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Isuzu 20LE Manuals
Manuals and User Guides for Isuzu 20LE. We have
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Isuzu 20LE manual available for free PDF download: Workshop Manual
Isuzu 20LE Workshop Manual (510 pages)
Isuzu GASOLINE ENGINE C22NE, 22LE, 20LE
Brand:
Isuzu
| Category:
Engine
| Size: 6.23 MB
Table of Contents
Section 6 Engine Diagnosis
4
Engine Diagnosis
2
Table of Contents
4
Engine Diagnosis
5
Hard Starting
5
Engine Compression Test Procedure
6
Rough Engine Idling or Engine Stalling
7
Rough Engine Running
8
Hesitation
9
Engine Lacks Power
10
Engine Noisy
11
Abnormal Noise Due to Hydraulic Lash Adjustor
12
Troubleshooting Procedure
12
Abnormal Combustion
14
Engine Oil Consumption Excessive
15
Fuel Consumption Excessive
16
Oil Problems
16
Engine Oil Pressure Check
16
Malfunction Indicator Lamp
17
Section 6A Engine Mechanical
18
Engine Mechanical
18
General Description
21
Engine Pictorial
23
Rear View
25
Top View
27
Main Data and Specification
28
Crankcase Ventilation System
35
Engine Assembly & Loose Parts
36
Operations on Engine Aggregates
37
Engine Damping Blocks(Engine Without Transmission)
37
Toothed Belt Tension, Adjust
42
Toothed Belt, Replace
43
Operations on Installed Engine
45
Gasket, Exhaust Manifold, Cylinder Head
45
Gasket, Intake Manifold, Clinder Head
45
Seal Ring, Camshaft Housing, Timing Side
46
Seal Ring, Thermostat Housing, Cylinder Head
46
Seal Ring - Front Camshaft Housing, Replace
47
Toother Belt Rear Cover
49
Toother Belt Tension Roller
50
Component Parts
51
Cylinder Head
51
Hydraulic Valve Lifter
52
Operations on Cylinder Head and Camshaft Housing
53
Camshaft
53
Camshaft Housing Removal and Installation
54
Cylinder Head
54
Hydraulic Valve Lifers, Replace
56
Camshaft Housing, Replace
56
Camshaft Housing, Check for Plance Surface
58
Cylinder Head, Removal and Installation
58
Cylinder Head, Disassemble and Assemble
61
Valve, Grind
63
Valve Seating, Mill
64
Cylinder Head, Overhaul
64
Flywheel
65
Starter Ring Gear(Manual Transmission)
66
Seal Ring, Crankshaft
67
Seal Ring, Crankshaft Rear
67
Gasket, Oil Pan
68
Operations on Crank Drive
70
Con-Rod Bearing
70
Piston with Con-Rod
70
Con-Rod
71
Operations on Removed Engine
74
Crankshaft
74
Bearing Free Play Measurement
76
Plastigage Method
76
Micrometer and Gauge Method
77
Bypass Valve
78
Oil Filter
78
Oil Pump
78
Oil Pump Safety Valve
79
Oil Pump(Overhaul)
79
Operations on Oil Circulation
80
Cylinder Head Safety Valve
80
Operations on Cooling Sysytem
82
Cooling System, Check for Leakes
82
Cooling System, Fill up and Bleed
82
Refill Coolant
83
Ignition Timing, Check
83
Engine External Parts
84
Engine Mechanical (C22Ne, 22Le, 20Le) 6A-3
84
Radiator
84
Thermostat
84
Water Pump
85
Coating Sealing Surfaces with Silicone Grease
85
Alternator
85
Starter
85
V-Belt Tension of Alternator
86
Fuel Injection System
87
Map Sensor
87
Pressure Regulator
87
ECM (Engine Control Module)
87
Ect
88
Idle Air Control(IAC) Valve
88
Ignition Coil
88
Crank Position Sensor
89
Fuel Injector
90
Knock Sensor
90
Oxygen Sensor
91
Throttle Valve Position Sensor
91
Air Cleaner Filter
92
Spark Plug Thread
92
Technical Data
93
Engine Oil Viscosity
93
Radiator Cap
94
Recommended Torque Values
104
Special Service Tools
105
Section 6B Engine Cooling
107
Special Service Tool
107
Engine Cooling
107
General Description
108
Service Precaution
109
Diagnosis
111
Draining and Refilling Cooling System
112
Water Pump
113
Inspection
113
Removal
113
Water Pump and Associated Parts
113
Installation
114
Thermostat
115
Inspection
115
Installation
115
Removal
115
Fan Clutch with Cooling Fan
115
Inspection and Repair
115
Radiator
117
Radiator and Associated Parts
117
Removal
117
Inspection
118
Installation
119
Main Data and Specifications
119
Special Service Tool
120
Section 6C Engine Fuel
121
Engine Fuel
121
General Description
123
Service Precaution
124
Fuel Metering
125
Fuel Filter
126
Fuel Filter and Associated Parts
126
Removal
126
Inspection
127
Installation
