Isuzu C22NE Manuals

Manuals and User Guides for Isuzu C22NE. We have 1 Isuzu C22NE manual available for free PDF download: Workshop Manual

Isuzu C22NE Workshop Manual (510 pages)

Isuzu GASOLINE ENGINE C22NE, 22LE, 20LE

Brand: Isuzu | Category: Engine | Size: 6 MB

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
- Operations on Installed Engine
  
  45
- 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
- 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
- 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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Isuzu C22NE Manuals

Isuzu C22NE Workshop Manual (510 pages)

Table of Contents

Section 6 Engine Diagnosis

Section 6A Engine Mechanical

General Description

Main Data and Specification

Operations on Engine Aggregates

Operations on Installed Engine

Component Parts

Operations on Cylinder Head and Camshaft Housing

Operations on Crank Drive

Operations on Removed Engine

Operations on Oil Circulation

Operations on Cooling Sysytem

Engine External Parts

Fuel Injection System

Fuel Injector

Technical Data

Section 6B Engine Cooling

Section 6C Engine Fuel

Section 6D1 Engine Electrical

Section 6D2 Ignition System

Section 6D3 Starting and Charging System

Section 6E Driveability and Emissions

Hesitation, Sag, Stumble Symptom (Cont'D)

Step Action Value(S)

Yes no

Section 6F Engine Exhaust

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