OK that s good but the trouble is there are 2 flap valves the other one is not accessible as it is inside the head of the filter You can t get to it without cutting open the pressed on metal cap Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 29 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Not an option if you want to continue using it You could take the filter head and try getting some petrol into it blocking all the holes with your fingers shaking it about around and then emptying it into a clean container Keep repeating this until you are sure no more dirt or bits come out Another problem is the rubber diaphragm can deteriorate and leak In that case you will find the fuel may leak a little around the plunger Air can get in causing poor running and starting or even no start Fuel will leak back to the tank and will be replaced by air through the leaking diaphragm BTW your tank won t rust but it may not be clean The pickup is not going to be blocked by paint or rust You could take off the tank cap then blow back down the pickup pipe from the engine bay with compressed air Then drain some fuel out the tank The only way to clean the tank properly is to take it out as the drain is way too sm
104. mm lam sure might think of some more possibilities tonight Injector Harness Seals 4JX1 injector harness seals engine end has 4 x white blue all weather seals on top of the injectors and 1 x white maroon seal for the oil pressure sensor as separate parts My seals have deteriorated and need to be replaced Waterproof electrical wire connector plug try e bay for source Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 34 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Catch can Bugbear Posted 06 April 2010 09 44 PM fitted a catch can a few years ago Started with a SCA rectangular can and added a few internal parts to catch the oil Fill one side with stainless steel wool scrub from kitchen supplies and the other side with nylon filter material Empty quite a bit of oil out every time I change the oil so it must be doing something Still get some oil in the intercooler but not a lot and there seems to be a lot less on the turbo inlet Posted 06 April 2010 09 46 PM have put 1 on my patrol no more oil running into the intercooler and hoses have the Provent 200 purchased from western filters 11 Engine head Some reading http forum australia4wd com index php topic 25194 top end overhaul Injectors The vehicles were sold in Australia by Holden GM as the Jackaroo In Australia these problems appear to be little understood by the general
105. n normal level and smells in diesel how could you help me Right now I m still using my trooper Is it safe to use You need to replacing Injector O rings properly Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 98 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 My Isuzu Bighorn 4JX1 RJM Engine stalled after fitting it with new oil pump It can crank but is emits smoke but not run What could be the problem have tried to check if the fuel pump is not working but the test showed that it is working well The engine oil pumps are in the rear of the engine trans out and behind flexplate flywheel were any of these 2 engine oil pumps touched if so the flywheel flexplate has to be timed to crankshaft position So you might have it in the wrong position if your talking about the diesel lift pump injector pump that also supplies high pressure engine oil to injectors after replacing this there is a learn procedure for the rail pressure control valve that is on pump Dealer or some one with Tech2 scanner tool can only do this Don t start after oil change have a 4jx1 trooper It cut off after oil change open the engine and change rings Everything is new but the injectors The mechanic put some 15 40 oil in it It doesn t start What else can do if can t get the Tech2 I HAVE A TROOPER 3 0 L THE SAME AS YOU AND I KNOW THAT WHEN CHANGING OIL YOU MUST USE
106. nd solder in a link between terminals 7 and 8 Put the cover back on plug it back in and each time you turn on your radio you get FULL extension on your aerial When you turn the radio off the aerial goes down Whole job took less than 30 min Nice Panasonic MP3 WMA player ANTENNA selaga on 18 Dec 2007 8 24 PM said Re the antenna control module GM 92029494 remove it open the back cover and solder in a link between terminals 7 and 8 Put the cover back on plug it back in and each time you turn on your radio you get FULL extension on your aerial When you turn the radio off the aerial goes down OK I found the self same module in my 1997 SE it is high up behind the glove box bolted to the transverse tubular strut which strengthens the body under the dash Hi all hope someone knows how to do this have had enough of the eurovox so have a pioneer DEH P7850BT to install but I m not sure about some of the wiring for the auto antenna have photo s and I m hoping someone may know The Blue wire is from the pioneer It is to go to Auto antenna relay control terminal There were 4 wires that came from the Eurovox In to the relay box on the jack Yellow Red Blue White Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 105 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Now the red I believe is 12v back up The Yellow is 12v The blue is Antenn
107. nd this to my mind is the ideal size unless you want to do some serious engineering or law breaking Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 107 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 25 Body Issues Reduction of Drag https www buyairtab com Airtabs are patented unique wishbone shaped vortex generators designed to increase vehicle aerodynamic performance and fuel economy by reducing aerodynamic pressure drag at two key locations The tractor trailer gap and the rear facing surface the base area of any commercial or private square backed vehicle or trailer that routinely attains highway speeds Drag reduction and fuel economy benefits from Airtab application is not limited to commercial trucking operations Airtabs enhance aerodynamic performance equally well on cube vans straight trucks expeditors SUVs RVs buses horse toy and utility trailers faired bob tail tractors flat beds and tankers The results may vary somewhat with vehicle type but the aerodynamic theory and principles are the same for all Each Airtab creates two tight swirls of air or vortices that combine to reduce the suction and drag at the rear of vehicles traveling at speeds above approximately 35 mph or 55kmh Airtabs are also effective at the rear rooflines of automobiles that have a rear window slope of greater than 30 degrees Airtabs offer several safe
108. nector block or you can open the connector and have a look inside there will be oil there if this is your problem From memory the cables were red in colour When they replace the harness the cables will be pink they told me this component has been redesigned to prevent this happening again It cost me 500 to replace as again from memory it controls a fuel pressure valve which will need to be replaced If this is this case do not muck about trying to do temporary repairs as it may affect your spray patterns and cause flame impingement on your pistons not good with alloy gear Anyway pulling out of the drive last week as soon as the car went over the hill and was pointing downhill the engine speed suddenly dropped back to idle regardless of throttle pressure The engine did not stall but would not rev up beyond idle so came to a gradual stop engaged reverse and slowly crawled back to the shed front for a think eEEEE After a Cuppa remembered a wiring connector that I ve long thought didn t look right With the engine again idling found could make the engine speed up slightly but noticeable by moving the connector block which is located next to the oil filler cap Very strange so stopped the engine pulled it apart and found it coated with oil so cleaned it with electrical contact cleaner and no problem since There is some oil around the intercooler outlet pipe which think had got into the connector and perhaps
109. ng a TECH II I think you can watch the output and see if it is in range If you replace the ORPS then yes you need to get a TECH II and calibrate the ECU to the new sensor It will start and run though without doing this but things will not be at their most efficient It should be calibrated with the tech2 it will run but not to it s optimum It s like giving an engineer something to measure and him not zeroing his measuring device so from that point on all his measurements will be out slightly This could lead to over or under fueling and on this type of engine that s not good It does need to be coded to let the ecu know where the zero point is it s like when an engineer measures something they will always zero their measuring instrument so that it gives an exact reading well this works on the same principle As far as know it s not a learning ecu there is no knock sensor to pick up pre detonation or pinking so it won t know to retard the injection It doesn t use the cam sensor when it s running either so it only uses the crank to know when to inject and the ORPS to know how much to inject along with the pedal position sensor Well have had my rail pressure sensor calibrated by our dealer All though they said the reading from the sensor did not change when it was recalibrated the vehicle now starts better with virtually no smoke and the idle quality is far better Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manua