127
In-Tank Fuel Filter
127
Fuel Pump
128
Fuel Pump and Associated Parts
128
Removal
128
Installation
129
Fuel Pump Relay
129
General Description
129
Fuel Tank
130
Fuel Tank and Associated Parts
130
Removal
130
Installation
131
Fuel Gage Unit
131
Removal and Installation
131
Fuel Filler Cap
132
General Description
132
Inspection
132
Fuel Filter
133
Removal
133
Installation
133
Fuel Tank
135
Removal
135
Installation
135
Main Data and Specifications
137
Section 6D1 Engine Electrical
138
Engine Electrical
138
Battery
139
General Description
139
Service Precaution
139
Diagnosis
140
Battery Charging
141
Jump Starting
141
Installation
143
Main Data and Specifications
143
Removal
143
Section 6D2 Ignition System
144
Diagnosis
145
General Description
145
Ignition Coil
145
Removal
145
Installation
145
Service Precaution
145
Spark Plug
146
Removal
146
Inspection and Repair
146
Installation
147
Crankshaft Angle Sensor
147
Removal
147
Main Data and Specifications
148
Section 6D3 Starting and Charging System
149
Starting and Charging System
149
Diagnosis
150
General Description
150
Service Precaution
150
Starting System
150
Starter
151
Removal
151
Installation
151
Disassembled View
152
Inspection and Repair
153
Characteristic Test
154
Charging System
155
General Description
155
General On-Vehicle Inspection
156
Generator
156
Removal
156
Inspection
156
Installation
157
Diagnosis
160
Disassembly
161
Clean
162
Inspection
162
Reassembly
166
Inspection
167
Technical Data
169
Section 6E Driveability and Emissions
171
Driveability and Emissions
171
Emission Control System Schematics
194
Engine Coolant Temperature Sensor
194
Spark Plugs
194
Specification
194
Tightening Specifications
194
Diagrams and Schematics
195
ECM Pinout Table, 32-Pin Blue Connector-Row "J1
205
ECM Pinout Table, 32-Pin Blue Connector-Row "J1
206
Ecm Pinouts
207
ECM Pinout Table, 32-Pin Red Connector-Row "J2
207
ECM Pinout Table, 32-Pin Red Connector-Row "J2
208
Component Locator
209
Engine Component Locator Table
211
Undercarriage Component Locator Table
211
Instrument Panel (I/P) Fuse Block
212
Underhood (U/H) Fuse and Relay Panel
212
Diagnosis
213
Strategy-Based Diagnostics
213
Dtc Stored
213
No Dtc
213
No Matching Symptom
213
Intermittents
213
No Trouble Found
213
Verifying Vehicle Repair
214
Generalservice Information
214
Maintenance Schedule
214
Obd Serviceability Issues
214
Fuel Quality
214
Non-OEM Parts
214
Poor Vehicle Maintenance
214
Related System Faults
214
On-Board Diagnostic (Obd)
214
Visual/Physical Engine Compartment Inspection
214
Basic Knowledge of Tools Required
215
On-Board Diagnostic Tests
215
Input Components
216
Output Components
216
Passive and Active Diagnosis Tests
216
Intrusive Diagnosis Tests
216
Warm-Up Cycle
216
Serial Data Communications
215
Common Obd Terms
216
Diagnostic for Closed Loop System
216
Enable Criteria
216
Trip
216
The Diagnositic Executive
217
Diagnostic Information
217
Malfunction Indicator Lamp (MIL)
217
Extinguish the MIL
217
Data Link Connector (DLC)
217
Reading Flash Diagnostic Trouble Codes
218
Reading Diagnostic Trouble Codes Using a TECH 2
218
Clearing Diagnostic Trouble Codes
218
On-Board Diagnosis (Self-Diagnosis)
219
Tech 2 Scan Tool
220
Getting Started
221
Operating Procedure
221
Menu
222
Reading Diagnostic Trouble Codes Using a Scan Tool
223
Clearing Diagnostic Trouble Codes
223
Verifying Vehicle Repair
223
Clear DTC Information
224
DTC Information Mode
224
Dtc Modes
224
Fuel Control Heated Oxygen Sensors (if Applicable)
224
Ho2S Heater
224
Primary System-Based Diagnostics
224
On-Board Diagnostic (Obd) System Check
225
Circuit Description
225
Diagnostic Aids
225
Test Description
225
On-Board Diagnostic (OBD) System Check
226
A/C Clutch Control Circuit Diagnosis
229
Circuit Description
229
A/C Clutch Diagnosis
229
Diagnostic Aids
230
Electric Ignition System Diagnosis
232
Evap Canister Purge Solenoid (if Applicable)
232
Fuel System Pressure Test
232
Idle Air Control (Iac) Valve
232
Visual Check of the Evaporative Emission Canister (if Applicable)
