1988-2002 Isuzu KB Service & Repair Manual

WORKSHOP MANUAL TF SERIES ENGINE 4JA1/4JH1-TC SECTION 6

TROUBLESHOOTING 6 – 1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS PAGE PAGE BASIC INSPECTION PROCEDURE ... 6– 2 1. HARD STARTING ........................... 6– 3 1-1.Starter Motor Inoperative ......... 6– 3 1-2. Starter Motor Operates But Engine Does Not Turn Over .......... 6– 3 1-3. Engine Turns Over But Does Not Start Engine ............................. 6– 4 2. UNSTABLE IDLING ........................ 6– 5 3. INSUFFICIENT POWER ................. 6– 6 4. EXCESSIVE FUEL CONSUMPTION ................................. 6– 7 5. EXCESSIVE OIL CONSUMPTION.. 6– 8 6. OVERHEATING............................... 6– 9 7. WHITE EXHAUST SMOKE ............. 6– 9 8. DARK EXHAUST SMOKE .............. 6– 10 9. OIL PRESSURE DOES NOT RISE . 6– 11 10. ABNORMAL ENGINE NOISE ....... 6– 12 10-1. Engine Knocking.................... 6– 12 10-2. Gas Leakage Noise ................ 6– 12 10-3. Continuous Noise .................. 6– 13 10-4. Slapping Noise ....................... 6– 13 10-5. Excessive Turbocharger Noise ............................................... 6– 14 11. ROTATING PART WEAR OF TURBOCHARGER ............................. 6– 14 12. OIL LEAKAGE FROM TURBOCHRGER ............................... 6– 15 13. INSUFFICIENT ACCELERATION AND/OR LACK OF POWER DUE TO TURBOCHARGER ....................... 6– 15 14. BATTERY CHARGING AND NOISE PROBLEM.............................. 6– 16 14-1. Battery No Charging .............. 6– 16 14-2. Battery Overcharging ............ 6– 16 14-3. Battery Under Charging......... 6– 17 14-4. Battery Unstable Charging Current ............................................ 6– 17 14-5. Charging System Noise ......... 6– 18 15. STARTER MOTOR PROBLEM..... 6– 19 15-1. Starter Motor Pinion Engages to Ring Gear But Engine Does Not Turn Over ................................. 6– 19 15-2. Incorrect Pinion And Ring Gear Engagement .......................... 6– 19 15-3. Starter Motor Continues To Run After The Starter Switch Is Turned Off ....................................... 6– 20 15-4. Excessive Commutator Sparking .......................................... 6– 20

6 – 2 TROUBLESHOOTING Basic Inspection Procedure Follow the under inspection procedure, when the problem vehicle comes workshop. Step Inspection point Inspection result YES NO 1 Check the check engine lamp Is the check engine lamp turn ON ? Go to section 6E “On Board Diagnostic (OBD) System Check" Go to Step 2 2 The battery fluid level and the gravity Was the problem found? Re-charge the battery or replace the battery Go to Step 3 3 The engine coolant capacity Was the problem found? Replenish the engine coolant Go to Step 4 4 The engine oil level Was the problem found? Replenish the engine oil Go to Step 5 5 The air cleaner element Was the problem found? Clean or replace Go to Step 6 6 The piping fixing condition (oil, vacuum and fuel piping) Was the problem found? Return normal condition Go to Step 7 7 The drive belt tension and break Was the problem found? Re-adjust the tension or replace Go to Step 8 8 Go to section 6E “On Board Diagnostic (OBD) System Check” Was the problem found? Verify repair Go to Step 9 9 Go to mechanical troubleshooting chart Was the problem found? Verify repair —

TROUBLESHOOTING 6 – 3 1. Hard Starting Inspect the following items before diagnosis. 1. The battery conditions. The terminal connection condition. The battery charge condition or battery power weakness. 2. The fan belt loosen or broken. 3. The main fuse condition (open or not). 4. Fuel quantity level. 1–1 Starter motor inoperative Step Action Value(s) Yes No 1 Check the starter switch. Does the starter switch work? — Go to Step 2 Repair or replace the starter switch 2 Check the starter relay. Does the starter relay work? — Go to Step 3 Repair or replace the starter relay 3 Check the magnetic switch. Does the magnetic switch work? — Go to Step 4 Repair or replace the magnetic switch 4 Check the pinion gear condition on the starter motor. Was the condition normal? — Go to Step 5 Replace the pinion gear 5 Check the brush wear or brush spring weakness. Was the condition normal? — Replace the starter motor assembly Repair or replace the brush or brush spring 1-2 Starter motor operates but engine does not turn over Step Action Value(s) Yes No 1 Check the engine internal seizure. Was the engine seized? — Repair or replace seized parts Check other DTC by Tech 2 and go to indicated DTC

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1988-2002 Isuzu KB Service & Repair Manual

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1988-2002 Isuzu KB Service & Repair Manual

Engines covered:

What’s Inside the 1988-2002 Isuzu KB Service & Repair Manual

General Information & Service Fundamentals

Scheduled Maintenance & Lubrication Charts

Heating, Ventilation & Air-Conditioning (HVAC)

Body, Frame & Exterior Systems

Steering & Suspension

Axles, Driveline & Transmission

Brake System

Engine Repair – Diesel & Petrol

Ignition, Charging & Starting Systems

Body Electrical Systems

Interior, Seating & Trim

Security & Restraint Systems

Cruise Control & Accessory Systems

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