110. ng the same except now the motor oil is much cleaner Also some time later removed the intake pipework and checked it out the inner air passage was almost blocked with black sticky carbon gunk took forever to get off Blocking the EGR will extend your motors life by removing the carbon soot from the intake this rubbish acts like sand paper and will destroy your motor Some people commented that Toyota actually recommend blocking this pipe off To block the EGR off remove the pipe from the exhaust manifold remove the gasket make a new gasket out of tin but don t cut out a hole to stop the exhaust from flowing through reinstall the pipe work all done without any sign of a modification As for it providing some form of pollution control this also is a load of crock by recirculating some of the exhaust gasses it dilutes the gas heading out the rear fooling the equipment into thinking it s cleaner Posted 13 August 2013 08 57 AM Our 4jx1 engine was designed with EGR system built in If its faulty or blocked The temperature balance MAP Sensor Blocked With Carbon UBS 4JX1 Group 6C Ref No TL1046 0511 CONDITION Vehides with a blocked MAP sensor may exhibit one or more or the following conditions Flat spot e Blowing Biack Smoke Tech 2 shows nsufficient manifold boost pressure MAP sensor is slow to respond when viewed through Tech 2 The above conditions can wary with change in vehicle
111. njector Sleeves removal replacement e eere eere eene eene eene tne tn setas etse tta setas tense es se ese sese sta 36 Manifold Caskets mE 36 Valve Clearanc e H J 37 Exh asst O 39 Poor Idle Quality E M M M T 41 MAP Sensor EGV valle seess tsoos 41 Il EID ad UOTE TOT Y P T 43 EAEN eee e C M O 44 Glow plugs Cleaning intake manifold e eee crece eee eee eene eene eene eene ense ta sense en sees e siae suo 46 NI L 46 Checking Glow dr C 47 12 Cooling Water System Heater Coolant eee ee ee eee ee eese eene eene tn nete setate 50 Radiator A 50 vb 50 Faulty O Ring rear ci m 51 DUET METTE AEA 52 Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 3 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Water Pumps H 54 13 D CPU NILUS DH 56 hublogulitareniitior dc
112. nning well oil rail pressure sensor injector wiring harness and injector sleeve O ring seals Ignore these at your peril If these were done together at say 100 000 km intervals I am sure many people would be saved from much grief EEEEHEHEHEHEHEEHEHEHEHEHEEHEHEHEHE EE HERE EE ERE HERE ERE EHE HERE ETE HE ERE E RE HHHH Fuel leak diagrams sleeves o rings http forum australia4wd com index php topic 27750 what a fuel leak in a sleeve looks like Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 71 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 16 Sump and Engine Front end High pressure Pump Harmonic Balancer and O rings It turned out to be a good call The small o ring was totally shagged The cost for parts was only 40 but labour was 840 which I thought was pretty good considering they had 2 guys on it all day to get access and compared to Holden that was going to charge approx 1300 labour to do the job harmonic balancer crankshaft pulley If you re having problems with the HPOP or as diagnosed on Tech II lack of pressure min 2 8 Mpa to enable injectors have a search on ITOCUK for Oil Rail Control valve known as ORPCV or ROPCY search posts by Gribble for a piccy step by step Obviously check ORPS first Harmonic Balancer is main pulley on crankshaft it is balanced to reduce any vibration in crankshaft As well as drive fan etc th
113. on the air intake have the large 1 OD that goes to the rocker cover and a smaller 1 4 OD that goes to the EGR Valve Posted 30 September 2010 07 16 PM Hi Jack Know a little about the MAP sensor on this engine as had to replace one about 18 months ago When the original went bad the check engine light came up solid and the engine went to limp home 5096 power mode about 400 K from home Did some research on the net and found a replacement non genuine sensor in Vic at a injection specialist May be able to dig up the info if you need it From what understand and can see under the bonnet one of them is the MAP the other is the EGR Pressure Sensor have attached pics to see what you all think Just from following hoses to me it appears that the one next to the EGR is the the MAP as it has a hose direct to the Manifold The one under the manifold appears to be the EGR Pressure Sensor as it has a hose which is T off into the EGR and off to the EGR EVRV INJECTOR SEALS Good article at http forum australiadwd com index php topic 22839 injector sleeve repair do it yourself step by step Please be in injector seals and not the head And 9 times out of ten it will be the injector seal As I have said previously on this forum this procedure should be in the maintenance manual for every 100 000km s for the 4JX1 Basically get the M16 Dynabolt as long as you can About 150mm from memory I welded on about 200m
114. onal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 68 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Rough idling long starting crank cycles or your engine not starting are all tell tale signs that your Isuzu 4JX1 engine has compromised components in the hydraulic system Our Oil Rail Pressure Meter can help in identifying which components are faulty or failing based on the oil pressure readings at different engine states Under normal driving conditions the Oil Rail Pressure Meter readings should read between 1 00 and 3 50 Should the meter readings fall outside of these parameters for normal driving and no noticeable change in performance it is possible that the oil rail sensor is faulty With a cold engine and the cam angle sensor disconnected cranking the engine should give a reading above 1 20 depending on oil temperature battery condition type and grade of oil used Note that the engine will not start with the cam angle sensor disconnected Under normal operation if the Oil Rail Pressure Meter reading does not reach 1 00 the engine will not start Likely causes are e HEUI pump control voltage missing reading should be approximately 10 00 or more e Loose connection oil leak on an injector or associated hydraulics e Low oil in sump and or e Air leak in the pickup for the hydraulic priming pump If the Oil Rail Pressure Meter reading is above 1 00 the engine will not start The
115. onger pulls the springs and disengages the clutch How does the clip that holds the thrust bearing in the pressure plate springs work is it possible this has broken and could be replaced have found a video here of someone showing how the wedge collar wire ring pressure plate and release bearing work together in a pull type clutch It looks from the workshop manual at 7C 14 that the Jackaroo clutch works the same way is this right If so it looks like need to get a new wedge collar wire ring and possibly release bearing will need to remove the pressure plate to install the wire ring on the wedge collar Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 102 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Hopefully won t need to replace the pressure plate which am guessing would be horribly expensive Well have finally removed the gearbox and disassembled the clutch The problem is indeed the wedge collar It has worn on the inside of the lugs where they contact the release bearing Several lugs have broken along the wear line and the wire ring came off finished the job today In the end I replaced the wedge collar Holden part number 8970650730 20 clutch release bearing Exedy part number BRG2247 80 this is the same as the original which must be made by Exedy and pilot bearing NSK 6203VVCM 5 replaced the release bearing mainly because th
116. ontrol Valve This electronically operated valve controls oil pump output and injection pressure Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 9 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 3 Oil Supply Diagram amp C 4 ENGINE FUEL HIGH PRESSURE OIL PUMP OIL FLOW ma dotrHa motHrOD q peer n Legend 1 Camshaft 2 Balance Shaft 3 Crankshaft 4 Ot Cooler and Oll Filter Assembly 5 Of Filler Relef Valve 38 Kpa 1 kgicm t4 2 Psi 5 Of Cooler Relef Valve 245 Kpa 2 5 kgiomy 36 Psi First Of Pump 8 Main Oll Relief Valve S86 Kpa 6 kgicnr BS Psi 3 To Oll Pan 10 To Oll Pan 11 Injector 12 Of Rall 13 Sub Of Fiter Relief Valve 93 Kpa 1 kgicme 14 2 Psi 14 Sub Of Fiter 15 Reef Vave 588 Kpa E kg cm 85 Pel 15 Second Ot Pump Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc Oll Pan To Oil Pan Balance Shaft Cooling Jet Relief Valve 245 Kpa 2 5 kgiom 10 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 4 Diagnostic gear TECH II http www uobd2 net wholesale gm tech2 gm diagnostic scanner html I believe it is this card http www uobd2 net wholesale 32mb card for gm tech2 1538 html ISUZU ISUZU English 107 021 2006 2010 ISUZU CANBUS is for ISUZU after 2010 ISUZU K line is for ISUZU from 1996 to 2010 Req
117. or an approx 200 Coolant 50 000km Replace orange dexcool type coolant for Al heads radiators Glow Plugs 100 000km Check replace Cam Timing Belt 100 000km Replace Type Valve clearance 20000km then 30000km 50 after every 80 120 etc Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 19 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 General issues and things to look for in your Jackaroo when you first get it When got the 2000 jack the seller serviced it 1 It was leaking oil out of all oil filters I replaced all 2 cleaned engine replaced turbo and oil supply line 3 fixed oil leaking out of tappet cover with new seal and taking 2mm off spacers 4 fixed leaking diesel out of metal block at back of motor missing copper washer that Holden said they could not fix took me 20 mins 5 replaced timing belt and rollers cleaned up wiring loom and plug that was full of oil and spray a sealer on top of plug no oil so far 6 Now next job is to have a go at why coolant is being pushed back into reserve tank 7 lreplaced thermostat and cap 8 It only seemed to do it after was playing with glow plugs as had the manifold off so back to removing it 9 Well tried removing glow plugs snapped two replaced one and left other one after cleaning and spraying with crc wd40 and some other stuff 10 only have two