232
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure
233
Test Description
233
Injector Balance Test Procedure (Step7-11)
234
Injector Balance Test Procedure (Step7-11)
235
Fuel Metering System Check
233
Engine Control Module(Ecm) Diagnosis
238
MULTIPLE ECM INFORMATION SENSOR Dtcs SET
238
Circuit Description
238
Diagnostic Aids
239
Poor Connection at ECM
239
Damaged Harness
239
Legend
246
Results of Incorrect Operation
246
Diagnosis
247
Legend
247
Visual Check of Canister
247
Evaporative Emission Canister Purge Control Solenoid Valve Check (if Applicable)
248
Circuit Description
248
Diagnostic Aids
248
Test Description
248
General Description
249
Legend
249
ECM Diagnostic Trouble Codes
250
Symptom Diagnosis
251
Preliminary Checks
251
Visual/Physical Check
251
Intermittent
251
Hard Start Symptom
252
Surges And/Or Chuggles Symptom
254
Lack of Power, Sluggish or Spongy Symptom
256
Detonation/Spark Knock Symptom
258
Rough, Unstable, or Incorrect Idle, Stalling Symptom (for Open Loop System)
260
Rough, Unstable, or Incorrect Idle, Stalling Sympton (for Closed Loop System)
262
Idle CO Concentration Check and Adjustment
264
Poor Fuel Economy Symptom
265
Dieseling, Run-On Symptom
267
Backfire Symptom
268
Cuts Out, Misses Symptom
270
Hesitation, Sag, Stumble Symptom
273
Hesitation, Sag, Stumble Symptom (Cont'D)
274
Step Action Value(S)
279
Was a Problem Found
279
Cyl. 4.7Kω
279
Cyl. 3.9Kω
279
Cyl. 3.4Kω
279
Engine Cranks but will Not Run
279
Engine Cranks but will Not Run
280
Ignition on
280
Step Action
280
Verify Repair
280
Was a Problem Found
281
Broken Locks, Improperly Formed or Damaged
283
Terminals, Poor Terminal-To-Wire Connection, and Damaged Harness
283
Go to Step 2 Check
284
Is the Action Complete
284
Was a Problem Found
285
Verify Repair Go to Step
285
Verify Repair Go to Step
289
Was the "On-Board Diagnostic (OBD) System Check" Performed
289
Yes no
290
Fuel System Diagnosis
290
Verify Repair Go to Step
290
Fuel System Diagnosis
291
Verify Repair
297
Replace the TP Sensor
301
Check for the Following Conditions
304
Fuel System Diagnosis
316
Specified Value
317
OBD System Check
332
OBD System Check
336
ECM Fuse
351
Diagnostic Aids
354
Ignition System
366
Ignition System
368
Circuit Description
369
Broken Inside the Insulation. Check for the Following
378
Connection, Rubbed-Through Wire Insulation or a Wire
378
Poor Connection or Damaged Harness - Inspect the ECM Harness and Connectors for Improper Mating
382
Value(S) Yes no
384
Verify Repair Go to Step
400
Go to OBD System
404
Throttle Position Sensor
425
Air Filter
427
Cleaning and Inspection
427
Oil Pressure Switch
430
Fuel Injectors
434
Fuel Pressure Relief
437
Ignition Timing Adjustment
447
Wiring Harness Service
449
Tools Required
452
Section 6F Engine Exhaust
478
Engine Exhaust
478
General Description
480
Service Precaution
482
Exhaust Pipe
483
Exhaust Pipe and Associated Parts
483
Removal
483
Installation
483
Inspection
484
Front Exhaust Pipe
485
Front Exhaust Pipe and Associated Parts
485
Removal
485
Installation
486
MID Pipe
487
MID Pipe and Associated Parts
487
Removal
487
Installation
488
Catalytic Converter (if Applicable)
489
Catalytic Converter and Associated Parts
489
Removal
489
Installation
489
Way Catalytic Converter System
490
Exhaust Silencer
492
Exhaust Silencer and Associated Parts
492
Removal
492
Installation
493
Rear Exhaust Pipe
494
Rear Exhaust Pipe and Associated Parts
494
Removal
494
Installation
495
Engine Lubrication
497
General Description
498
Service Precaution
499
Oil Pump
500
Disassembly
500
Oil Pump and Associated Parts
500
Inspection and Repair
501
Reassembly
501
Oil Pan
502
Disassembly
502
Oil Pan and Associated Parts
502
Inspection and Repair
503
Reassembly
503
Engine Speed Control System
504
Service Precaution
505
Accelerator Pedal Control Cable
505
Inspection
505
Installation
505
Removal
505
Accelerator Pedal
506
Accelerator Pedal and Associated Parts
506
Adjustment
506
Installation
506
Removal
506
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