Isuzu C-240PW-28 Manuals

Isuzu C-240PW-28 Manuals

Manuals and User Guides for Isuzu C-240PW-28. We have 1 Isuzu C-240PW-28 manual available for free PDF download: Technical Manual

Isuzu C-240PW-28 Technical Manual

Isuzu C-240PW-28 Technical Manual (236 pages)

4 CYLINDER 2.4 LITER NSN: 2815-01-350-2207

Brand: Isuzu | Category: Engine | Size: 1.99 MB

Table of Contents

Safety Summary
3
Table of Contents
9
List of Illustrations
12
List of Tables
15
Chapter 1 INTRODUCTION
17
General Information
17
Scope
17
Maintenance Forms Records and Reports
17
Reporting Equipment Improvement Recommendations (EIR)
17
Warranty
18
Equipment Description and Data
19
1-7. General
19
Detailed Description
19
- Engine Components
  20
- Table of Specifications
  21
  - Inspecting and Servicing Engine
    22
  - Preparation for Use
    22
  - Cooling System
    23
  - Fuel System
    23
  - Lubrication System
    23
  - Principles of Operation
    23
  - Electrical System
    24
- Preventive Maintenance Checks and Services (PMCS)
  27
  - Symptom Index
    29
  - Troubleshooting
    29
  - Engine Cranks but Fails to Start
    30
  - Engine will Not Crank
    30
  - Starter Operates but Engine Does Not Turn over
    30
  - Engine Hart to Start or will Not Start in Cold Weather
    31
  - Engine Misfires of Runs Irregularly or Stalls Frequently
    31
  - Engine Does Not Develop Full Power
    32
  - Engine Overheating
    32
  - Excessive Oil Consumption
    32
  - Excessive Fuel Consumption
    33
  - Low Oil Pressure
    33
  - Black or Gray Smoke
    34
  - Blue Exhaust Smoke
    34
  - Engine Knocks
    35
  - Engine Makes Abnormal Noise
    35
  - Battery Charge Ammeter Shows Charge When Batteries Are Low
    36
  - Detonation of Pre-Ignition
    36
  - Engine Makes a Gas Leaking Noise
    36
  - Battery Charge Ammeter Shows Excessive Charging after Prolonged Period
    37
  - Disassembly and Assembly Sequence for Overhaul
    38
  - General Maintenance
    38
  - Cooling System Maintenance
    42
  - Thermostat and Housing
    42
  - Water Pump Removal and Installation
    44
  - Water Pump View
    46
  - Fuel Filter Assembly Removal and Installation
    47
  - Fuel System Maintenance
    47
  - Fuel Filter Assembly View
    49
  - Fuel Injectors and Piping Removal and Installation
    50
  - Fuel Lnjectors and Piping View
    52
  - Fuel Injector Inspection
    53
  - Piping Inspection
    53
  - Fuel Injector Cleaning
    54
  - Fuel Injector Assembly
    55
  - Fuel Injector Test/Adjustment
    55
  - Fuel Injector Spray Pattern
    56
  - Fuel Injection Pump Removal and Installation
    57
  - Fuel Feed Pump and Timer Assembly View
    60
  - Fuel Injection Pump Assembly View
    61
  - Removing Delivery Valve
    66
  - Feed Pump
    67
  - Removing Plunger Barrel
    67
  - Timer Assembly
    68
  - Injection Pump Inspection
    69
  - Checking Plunger and Barrel Movement
    70
  - Delivery Valve View
    70
  - Checking Plunger and Barrel for Damage
    71
  - Camshaft Check
    72
  - Lower Spring Seat
    72
  - Camshaft Bearings
    73
  - Feed Pump Check
    73
  - Tuner Assembly
    74
  - Injection Pump
    76
  - Checking Sleeve Pinion Movement
    77
  - Inserting Plunger
    77
  - Fuel Pump Testing
    80
- Fuel Pump Test Specifications
  82
  - Feed Pump Test
    85
  - Priming Pump Test
    86
- Capacity Test
  87
  - Air Tightness Test
    88
  - Feed Pump Pressure Test
    88
  - Injection Pump Installation
    89
  - Removal of Mechanical Governor
    90
  - Bleeding and Priming Fuel System
    91
  - Fuel Injection Pump Timing
    91
  - Cartridge Replacement
    95
  - Oil Filter
    95
  - Oil Pressure Relief Valve Removal and Installation
    96
  - Oil Piping Removal and Installation
    97
  - Oil Pan Removal and Installation
    99
  - Oil Pump Removal and Installation
    101
  - Oil Pressure Test
    102
- Oil Pressure Test Setup
  104
- Intake and Exhaust Manifolds
  109
  - Glow Plugs Removal and Installation
    111
  - Starter Assembly Removal and Installation
    111
- Glow Plugs Assembly
  112
- Starter Assembly
  114
- Testing Starter
  114
- Starter Solenoid Test Circuit
  115
  - Test Armature for Grounds
    115
  - Test Armature for Open Circuits
    115