118. or yellow sticker for disabling the emissions reduction system and the tree huggers won t be happy either Easy solution to keeping the intake throttle clean is to use a catch can on the breather hose No more oil into the intake clean throttle plate and cleaner intake manifold If you use a EGR filter soot catch can thingo they do actually exist you will then reduce the soot in the intake and the intake manifold will be nice and clean No oil or soot Problem solved MAP sensor EGR valve EGR pressure sensor might be wrong but there is a thread in Isuzu DYI about someone who fitted an EGR valve out of a VT commodore bought it for 77 00 and it fitted in and works fine Regards lan Posted 26 October 2009 01 55 AM Hi Guys just an update Removed the EGR valve completely as the diaphragm had a hole and was leaking exhaust gas and boost into the engine bay Removed and cleaned the MAP sensor but it was pretty clean inside Bit of fiddling to refit the actual valve to seal the hole between the exhaust and intake manifolds but did it in the end and an instant increase in power and torque Don t think I ll bother replacing it as I ve read that the EGV valve only reduces some of the nasty exhaust emissions Not very green of me I know Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 85 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 EGR Removal and Ser
119. place INSTALLATION 1 Put gasket on the intake manifold and install throttle valve 2 Tighten nuts to the specified torque Torque 20 N m 2 0 kg m 14 5 Ib ft 3 Reconnect harness connector to motor and ITPsensor 4 Install intercooler assembly Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 91 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Rail Pressure Control Valve RPCV or Pressure control valve PCV by DieMonty Recommend retail price 680 Obviously dealer dependant Part G 8971748720 The rail pressure control valve is in the high pressure oil circuit It is an important device which is used to control oil pressure in the HEUI system High oil pressure high voltage and Low oil pressure low voltage The reason the engine won t start is because the ECU sets the ORPCV at a position that returns the wanted 1 volt but because the ORPS is giving a false high the pressure is actually too low for the injectors to work correctly The workshop manual also establishes this information i e the relation ship between pressure volts Symptoms If faulty these occurred to me and replacing the valve fixed all of them MAY 2009 1 Shuddering or missing like petrol engine 2 Below average horse power and performance and a slight rise in fuel consumption 3 Delayed auto change down and laboring in all gears Generally a good strip and clean of th
120. place the O rings between injectors and sleeves and between sleeves and cylinder head as a precaution This will add little to the overall cost of the service as the mechanic will already be working in this part of the engine checking and adjusting the valve clearances e If the oil level in the sump rises to the point that it enters the crankcase breather pipe the engine may start to run on it s own oil In this situation in Holdens words this may result in an unintentional increase in engine speed and possibly vehicle speed If this happened it would cause most people to get very alarmed especially if it happened in heavy traffic driving at high speed etc The engine will no longer respond to normal throttle operation and will continue to run even with the ignition switched off e In extreme cases engines have been known to red line and self destruct In the UK there have been cases of engines being replaced free of charge by Isuzu e If a motorist is unfortunate enough to experience a run away engine the best advice is to immediately steer in a safe direction engage the highest possible gear and jump on the footbrake and hand brake together to stall the engine Only depress the clutch or engage neutral as a last resort as this will allow the engine to spin freely out of control Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 6 Page Manual Jackaroo 4JX1 Engine March 2014 Mon
121. pply the correct amount of diesel In which the engine oil coming from low pressure pickup pump to then high pressure oil pump to rail and injectors How to test the high pressure oil pump Good day sirs we are from the Philippines and we bought a 2nd hand Isuzu trooper with a 4jx1 engine we had the trooper for almost 4 years now the problem was the turbo the impeller and its shaft was broken so we had it replaced we drive tested it and after a few kilometers on the road 6 kms Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 99 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 It emitted a white smoke we towed the car and brought it home and contacted the supplier of the new turbo because it was again broken So he came to see the car and tried starting it then he said that there was no oil coming to the turbo that s why it broke What seems to be the problem A mechanic told us that it could be the high pressure oil pump but he is not sure This pump is expensive and we don t want to be gambling our money on this considering that we have spend so much money on this vehicle rpcv rps turbo injector you name it we have changed them all Any help Thanks YOU should have a oil pipe at the top and another one at the bottom of turbo now these are the feed top and the return the bottom pipe Take off top pipe turn engine over oil should come out Now take off the
122. preciated thanks Check the hose from MAP sensor to the manifold and the channel in the manifold Try push in a piece of wire or something like this this channel could be blocked by deposits of carbon Check that new TPS sensor is adjusted correctly Try genuine oil filters Disconnect a battery for a few hours to clean the MIL codes from memory Drive car a day more than read possible MIL codes with paperclip Cheers Sergey Air flow inside intake manifold Outer wall of intake manifold GENER Metal pipe pressed in to connect rubber hose to MAP sensor Channel in the manifold drilled Bended pice of wire to clean the channel Hold here Twist by another hand Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 115 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 27 Parts List have not checked all these yet but updating as go Description Brand Part No Main Oil Filter Isuzu 8971 679 720 Ryco Z600 Do not use Nippon Max Mont Secon ety tter eaa Filter Z79A NN SEE not use E eesper Wesfl M ___ IRE es ATE WA1081 A1081 pe te FC 1301 8943 935 211 Isuzu 8943 940 790 asket seals etc required for installing injectors amp sleeves Isuzu 8972 407 980 njector body O ring x4 9724 0798 8971 757 830 9717 5783 Copper washer for injector tip x 4 8971 611 092 High pressure oil pipe gasket x2 8971 842 160 8972
123. r exhaust into the cooling system Either way your engine needs a rebuild HEATER leaks under Dash Both pipes where the go into the heater matrix are plastic see photo attached Did this job several months ago myself yep time consuming s t of a job had to let the gas out of the air con to get the a c box out to get to the heater element Had to pull most of the dash apart to get at it because of where the heater sits and the way to get it out All can say further is have fun I did find a radiator place in Canberra I think was the cheapest place to source a new core wasn t going to put a 2 hand 1 in that could break as well soon down the track After checking try Autoheat in Canberra Ken Faulty O Ring rear head Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 51 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Of one more explanation about o rings at the sleeves and possible reason of their damage It could be overheating Not a big overheating that comes before cracks in the head but small regular overheating every time your start the cold engine Place The reason for this could be a faulty or just old O ring at the L shape metal coolant pipe going from the block of the engine to the head At the block side its flange is bolted by 2 bolts m10 size and at the other side its just pressed in the head This L shape pipe is located under the air
124. r the car A bit of measurements Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 52 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Old o ring dimensions Inner D 20mm Outer D 25 H 3 5mm I ve tried to fit a replacement o ring from Bunnings with Inner D 19 and Outer D 26 it was very hard and I decided not to force it in A little bit smaller from the same plumbing o ring kit 2 50 for a lot of them fits well But few weeks later it will be replaced with a genuine one of course Or a vitton one if I ll find an equal replacement and it will pass my tests replaced most of the hoses with genuine as several hoses involve sharp bends etc Bear in mind mine TU Q Q ut wr ez Vg Drs A LOS br Sy TNS x A ST 114 FRONT l pipe jpg Size 159 08KB SAVE had lasted for 10 years which think is extremely good However some of the coolant hoses are no longer available from Holden these just happen to be the straight ones and most are relatively easy to get at where cut lengths of generic hose can be used That little hose is definitely in the tight bend very difficult to reach category and would advise using genuine 10 Big Coolant Leak post 410 jacksdad Posted 22 September 2011 07 49 AM The same hose went on my trooper got a new one next day from my local Isuzu dealer cost about 5 what a total H H to change its
125. rade of oil was used The oil must be 5W 30 40 0W 1f in cold climates else it wont start Interestingly the 2 oils that is known to work well with this engine Penrite HPR Diesel 5 and Mobil Delvac1 Both have the lowest pour points available from oils around 48 degrees C Notes on Oil related matters The injectors are hydraulic Correct me if I am wrong and use the oil to operate If there is not enough oil pressure they don t fire Pretty simple really Many 4JX1 owners and myself use Penrite HPR 5 5W40 oil with Nippon Max filters which can be bought from Sydney Filters Ryco filters have caused oil pressure issues for some people Small oil filter meant to be changed every second service so 20 000km OIL TYPE The other question I have is why would Holden recommend an oil that is SL CF rated Isuzu recommends a minimum of CH 4 or better In the industry that I work it the OEM recommendations are there for a reason and it takes a great deal of engineering research to deviate from it even then it has to be promulgated before end users can use the alternative HPR DIESELS CH 4 rated Penrite HPR Diesel 5 meets the requirements of API CH 4 SL and the European Standards ACEA A3 B4 and E 4 as well as many manufacturers specifications Designed for used in the latest generation light duty diesel engines including the new generation common rail and hydraulically actuated injector equipped units Specific examples include BMW
