Table Of Contents - Isuzu C-240PW-28 Technical Manual

Table of Contents

Safety Summary3
Table Of Contents9
List Of Illustrations12
List Of Tables15
General Information17
Chapter 1 Introduction17
Scope17
Maintenance Forms Records And Reports17
Reporting Equipment Improvement Recommendations (Eir)17
Warranty18
Equipment Description And Data19
1-7. General19
Detailed Description19
Engine Components20
Table Of Specifications21
Preparation For Use22
Inspecting And Servicing Engine22
Principles Of Operation23
Cooling System23
Lubrication System23
Fuel System23
Electrical System24
Preventive Maintenance Checks And Services (Pmcs)27
Troubleshooting29
Symptom Index29
Engine Will Not Crank30
Starter Operates But Engine Does Not Turn Over30
Engine Cranks But Fails To Start30
Engine Hart To Start Or Will Not Start In Cold Weather31
Engine Misfires Of Runs Irregularly Or Stalls Frequently31
Engine Does Not Develop Full Power32
Engine Overheating32
Excessive Oil Consumption32
Low Oil Pressure33
Excessive Fuel Consumption33
Black Or Gray Smoke34
Blue Exhaust Smoke34
Engine Knocks35
Engine Makes Abnormal Noise35
Engine Makes A Gas Leaking Noise36
Detonation Of Pre-Ignition36
Battery Charge Ammeter Shows Charge When Batteries Are Low36
Battery Charge Ammeter Shows Excessive Charging After Prolonged Period37
General Maintenance38
Disassembly And Assembly Sequence For Overhaul38
Cooling System Maintenance42
Thermostat And Housing42
Water Pump Removal And Installation44
Water Pump View46
Fuel System Maintenance47
Fuel Filter Assembly Removal And Installation47
Fuel Filter Assembly View49
Fuel Injectors And Piping Removal And Installation50
Fuel Lnjectors And Piping View52
Fuel Injector Inspection53
Piping Inspection53
Fuel Injector Cleaning54
Fuel Injector Assembly55
Fuel Injector Test/Adjustment55
Fuel Injector Spray Pattern56
Fuel Injection Pump Removal And Installation57
Fuel Feed Pump And Timer Assembly View60
Fuel Injection Pump Assembly View61
Removing Delivery Valve66
Feed Pump67
Removing Plunger Barrel67
Timer Assembly68
Injection Pump Inspection69
Checking Plunger And Barrel Movement70
Delivery Valve View70
Checking Plunger And Barrel For Damage71
Lower Spring Seat72
Camshaft Check72
Feed Pump Check73
Camshaft Bearings73
Tuner Assembly74
Injection Pump76
Checking Sleeve Pinion Movement77
Inserting Plunger77
Fuel Pump Testing80
Fuel Pump Test Specifications82
Feed Pump Test85
Priming Pump Test86
Capacity Test87
Feed Pump Pressure Test88
Air Tightness Test88
Injection Pump Installation89
Removal Of Mechanical Governor90
Bleeding And Priming Fuel System91
Fuel Injection Pump Timing91
Oil Filter95
Cartridge Replacement95
Oil Pressure Relief Valve Removal And Installation96
Oil Piping Removal And Installation97
Oil Pan Removal And Installation99
Oil Pump Removal And Installation101
Oil Pressure Test102
Oil Pressure Test Setup104
Intake And Exhaust System Maintenance105
Pcv Assembly Removal And Installation105
Intake And Exhaust Manifolds Removal And Installation108
Intake And Exhaust Manifolds109
Glow Plugs Removal And Installation111
Starter Assembly Removal And Installation111
Glow Plugs Assembly112
Testing Starter114
Starter Assembly114
Starter Solenoid Test Circuit115
Testing Starter Components115
Test Armature For Grounds115
Test Armature For Open Circuits115
Test Field Coil116
Battery Charging Alternator Test119
Alternator Removal119
Alternator Disassembly120
Alternator Inspection/Testing121
Alternator Assembly View122
Alternator Assembly Assembly123
Alternator Assembly Installation124
Engine Block Maintenance125
Front Gear Cover Removal And Installation125
Front Gear Cover Screw Lightening Sequence127