  - Testing Starter Components
    115
  - Test Field Coil
    116
  - Alternator Removal
    119
  - Battery Charging Alternator Test
    119
  - Alternator Disassembly
    120
  - Alternator Inspection/Testing
    121
  - Alternator Assembly View
    122
  - Alternator Assembly Assembly
    123
  - Alternator Assembly Installation
    124
  - Engine Block Maintenance
    125
  - Front Gear Cover Removal and Installation
    125
  - Front Gear Cover Screw Lightening Sequence
    127
- 3-26. Rocker Cover and Arms
  128
  - Rocker Cover and Arms Removal and Installation
    128
  - Rocker Covet and Arms View
    129
- Rocker Arm Retaining Plate Bolt Loosening Sequence
  130
- Rocker Arm Shaft Runout
  130
- Rocker Arm Shaft Outside Diameter
  131
- Rocker Arm Oil Ports, Location of
  132
- Rocker Arm Correction
  133
- Rocker Arm Retaining Plate Bolt Tightening Sequence
  134
- Valve Clearance Adjustment Sequence
  135
- Cylinder Head Assembly Removal
  136
- Cylinder Head Assembly
  137
- Cylinder Head Assembly Disassembly
  138
- Cylinder Head Bolt Loosening Sequence
  138
- Hot Plug Removal
  139
- Cylinder Head Inspection
  140
- Cylinder Head Height (Reference)
  141
- Hot Plug Depression
  142
- Valve Stem and Guide Clearance
  143
- Valve Stem Outside Diameter
  143
- Checking Valve Thickness
  144
- Valve Depression
  144
- Checking Valve Contact Width
  145
- Valve Spring Free Height
  146
- Valve Spring Tension
  146
- Push Rod Curvature
  147
- Valve Seat Correction
  148
- Valve Seat Insert Installation
  149
- Cylinder Head Installation
  151
- Cylinder Head Bolt Tightening Sequence
  152
  - Compression Check
    153
  - Pistons, Connecting Rods and Crankshaft Removal
    153
- Pistons, Connecting Rods, and Crankshaft
  155
- Crankshaft Bearing Cap Bolt Loosening Sequence
  156
- Crankshaft End Play
  156
  - Piston and Connecting Rod Check
    157
  - Piston Ring and Groove Clearance
    158
- Measuring Piston Ring Gap
  159
- Connecting Rod Side Face Clearance
  160
- Crankshaft and Bearings
  160
- Basic Dimension Measurements
  161
- Check Crankshaft Run-Out
  161
- Bearing Spread Measurement
  162
- Crankshaft Run-Out
  162
- Crankshaft Journal and Crankpin Diameter
  163
- Connecting Rod Bearing Inside Diameter
  164
- Crankshaft Journal and Bearing Clearance
  164
  - Check Crankpin and Bearing Clearance
    166
  - Crankshaft Assembly
    167
  - Crankshaft Installation
    169
  - Crankshaft Bearing Location
    170
  - Crankshaft Bearing Cap Bolts Tightening Sequence
    171
- Crankshaft Rear Oil Seal and Spacer
  172
- Piston Ring Gap Setting
  173
- Crankcase Fastener Tightening Sequence
  176
- Measuring Timing Gear Backlash
  177
  - Camshaft and Idler Gear Assemblies View
    178
  - Disassembly of Camshaft
    179
- Thrust Plate Removal
  179
- Idler Gear and Shaft Inspection
  180
- Cam Height
  181
- Camshaft Journal Diameter
  181
- Check Camshaft Run-Out
  181
- Camshaft Runout
  182
  - Assembly of Camshaft
    183
  - Camshaft Installation
    183
  - Flywheel and Housing Removal
    184
- Flywheel and Housing
  185
- Flywheel and Housing Inspection/Repair
  186
- Flywheel Bolt Loosening Sequence
  186
- Flywheel and Housing Installation
  187
- Flywheel Housing Installation Sequence
  187
- Cylinder Block Assembly Disassembly
  188
- Flywheel Bolt Tightening Sequence
  188
- Cylinder Block Height Measurement
  192
- Cylinder Block Upper Face Warpage Measurement
  192
  - Measure Cylinder Liner Bore
    192
  - Check Cylinder Liner Projection
    193
  - Select Piston Grade
    193
- Cylinder Liner Bore Measurement
  194
  - Measure New Cylinder Liner Bore
    194
  - Cylinder Block Assembly Assembly
    195
- Cylinder Liner Installation
  196
- Pressing Cylinder Liner
  197
- P R E S S I N G C y L I N D E R L I N E R
  199
- Front Gear Cover
  206
- PCV Assembly
  206
- Crankcase
  207
- Tool and Test Equipment Requirements
  208
- Remarks for Diesel Engine
  209
- Expendable/Durable Supplies and Materials List
  211
- Fuel Injection Pump Tappet Holder View
  213
- Maintenance Procedure and Authorized Level of Maintenance
  215
- Index
  217
- The Metric System and Equivalents
  233
- Approximate Conversion Factors
  233

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