126. rankshaft pulley Unfortunately this is very difficult to see In fact to see it you must first remove the sound cover that surrounds the crankshaft pulley The mark can then be seen as a small cut across the rear most edge of the pulley For piece of mind I would follow the advice in the manual which states to rotate the crank at least two turns after fitting the new timing belt to ensure that the camshaft is correctly timed After rotating the crank twice loosen off the tensioner bolt to allow the tensioner to find the correct tension then retighten Having another look at the photo you posted it looks like you probably didn t have the crank exactly at 1 TDC unless of course the timing gears have been interfered with To determine if the timing gears are out rotate the crank at least six times stopping at 1 TDC each time On at least one of these rotations the timing marks on the HPOP crankshaft and camshaft should all be aligned PARTS Just replaced my timing belt today It was a fairly easy job The old belt was in good condition seeing that has been going around for 180000km The tensioner bearing was a little dry so I added a little grease This is easy to do just pop of the seal add grease and replace the seal Having a good look at the bearing and roller it looks like the roller is shrink fit over the bearing I think it would be possible to replace the bearing with a little bit of effort The bearing is a NSK B35 139DWAI also the
127. recall thinking to myself that the Jack seemed to be performing noticeably better toward the end of my trip It was pulling much harder with the caravan on than it normally did Oil Blow by Turbo motors both petrol and diesel often suffer with blow by causing oil mist to be blown out the crankcase breather Most performance shops sell oil air separators catch cans to strip the oil out of the air before it hits the air filter and the rest of the intake made one for a previous turbo car and 4 o j haven t yet fitted it to my jack From dead cold start am getting 20 30 seconds of thick blue smoke as the oil in the cooler and manifold feeds through the engine pila wa swell CLOSE X Something like this is what you want Maybe this weekend Oil Pickup Pipes checked my oil pickup pipes on the W E due to fluctuating pressure The injector pickup is quite short and should not be prone to problems but the main pressure pickup is quite long about 10 or 11 inches and enters the oil galleries to the pump well above the oil level The O ring was looseish but what believe the problem to be is the lack of support allowing the pipe to move about and then suck air through the O ring area After fitting new O rings fashioned a small bracket to fix both pipes together and hopefully making them more secure Oil pressure is now back to normal so it looks like that was the cause of the problem IMG 1978 JPG Size 53 87KB
128. return valve in the fuel line just upstream from the filter as I had been advised an air leak could sometimes develop around the filter leading to air ingress when stood overnight A bloke in the UK told me this was yet another known irritating problem with this engine the valve was only about 20 so I thought nothing to lose I also changed air and fuel filters But poor starting continued and winter came The Jackaroo was in for the injector seal recall so I got them the check the glowplugs result all u s The front three were removed and replaced successfully but the rear one was snapped off Craig s current problem I left the damaged one in situ and get by on three as I reasoned much more serious damage could be done trying the get the broken plug out I find it starts ok on three plugs and will remove the broken one when I am convinced a reliable method exists A warning to those who like to do things by the book The Isuzu book that is Three new glowplugs were totaled when they were tightened to the spec set out in the genuine Isuzu manual 23NM 17 ft Ib This spec is still in the current Isuzu update used by Holden 23Nm isn t a lot of torque As a comparison spark plugs on the V6 are 18Nm and wheel nuts are 118Nm At 23Nm the tightness of the glow plug shouldn t be more than about 1 8th of a turn after it seated CraigS The supplier of the glowplugs said the maximum should be around 12 to 14NM Said I should discuss with I
129. ry pushbutton from same shop To start I completely removed cabling from the positive side of the passenger side battery and also removed the other end from the connector on the solenoid of the starter motor Leave the negative where it is or if non existent ie don t have battery there yet then attach to engine block Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 23 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 on passenger side with a sturdy bolt and steel crimp soldered if you don t posses an industrial crimper then wire the rest in as per the drawing attached I also put in an Anderson plug into the rear of the jack as well as to the tail gate for the trailer off the auxiliary stud of the smart solenoid with a 80 amp automatic circuit breaker fuse Hope this helps Jas EEEEEHEHEHEHEHEEHEHEHEHEHEEHEHEHE EHE EHEHEHE EE HERE EE EHE HHHH HHHH ER HERR RH ERR TR RF 7 Parts List Isuzu Ryco Cooper Wesfil Nippon E Max Change at Main Oil Filter Part 8 97167 972 0 Z600 WZ554 MO 024 5000 to 10000 km Secondary Filter Z79A W279 Air Filter A1081 WA1081 Fuel Filter Donaldson P550225 FF Tensioner Belt NSK 835 139D WA1 TT10007 Tensioner Bearing Belt Gates T312 Supercheap Out of all the above the Wesfil products are not only the cheapest but also seem best quality suited to the Jackaroo The main filter from th
130. s We p we p nm jj Referto Engine Mechanical Diagnosis to diagnose the following conditions Faulty camshaft drive belts Leaking or sticky valves or rings Excessive valve deposits Weak valve springs Incorrect yalve timing Leaking head gasket Is the action complete Verify repair Goto Step 11 11 Observe the Engine Speed data display on the Tech 2 while cranking the engine Isthe engine RPM indicated Ifthe Tech 2 is normally powered from the cigarette lighter socket and if the Tech 2 display goes blank while cranking the engine it willbe necessary to powerthe Tech 2 directly from the vehicle battery Goto Step 12 Goto Sep 17 12 At the ECM female side of the connector mentioned in step connect a test light between the ignition terminal and one of the injector driver circuits at the same connector 2 Ignition ON 3 Observe the test light and repeat the test for each injector driver circuit by oscilloscope Did the test light stay on when checking any of the 4 injector driver circuits Goto Step 13 Goto Step 15 1 1 Ignition OFF disconnect the ECM 2 Ignition OM observe the test light Is the test light ON Goto Step f4 Goto Step T5 Locate and repair the short to ground in the injector driver circuit Is the action complete Verify repair Check for an open injector driver circuit Was a problem found Verify repair Goto Step 16 1 Replace the ECM Refer ta the Data Programming in Case af ECM change
131. s above the normal oil level whereas the other one is fully immersed Clean the jointing compound from both faces of the oil pan joint found kero and a scotch mitt to be best otherwise persevere both surfaces must be spotless For reassemble you will need to rejoint the oil pan with a suitable compound found Permatex Blue to be very good After all that I did not do the overfilling thing the problem was not rectified and eventually traced the fault to the pressure sender mounted on the oil filter block That part cost me 237 and I had to remove the top control arm of the suspension to get at it Although this is not a job for the faint hearted it can be done timg on 7 Sep 2007 06 31 PM said have a 98 Jackaroo 3 0 TD with 138000 on the clock with long motor replaced under warranty at 90000 l ve had inconsistent oil pressure issues but the most annoying problem is that after short trips when the engine is up to normal temp it takes ages to start If it is left 15 minutes or more its fine Cold starts take about 5 cranks l ve had the injectors done rail pressure sensor replaced harness replaced EGR valve replaced Are there pearls of wisdom that the apostles can shed I ve had a similar problem with mine after dropped a fan belt It was the crank angle sensor which is within striking distance of the belt replaced it and all was fine If you do purchase one shop around as the genuine article varied by about 40
132. s like no current on injection pump Where to check Where is the connection or valve are located You have no injection pump each injector does that job You have a faulty rail oil pressure sensor ORPS I think read my tips to test this sensor Isuzu 4JX1 Engine Won t Start after replacing new injector Can anyone suggest assist help me with these My newly replaced injector did not received any fuel as start crank the engine You probably need to enter the new injector numbers into the ECU using a Tech2 Tester by your nearest dealer 1999 trooper 4JX1 fuel black My trooper would fire then die in mornings but would eventually start Start ok when hot Removed fuel filter and it was full of black fuel New filter fitted and started fine but what can be causing this The recall work on injectors has been done Thanks Engine oil leaking past injector O rings and going into fuel return hose back to tank contaminates tank If recall done are O rings ok Can put clear plastic tube on return fitting in rear of head to see if black contaminated with oil or air leaks from cold start it isn t high pressure it could be from before or now My 1st experienced with my 4jx1 engine was diesel fuel mixing with water inside my radiator so replaced set of O ring at nozzle 2nd is after a month cant start my engine until replace RPCV sensor and oil pressure sensor and it works and now came to find out that my oil dip stick is getting high i