Rocker Cover And Arms Removal And Installation128
3-26. Rocker Cover And Arms128
Rocker Covet And Arms View129
Rocker Arm Retaining Plate Bolt Loosening Sequence130
Rocker Arm Shaft Runout130
Rocker Arm Shaft Outside Diameter131
Rocker Arm Oil Ports, Location Of132
Rocker Arm Correction133
Rocker Arm Retaining Plate Bolt Tightening Sequence134
Valve Clearance Adjustment Sequence135
Cylinder Head Assembly Removal136
Cylinder Head Assembly137
Cylinder Head Assembly Disassembly138
Cylinder Head Bolt Loosening Sequence138
Hot Plug Removal139
Cylinder Head Inspection140
Cylinder Head Height (Reference)141
Hot Plug Depression142
Valve Stem And Guide Clearance143
Valve Stem Outside Diameter143
Checking Valve Thickness144
Valve Depression144
Checking Valve Contact Width145
Valve Spring Free Height146
Valve Spring Tension146
Push Rod Curvature147
Valve Seat Correction148
Valve Seat Insert Installation149
Cylinder Head Installation151
Cylinder Head Bolt Tightening Sequence152
Pistons, Connecting Rods And Crankshaft Removal153
Compression Check153
Pistons, Connecting Rods, And Crankshaft155
Crankshaft End Play156
Crankshaft Bearing Cap Bolt Loosening Sequence156
Piston And Connecting Rod Check157
Piston Ring And Groove Clearance158
Measuring Piston Ring Gap159
Crankshaft And Bearings160
Connecting Rod Side Face Clearance160
Check Crankshaft Run-Out161
Basic Dimension Measurements161
Crankshaft Run-Out162
Bearing Spread Measurement162
Crankshaft Journal And Crankpin Diameter163
Crankshaft Journal And Bearing Clearance164
Connecting Rod Bearing Inside Diameter164
Check Crankpin And Bearing Clearance166
Crankshaft Assembly167
Crankshaft Installation169
Crankshaft Bearing Location170
Crankshaft Bearing Cap Bolts Tightening Sequence171
Crankshaft Rear Oil Seal And Spacer172
Piston Ring Gap Setting173
Crankcase Removal And Inspection174
Crankcase Installation175
Camshaft And Idler Gear Assemblies Removal176
Crankcase Fastener Tightening Sequence176
Measuring Timing Gear Backlash177
Camshaft And Idler Gear Assemblies View178
Disassembly Of Camshaft179
Thrust Plate Removal179
Idler Gear And Shaft Inspection180
Camshaft Journal Diameter181
Cam Height181
Check Camshaft Run-Out181
Camshaft Runout182
Assembly Of Camshaft183
Camshaft Installation183
Flywheel And Housing Removal184
Flywheel And Housing185
Flywheel And Housing Inspection/Repair186
Flywheel Bolt Loosening Sequence186
Flywheel And Housing Installation187
Flywheel Housing Installation Sequence187
Cylinder Block Assembly Disassembly188
Flywheel Bolt Tightening Sequence188
Cylinder Block Assembly View190
Cylinder Block Inspection/Repair191
Check Cylinder Block Upper Face Warpage191
Cylinder Block Upper Face Warpage Measurement192
Cylinder Block Height Measurement192
Measure Cylinder Liner Bore192
Check Cylinder Liner Projection193
Select Piston Grade193
Measure New Cylinder Liner Bore194
Cylinder Liner Bore Measurement194
Cylinder Block Assembly Assembly195
Cylinder Liner Installation196
Pressing Cylinder Liner197
P R E S S I N G C Y L I N D E R L I N E R199
Maintenance Allocation Chart201
Maintenance Functions201
Explanation Of Columns In The Mac, Section Ii202
Explanation Of Columns In Tool And Test Equipment Requirements203
Explanation Of Columns In Remarks, Section Iv204
Maintenance Allocation Chart For Diesel Engine205
Pcv Assembly206
Front Gear Cover206
Crankcase207
Tool And Test Equipment Requirements208
Remarks For Diesel Engine209
Expendable/Durable Supplies And Materials List211
Fuel Injection Pump Tappet Holder View213
Maintenance Procedure And Authorized Level Of Maintenance215
Index217
The Metric System And Equivalents233
Approximate Conversion Factors233