133. s or exceeds all major standards and is recommended for major European Japanese and USA gasoline diesel and heavy duty wet sleeve diesel engines Supplier Quinlan s Auto Spares PTY LTD 325 Townsend St Albury S NSW 2640 Australia 02 6021 5311 SR400 can be added to the cooling system as top up adjustment of freeze point of the cooling water Product Benefits SR400 can be used in most OEM diesel petrol and natural gas engines allowing one coolant to be inventoried The product lasts up to 3 times as long as conventional coolants Reduces engine coolant cost up to 60 over conventional coolants The recommended maximum service interval without pre charging or recharging is 500 000 kms or 5 years at a 50 5096 mix for on highway diesel truck engines and 5 000 hrs for off road equipment and commercial engine applications http superroo com au SR400 Extra Long Life Coolant Concentrate htm Don t put normal off the shelf petrol engine stuff it wont protect the unique operating conditions of a diesel This is necessary to ensure that electrolysis does not eat the cylinder sleeves on the water side Electrolysis Cavitation Corossion for those who havent heard of it occurs due to the high compression in a diesel causing the bores to pant in and out momentarily during the point of combustion or expand causing air bubbles to form on the sleeve eating off a bit of metal at a time until you get compression and or water leakage into the cylinder o
134. sel tries to start there s about 20A going to the glow plugs about 15A going to the power transistors in the ECM and about 25A going to the starter motor I hope you bled the fuel lines properly after draining the tank to check for coolant in there If the seals were leaking it could be full of water Did you pre fill oil gallery before connecting injectors to it Did you pre fill oil filters before installation What filters did you use Genuine Wiring loom is connected properly Oil pressure gauge showing no oil pressure which one at the dash or extra Oil level is ok Any MIL codes Check that the o rings have not caught when you put the sleeves in and don t have fuel in the coolant etc Otherwise as SergAnt says above it takes a lot of oil to fill up again if you emptied all the system I was cranking my engine for quite a while Two battery charges from memory The Jack LIVES After reading through your questions sergey i took everything apart gave the wiring loom another thorough clean reinstalled everything again and hey presto oil pressure on the dash and no cel Red one Have just completed the sleeve O ring replacement job have run engine all seems fine A few hints and observations There is a plug under the front end of the oil rail to empty it of oil before lifting it out This makes it lighter as well as avoiding oil running into the chambers It is possible to remove the oil rail and injectors as a
135. single unit without disconnecting the electrical leads This removes the risk of snapping connectors as they remain connected throughout Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 70 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Before attempting to lift the oil rail injectors out slacken relevant bolts and work each injector in turn until all are freed In use some carbon deposits around each tip making it difficult to pull em all out together without doing this A toothbrush is nice and soft for gentle cleaning of the tips I made a dynabolt puller to get the sleeves out but instead of using a slide hammer on the end I used a separate nut on the thread to jack the sleeves out Used some hardwood packers to push down against the camshafts The lower O rings were in a worse condition than the upper ones The lower o rings seal between the diesel and coolant I had just started to get early symptoms of diesel in the radiator in fact my radiator cap was difficult to remove due to swelling of the rubber seal and was replaced a couple of weeks ago The hesitation I was starting to get when engine running in the 2000 s revs Under low load conditions now appears to have gone Apart from using the correct grade of oil etc etc That most are now aware of it seems to me that there are 3 key components that require regular replacement to keeping this engine ru
136. sosoesosoesosossoseee 72 Muir Y 72 OIRO W DY oc 74 Oil PIcKUp PIPES e 74 CPS Crank Position Sensor ccsccsscscssssscssccsessccssessssssssssscssesesssscssssssssscsscssesssssscssossscssoseseeee 75 Vi 0I 001 mp 77 jb rigro ea p 79 Turbo Famers 80 Turbo Changes Type Suitable inonsan eiia E EE E EEE TE R 80 TURBO Removal and replacement eese rieni bee aia nae eet P E GE E RE 80 Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 4 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 18 TPS Throttle Position Sensor sccscccccccccssssssssssccessssssssssssscccsssessccasssscccsscssccascsesececeess 83 Throttle IEInBXEOI c 84 EGR Removal and Service uoo eet eb eere oecte s si eoe vae ae coe oo ore eR FeEa sae sa VPE a Fe vue teet ate De Us etue lar sE dos vu seveeieecatunewessee 86 Calibrating the TPS Throttle Position Sensor eee e eese eren ee eere eee ee eet ene setae sees s eana 88 MES e e 88 ECU and calibration OF TPS ccssscecoscscccccassscesoccssscosasescosostssosesososccsoutasesessvvsesest
137. ssure is controlled almost entirely by the ECM which uses the ORPS to monitor Fuel Injector output and the RCPV to control it Pressure in the common rail provides a head to drive the injectors and is one mechanism that the ECM uses to correctly meter fuel to the cylinders Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 61 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Very short digital steps to achieve this pressure control the RCPV All computers use a high frequency rate of short jumps rather than a smooth analog flow The RCPV has a fast acting piston in it to do what the ECM tells it The RCPV piston becomes varnished with deposits as time goes by It is inevitable that the reaction time of the piston is reduced This will cause some binding of that piston so the steps in pressure will be larger than the new device This will likely be more noticeable at idle since the difference in the jumps looks higher then than when compared to total oil flow through the pump at higher rpm While a common rail injection system produces full pressure from very low rpms there is still a ramp up in pressure off of idle Therefore normal wear in the injector system will likely show up at rpms near idle first since that is the only time the Common Rail is not at full oil fuel pressure This is normal An engine is new only once and so it s normal condition is to be we
138. starter power up the Tech2 go to the Miscellaneous Test menu and select Throttle Position Motor 14 Scroll down the data display until you see TPS voltage above the Throttle Position at the bottom of the display 15 Use the Decrease soft key to get the stepper motor to zero steps if it isn t already there then rotate the TPS until the TPS voltage is as close to 0 50V as you can get The allowable voltage range is 0 44V to 0 56V Attached File Tech2 showing motor steps amp TPS voltage jpg 78 24KB 2 downloads 16 Tighten the TPS mounting screws and ensure that the TPS voltage has not changed 17 Use the Increase soft key to advance the stepper motor to 1 step then rotate the stepper motor until the TPS voltage is as close to 0 84V as you can get The allowable voltage range is 0 75V to 0 95V Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 89 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 18 Go through all the stepper motor positions and record the TPS voltage for each step The allowable voltage values are in the table below Attached File TPS values png 26 03KB 1 downloads 19 Repeat step 18 a number of times to see if the TPS voltage remains the same each time Note that the allowable voltage variation is by 0 02V between runs 20 With the stepper motor at step 1 tighten the stepper motor mounting screws and ensure that the TPS voltage doesn
139. sure oil pump to contaminates and get a good light this fella is in a bad spot 4 remove passenger front wheel or jack up so it drops away RH drive vehicle and remove small rubber skirt to gain access to engine bay from wheel arch 6 identify valve and disconnect electrical connection it has small clip just for added fun 7 remove pressed metal nut sleeve and coil using 1 1 8 spanner or tube socket unscrew valve from pump 9 the valve does come apart by unscrewing the front part where the oil holes are mine had vice grip marks on 1t 10 inspect condition and clean then carefully reassemble and do not to over tighten pressed metal nut The ROPCV can be changed without going through the wheel arch Disconnect the batteries Remove the fuel filter mount and put this aside with fuel lines still intact Unplug and remove the ECU putting it somewhere safe TOOL Stanley 1 1 8 th inch ring spanner from Supercheap costs 26 and if you cut the one third end off near the open ender with a metal drop saw you can easily access the ROPCV There is even no need to disconnect the fuel line in front of the ROPCV I did mine without the ECM being removed twice now From the top and even left the fuel line to the cylinder head sitting on the lower banjo bolt still although it was lose and removed from the top Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 93 Page Manual Jackaroo 4JX1 Engine
140. suzu I have been informed that the UK spec for the same motor is 15NM Posted 05 January 2007 03 13 PM Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 48 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 I put some nickel based grease on the threads when I put them in don t know f it will help with later removal they must get bloody hot in there glenos Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 49 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 12 Cooling Water System Heater Coolant Radiator Natrad have both radiator cores available in aluminium or brass the aluminium core was very efficient Use thicker than 25mm if replacing The workshop manual doesn t specify an interval for replacement It does specify that coolant concentration should be checked every 10000kms It depends on the coolant being used My V6 is now using the orange dexcool type coolant for aluminium radiators and alloy engines It is supposed to have a 5yr 100000km life but I ll replace it every 50000km or 2 5yrs regardless More often is better so 40000km would be a good move Coolant Sorry Jack can t answer that question The owner s handbook states that the coolant conforms to specification number HN2217 and should be 5096 coolant 5096 water found some Nulon long life coolant at Superc
141. t a difficult job Before you proceed though you can try over filling your sump with about 2 litres of oil This will raise the oil level to a point above that of the suspect seal thereby excluding air from the suction Fire the engine up and see if there is any improvement Obviously if the problem is rectified then the seals are gone and will need to be replaced Do not run your engine for longer than is absolutely necessary while the sump is overfilled To change the seals they are not expensive about 7 00 for both and you might as well do both you will need to put the car onto axle stands until the front wheels are at least clear of the floor Remove the cross member immediately behind the oil pan Drain and remove the oil pan you will need a 12mm thin walled socket spanner a 3 8 drive will do it as there is not much room around the bolt heads The jointing compound they used on the pan is extremely strong so be careful not to deform the pan as you remove it try running a knife around the joint as you go Try to resist any lateral movement as you remove the pan as the suctions are very close to it and are bent easily When it is removed the suction lines will become immediately obvious and if the seals are worn will practically fall out when the retaining bolts are undone Be careful with them they look very robust but are not The engine lubricant oil suction is on the driver s side of the engine you will see that its seal i
142. t a pain having to remove the intercooler etc to get to them As for the performance I ve had no problems since putting them in Suppliers SMS Diesel Spares http www smsdiesel com au main_pages product brands html they have competitive pricing on many of the parts that I would have needed and were very considerate with returned unused parts Glow plugs Australia for help with cost effective glow plug replacements and genuine assistance with technical problems www glowplugs com au Symptoms of Glow plug problems I have not been happy with the performance since Anyhow I had the check engine light appear last night and was blowing some white smoke in the mornings until it reached operating temperature ish Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 46 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 1 White smoke implies you have not yet got 4 working Glow Plugs Did you check the resistance was within spec 0 8 1 2 2 AFTER installing the new Plugs They re all supposed to be attached to a strong little bus bar Is THAT broken in some place or is there a good electrical connection at the bulkhead end 2 DTC 16 does indeed indicate a faulty Oil Temp Sensor but it MIGHT just be that you ve damaged the connector The sensor itself is pretty robust It s the sensor beside the ORPS on the HP Oil Rail All of those connectors are subject to hea
143. t and vibration and sometimes the locking clips break off Some folk have re attached the connectors with Cable Ties 3 DTC 774 is our old pal the TPS which again might NOT be faulty Whether with a new TPS or an old one the output voltage seen by the ECM measured at J1 18 varies with the MOUNTING ANGLE of the TPS on the side of the Throttle Body So loosen the 2 mounting bolts set up the Voltmeter between the ECM connector J1 pin J1 18 and Battery and turn the TPS until the voltage is about 0 85V that s with the Ignition ON and the Engine OFF It does NOT require a Tech2 as the voltage can be read directly from the ECM connectors TOOLS for Job Torque Wrench capable of 17ft Ibs 23 Nm Number 3 Phillips Number 3 Flat Blade 3 8SD Ratchet Drive 6 3 8SD Extension 1 4SD Ratchet Drive 6 or greater 1 4SD extension 10mm Socket 12mm Socket 12mm DEEP REACH socket 8mm socket 1 4SD WD40 RP7 CRC or similar pointy nose pliers Checking Glow plugs The other way to check my calculations for the resistance is 1 Rtotal 1 R1 1 R2 1 R3 1 R4 this is for resistors in parallel Seeing as the Glowplugs are meant to be 1 Ohm each Rtotal comes out to 0 25 Ohm for 4 or in my case 0 33 Ohm Meanwhile measured the resistance on my existing ones and they read 0 9 44 630 and 47 Ohms so guess it looks like they need changing The only thing I m worried about is snapping them when try to remove
144. t became progressively worse Went to start it two days later Zero just cranks We ve tried to clean the ORPS with WD 40O still nothing Try fitting a separate transfer pump between the tank and HP pump quick cheap fix only and see if this resolves the problem If yes check filler cap no air lock air leaks in supply hoses or transfer pump and of course the usual check the fuel filter If not dig deeper Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 97 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Isuzu Trooper 3 0D DOHC 4JX1 WON T START AFTER REPLACING FLYWHEEL Three weeks ago replaced the faulty dual mass flywheel with a second hand but working one Diesel and oil filters for engine and Turbo From then on the 4JX1 engine refused to start An expert mech checked the flywheel sensor and declared it fit still he could not start it It cranks and produces all the signs of attempting to start but fail to Did overlook something Can you please help out Open one of the injector lines till fuel pumps out My Isuzu Trooper 2004 4JX1 turbo just underwent a general engine overhaul Its cranking but will not start All electrical s are ok Does the PCM needed to be reset for it to start Check the alignment of the camshafts Make sure the marks were aligned correctly isuzu tropper 4jx1 my isuzu 4jx1 don t start Is it an electric problem look
145. t max torque seems to come in a little bit higher up the rev range now The biggest improvement from my point of view was fuel economy My wife drives the car mostly short trips to the shops dropping off the kids to school etc and the roo was averaging 11 5 12 5 Itr 100km Now it has dropped to 10 10 5 Itrs 100km Highway consumption is even less the best so far has been 9 8 Itrs 100km Note these figures were achieved with tyre pressures at 45psi air unifilter installed and conservative throttle application Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 39 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Overall I m happy with the out come but noise levels are higher in the cabin than the standard one I d recommend discussing all your concerns with the installer before hand and if you re not happy with their answers keep ringing around Just as a comparison Beaudesert Exhausts will do a 2 75 custom mandrel bend straight through system with glass packed muffler and a new dump pipe for 935 plus 125 fitting They claim that noise levels are the same as the standard one and ground clearance will not be compromised In hindsight would probably use them after the niggling issues had with my system Hi ANT and everybody else You can stop the ECU from learning too much by putting a restrictor in the line from the Intake manold to the MAP sensor Basical
146. the ECU The wire chaney is on about is the white wire in the big multi plug next to the dipstick this will bypass the pressure sensor if it starts then the sensor is at fault if not then chances are the control valve is stuck open k E The oil pressure sender under the tappet cover has a loom attached to it It seems that the oil seeps out of the sender and down in the loom and affects the plug by upsetting the readings to the computer Ours started out by running rough for a few seconds the first time and then clearing itself just like a small trace of rubbish in the fuel Second time would start but only run at about 700rpm at full throttle turned off would nt restart rang mechanic and talked for few minutes tried again started perfect No problem for a few weeks then would stop on way to town wait a minute starts no problem Pull off fuel filter water in fuel drain tank should be good week later same thing dealer decided to look further check fuel wiring harness oil in loom replace sender and loom around 600 thanks Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 57 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 eEEEEEKE You can easily check the harness it comes out on the left hand side of the rocker cover and joins a connector block at that level it s easy to find If it is playing up you will see oil coming out of the con
147. them I gave them a very tentative tug but none of them moved So I ve soaked them in WD40 and will leave it until get my new ones for another go Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 47 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Some fantastic stuff on this site thanks found instructions for checking glow plugs and finally took the plunge today minus the beer Feeling a bit chuffed that it wasn t too difficult Plug resistance was slightly higher than 1 00hms but all four were exactly the same 1 18Ohms also checked the voltage going to the plugs which seemed to be lower than the suggested 12volts got initially 9 5volts that went up to 10 3 after around 20 seconds had the same results with the ECT Sensor connected disconnected never checked the ECT Sensor what is the purpose of that on startup If all the plugs have a readable resistance in the order of 1 ohm and there is voltage supplied to the plugs my bet would be leaking copper washer on the injector letting diesel into the cylinder There is also the possibility of coolant leaking past the sleeve that the injector fits into cheers Dave l Jack My glowplugs were u s at 100 k kms but probably failed some time before that I suffered a gradual deterioration of starting and had gone through the ritual of making sure the correct oil was being used etc I also fitted a non
148. then had an even bigger problem when fitted a Digital Fuel Adjuster DFA which actually increased the fueling and power substantially and so have been playing with this for a couple of months By the way have a 3 inch mandrel bent exhaust which comes off the turbo and straight down the drivers side until past the gearbox after which it crosses over and follows the standard path This exhaust makes changing the oil filters heaps easier My muffler is a straight through even after specifically telling the exhaust guy that wanted a full proper muffler and makes a constant annoying drone The best improvement in economy and derivability have experienced is definitely from fitting the DFA however think this is only because I had already done the exhaust So far have only got around 10 improvement over standard and know that fuel economy can fall by that much simply by having the wrong oil in it Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 40 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 fisko on 17 Aug 2008 09 47 PM said hi edgo just thought i would BUMP to see how you went with the ECU Fisko Hi Fisko have been able to stop the ECU from learning around the big exhaust and DFA by placing a restrictor and adding length to hose in the line to the MAP sensor The restrictor has a 1 mm hole of about 15mm length and have put a 350 mm length of hose bet
149. to 2000kg as are brakes Perhaps the ideal would be to have the roof rack mounted on a boat rack on the trailer this would Reduce GVM of the car Provide for better ergonomics when loading the rack and subject to location of the rack above the trailer axle allow for increase in trailer loaded weight with little or no increase in tow ballload D OK looks like have a plan for the Lap Rig 8 Last Edit February 16 2014 08 35 41 PM by B amp B Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 114 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 Manifold blocked husq3092 on 24 Mar 2013 04 33 AM said Hi have tried to find a solution to this issue have with my Jackaroo 4jx1 The check engine light comes on intermittently and only while under acceleration when I back off say slowing down for a corner the check engine light goes out When the check engine light is on it does not surge but is under powered when the light is off it surges like a miss in a petrol engine Hot or Cold have changed the MAP TPS sensors changed these as they were indicated as faulty via MIL codes had an oil leak in the rocker cover gasket so when changed that also changed the OPRS sensor and main wiring harness All sensors are new have also changed fuel and oil filters delco and run penrite 5w oil Any assistance would be greatly ap
150. ts are replaced in a kit for the CAT HEUI injectors for 100 000 150 000km services Isuzu don t do a kit 1 When you removed the original injector was there any discolouration between the bottom O ring and the copper gasket Update for anyone interested I replaced seals on the 2 hand injector and reinstalled it this evening did all the usual things double checked everything soon as I got oil pressure up she fired up and sat there idling like it was brand new no smoke Took it for a run beautiful Starts easily I now have 3 spare injectors with new seals Total fix cost 100 for injector 45 for seals Thanks for advice and help In measuring the HEUI internals they 4 seemed to have little wear in the metal parts I would guess this is because they have light diesel fuel as well as heavier engine oil surging through their guts all the time Also they re water cooled so remain at a constant temperature rather than simply relying on the fuel temperature like in a standard common rail This would indicate that the reconditioned injectors for sale have simply had new O rings and springs fitted The solenoid would have been checked if not rewound SOLENOID O RING B SEE DIAGRAM ABOVE The CAT HUEI overhaul set is solenoid o rings spring Their kit sells for about A 65 85 per injector Recommended interval between overhaul is 100 000km This is why I am fiddling with it The Isuzu
151. ty benefits as well They improve vehicle stability by altering the airflow at the vehicle s rear The large random eddies at the rear surface are changed to an array of small vigorous stream wise vortices The majority of users comment immediately on the improved vehicle handling performance especially in gusty cross wind conditions or when passing or being passed by other vehicles This increases driver safety margins by reducing wandering and sudden adjacent lane incursions Mirror visibility in rain or snow is also improved as the Airtabs help suppress precipitation and spray patterns Safety is improved through better mirror visibility yielding safer lane changes as well as improving the visibility conditions for other road users By reducing the suction and aerodynamic drag at the rear of vehicles the tendency to accumulate snow and road grime at this location is reduced These help to improve corporate image and reduce cleaning time and expense It also enhances safety by keeping conspicuity tape tail and brake lights cleaner and helps the bottom line by reducing snow and weight build up in winter Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 108 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 26 CASE STUDY Uneven Idle At the end of a reasonably long drive during which it was stationary and idled well a couple of times it started running roughly as t
152. uest the K Line software as this covers our Jackaroo s PC Laptop or Netbook PC based scan tools allow you to diagnose and troubleshoot problems with your car truck or motorcycle They harness the power of your PC and have a number of important advantages over stand alone scanners http www myscantool com store http www scantool net scan tools pc based and http www easyobdii com index php http www control tech com au oil rail pressure meter Advanced technology yields higher performance f mechanical an landards for fuel effici The revolutionary HELI injector design is critical to the Plin arma economy and proven reliability of j timing resulting conomy Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 11 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 5 Diesel Initial analysis Diesel Troubleshooting Probable Cause Engine net Hard to Stain The Answer is in the Smoke We can generally understand whatis wrong with a diesel engine by the colour of smoke emitted from the exhaust There are three basic colours black white and tius Black Smoke Thisis due to a air to fuel ratio imbalance either the fuel system is delivering too much fuel into the engine or there is nnt enough clean air oxygen a few things tolook for Faulty injectors injectors need attention at about
153. urbo spins it creates a vacuum on the inlet side This sucks oil filled air from the engine it s designed this way all cars do it and through the turbo When the air cools in the intercooler the oil condenses and stays there One way to stop this is to make an air oil separator and install this between the head and air cleaner I have made a rough one and will let you know how it goes if required The first installed was nowhere near big enough for the job and filled full of oil in a 4 000 km trip The new one is much larger Most car sites that talk about turbo cars have a thread on oil air separators Saw a nice one for a Jag made from PVC pipes With regards to Oil Separators have been talking to a fella at SFS Sydney Filter Services who has been bringing in these you beaut little ProVent units See www mann hummel com They come from Germany and are supposed to be the ducks nuts in oil separators Turbo Mods The turbo system can be modified and the following gives some advice http www autospeed com cms article html amp A 2478 and for some construction of a fan system http www autospeed com cms article html amp A 110214 and http www autospeed com cms article html amp A 2110215 Airbox to turbo pipe Was adjusting my steering box preload today to eliminate some free play and in the process removed the airbox to turbo pipe to allow better access when I discovered that it had not been installed correctly by
154. urned into a driveway Starting a few minutes later the same thing happened Once it gets above about 1000rpm it seems normal It doesn t feel like it s missing but the idle goes up and down a bit and occasionally drops very low almost stalling The fluctuations are quite irregular The ORPS was replaced in March last year so I m hopeful that s not the cause although of course it could be The first job since it s so easy is to check the fuel filter and housing for a blockage don t think that s the problem though since it would affect high speed running as well What would like to know is could it be the oil rail PCV or the EGR valve I m trying to work through the simple things before allowing panic to set in Cheers Rich would check the fuel filter first Just cos its rough on idle wont mean u will have problems up high as the extra pressure in the lines will help Might be just some water in the fuel Couple of my simple points to do 1 Check the fuel filter If a bit of air comes inside the fuel line you could have a rough idling 2 clean inside TPS unit Throttle should go very easy Note do not unbolt TPS Posted 23 July 2012 07 18 AM No water or rubbish in the fuel filter oil and both filters changed and the problem seems to have gone away As we know nothing 4JX1 fixes itself though so as soon as have time I ll look at the TPS hadn t considered it before and make sure the throttle is moving properly
155. vice Posted 26 February 2011 07 38 AM am in the process of doing up a Jackaroo 3 0TD 1998 as per normal there is build up of soot and oil in the intake manifold The back inlet port on my manifold was sooted up that bad the hole was down to a size of a pen and the Jackaroo only done 134 000 kms have been doing allot of research and this is the best solution to the problem Take off the EGR valve wipe the seat clean and use 401 silicone on the seat and valve just to give a real good seal and put it back on Block up the vacuum line going to the EGR say with silicone and a ball bearing and push it back on so it looks still intact If your Jackaroo has done a few km s would pay to remove intake manifold and give a real good clean out took me over an hour just to clean the intake manifold out pressure wash best Make sure the area around MAP sensor is clean Buy an oil catch can off eBay us eBay best price about 75 litre size is large enough mount in a suitable location on the firewall route pipe from the PCV to the catch can Then route a pipe back to the original position on the intake between the air filter and the turbo use original looking rubber pipe to keep the engine bay looking tidy Job done Every time you change the engine oil also drain the catch can all the good catch cans come with sight glass and drain bungs EGR valve not opening will give more clean air and oxygen to give a better combustion etc
156. w to e Remove the battery battery holder and tray e Undo the hose that connects the turbo and intercooler you can take it off or just spin it out of the way e Undo the Air inlet solid black tube on turbo Also undo the clips on the air filter housing lift the air inlet out of the way e Loosen the pulley on the adjuster for the AC compressor belt release the tension and remove the belt Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 25 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 e Loosen the adjuster bolt for the alternator you will also need to loose the retaining bolt at the bottom of the alternator Now you can let the tension off the belts and remove them e Replacing is the reverse of the above except do up the alternator adjustor bolt top one first e To tension the alternator the good old broom stick was a bit too bendy I used a long socket handle I have I didn t get them super tight 10mm give between the fan pulley and drive pulley Harmonic Bal Alternator Specifications Posted 14 October 2008 11 56 PM http forum australia4wd com index php topic 12184 Ajx1 alternator two plugs According to my Jackaroo workshop manual the 98 99 and 02 model 4JX1 had either a LR190 750B 90amp or a LR 1100 731 100amp alternator The 00 and 01 4JX1 had either a LR160 734B 60amp or a LR 170 760 70amp alternator A search on the n
157. warning light for airbags will light up in the dash when she is running but the vehicle will still run perfectly well So if you swap those 2 relays and 1 The car starts to charge normally amp 2 The airbag warning light comes on then you know the big blue relay is definitely furked will warn you that when I tested all my relays on the bench they tested good However my main ECM relay was totally knackered and this only showed up by swapping relays and running her gt i e the fault Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 27 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 only occurred under load For this reason it is often wise to simply replace a suspect relay or fuse on the off chance It takes about 30 seconds Relays are not expensive to replace Edited by chilby 20 February 2013 09 14 PM Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 28 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 9 Fuel Supply Fuel Filter also fitted a non return valve in the fuel line just upstream from the filter as had been advised an air leak could sometimes develop around the filter leading to air ingress when stood overnight A bloke in the UK told me this was yet another known irritating problem with this engine the valve was only about 20 so I thought nothing to lose
158. ween this restrictor and the MAP sensor just did a 6000 km trip towing our 24ft caravan down to the snow fields and the ECU seems perfectly happy with this setup and has shown no signs of performance drop believe the restrictor and hose length introduce a delay in the sensing of the manifold air pressure thereby tricking the ECU into thinking that the engine is still operating normally even with the bigger exhaust and alterations to the fuel injection making the power and boost come on much faster than a standard engine edgo Poor Idle Quality JohnTD on 2 Jan 2008 03 15 PM said Could one of the experts tell me if poor idle quality can be fixed by getting the existing oil pressure sensor calibrated with Tech 2 The poor quality idle has existed since the injectors were replaced on recall I wonder if the mechanic calibrated the oil pressure sensor when the injectors were replaced Lately the engine is starting to hesitate on pick up from idle Idle OK when cold poor when hot Cold oil pressure 600kpa hot oil pressure 400kpa Could it be possible that the injectors weren t graded correctly upon installation MAP Sensor EGV valve Doing some checking in the manual Quote that round object with the triangle on the outside also fixed to the manifold That s the EGR valve Quote underneath the little black box that sits at the front of the inlet manifold behind the radiator hose The black plastic box is the MAP sensor The b
159. well detailed in the manual So before undoing anything drop the little plate and inspect It sounds like your bearing may have unclipped itself for some reason Perhaps the last person to work on it didn t clip it in properly Maybe the bearing will clip back in with a screwdriver Worth a try maybe don t have to drop the box at all There may of course be damage to the fork or clutch fingers instead But it s a very solid unit tim130 on 19 Nov 2013 5 41 PM said Thanks Chilby have looked into the space and found that the fork is disengaged from the release bearing The clutch was inclined to chatter so I m committed to replacing the major components The parts will arrive in a few days Then given the weight of things will most likely have the clutch replaced in a workshop Thanks again for your advice Tim Hi Tim have a special jack for the tranny Basically it s a plate that s adjustable for angle with a chain attached to clamp the trans to it It attaches to a trolley jack and the plate ends up high enough for the job if you have the Jackaroo up on front ramps highly recommend something as stable as ramps when working with heavy components under a vehicle axle stands etc are death waiting to happen see them on eBay still for 150 with the jack Additionally have a 20 tonne truck jack that use on my Mack with an overall height of 600mm so that gets up under the back of the engine to lift and hold it all easily
160. xtended the timing mark around the pulley with some liquid paper and all fixed Apart from that the job was pretty easy Posted 21 April 2013 01 49 PM Do have any oil leaks from the HP oil pump seals If so then now is the time to look at changing the o rings as you re half way there Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 67 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 15 PCV Valves Posted 27 August 2013 12 50 PM Hey AaronJack Just purchased a RPCV P N 89 7174 8720 from Ibrahim at Ramin Auto Parts in the UAE Good bloke to deal with and got the parts within a week Cost was US205 plus freight His contact details Ramin Auto Spare Parts Trading P O Box 30199 Dubai United Arab Emirates Tel 971 4 2670081 Fax 971 4 2671502 Email raminaut emirates net ae Web www isuzuautopartsstore com Cheers JackDriver Injectors It is also suggested you replace the copper washer every 100 150k it as in CAT HEUI diesels and 4JX1 s in Russia as maintenance item Saves time later down the track Oil Rail Pressure Meter CTIs Oil Rail Pressure Meter is a diagnostic tool designed to verify the oil pressure in the injection system of Isuzu 4JX1 3 0 Litre Turbo Diesel engines The Oil Rail Pressure Meter can be retrofit to any existing vehicle using the 4JX1 motor in approximately 1 hour by someone with handyman skills Quote file d 5 pers
161. y shaft and even when brand new oil comes from the breather system not necessarily the turbo It is a simple carbon film POT and the fingers eventually wear the carbon film through The TPS is only used for input to the ECU regarding what level of EGR to apply to the engine yes it can cause rough idle when on the way out but this is because the EGR valve is being told by the ECU the wrong information have never seen hard to start and no acceleration caused by the TPS my money would be on the ORP sensor for that problem Don t forget the easy way to find out what code is set when the check engine light comes on is to bridge 4 and 6 in the data connector 2 minutes work and free TPS fault code is 73 or 74 ORP fault code could be 61 62 63 but regularly does not set a code when faulty Therefore NO ORPS fault code does not necessarily mean a fault Cheers Dave L Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 16 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 DTC for 4JX1 BE 64 4JX1 TC ENGINE DRIVEABILIT Y AND EMISSIONS i i here are displayed by a Tech 2 the Tech 2 data maybe ECM Diagnostic Trouble Codes faulty nai de Lh 2 manufacturer of any DTCs The following table lists the diagnostic trouble codes i i i supported a Tech 2 and to fash If any DTCs not listed displayed that are not induded in the following table ECM Diagnostic Trouble Codes
162. ze in the shed and fitted that Good find not sure if your scan gauge will tell you but if the CPS is dead the RPM as shown on the scanner while cranking will be half of actual That is it seems to be cranking at normal speed 220 240 but shows around 120RPM Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc 75 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 HIGH PRESSURE OIL PUMP OIL FLOW M This is the pressed 7C metal nut Note this is designed LTE E so you can t crush fi A the solenoid coil e ici and damage the 31 e inner plunger clearance Here is the 1 1 8 or 28mm hex flange Quote file d 5 personal rob car jackaroo jackaroo 4jx1 engine manual 2014 ver 3 0 doc ded 8 Looking from the ESL dipstick past Egr yr rat 5 vacuum ohh there is i Re a bulge in that E 10 hose toward front of engine Oil Pan To Oil Pan Balance Shaft Cooling Jet Relief Valve 245 Kpa 2 5 kg cm2 36 Psi Cooling Jet To Oil Pan Two Way Check Valve Nipple Filter Edge Filter Edge Filter High Pressure Oil Pump Assembly To Oil Pan To Oil Pan Turbocharger Oil Gallery Timing Gear Train 76 Page Manual Jackaroo 4JX1 Engine March 2014 Monday March 31 2014 17 TURBO Cold Start Butterfly http forum australia4wd com index php topic 22288 no jackaroo problems page 3 p 165071 entry1

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