ISUZU TF Series C22NE 22LE 20LE Engine Workshop Manual

WORKSHOP MANUAL TF SERIES GASOLINE ENGINE (C22NE, 22LE, 20LE) SECTION 6, 6A, 6B, 6C, 6D, 6E, 6F, 6G, 6H & 6J

THIS MANUAL INCLUDES FOLLOWING SECTIONS SECTION CONTENTS 6 Engine Diagnosis 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System 6E Driveability and Emissions 6F Engine Exhaust 6G Engine Lubrication 6H Engine Speed Control System 6J Induction

NOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section - OA under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”. All material contained in this Manual is based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-1 SECTION 6 ENGINE DIAGNOSIS CONTENTS PAGE Engine Diagnosis............................................................................................................... 6- 2 Hard Starting ................................................................................................................. 6- 2 Engine Compression Test Procedure ......................................................................... 6- 3 Rough Engine Idling or Engine Stalling ...................................................................... 6- 4 Rough Engine Running ................................................................................................ 6- 5 Hesitation....................................................................................................................... 6- 6 Engine Lacks Power ..................................................................................................... 6- 7 Engine Noisy ................................................................................................................. 6- 8 Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9 Troubleshooting Procedure ......................................................................................... 6- 9 Abnormal Combustion.................................................................................................. 6-11 Engine Oil Consumption Excessive ............................................................................ 6-12 Fuel Consumption Excessive ...................................................................................... 6-13 Oil Problems .................................................................................................................. 6-13 Engine Oil Pressure Check .......................................................................................... 6-13 Malfunction Indicator Lamp ......................................................................................... 6-14

6-2 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Engine Diagnosis Hard Starting 1.Starting Motor Does Not Turn Over Trouble Shooting Procedure Turn on headlights and starter switch. Condition Possible cause Correction Headlights go out or dim considerably Battery run down or under charged Recharge or replace battery Terminals poorly connected Clean battery posts and terminals and connect properly Starting motor coil circuit shorted Overhaul or replace Starting motor defective Overhaul or replace 2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start Spark Test Disconnect a high tension cable from any spark plug. Connect the spark plug tester (use commercially available tool), crank the engine, and check if a spark is generated in the spark plug tester. Before cranking the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the high tension cable while the engine is running. Condition Possible cause Correction Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace Ignition timing incorrect Refer to Ignition System Fuel not reaching fuel injector(s) or engine Refer to item 3 (Trouble in fuel system) Valve timing incorrect Adjust Engine lacks compression Refer to item 4 (Engine lacks compression) No sparking takes place Ignition coil disconnected or broken Connect properly or replace Electronic Ignition System with module Replace Poor connections in engine harness Correct Engine Control Module cable disconnected or defective Correct or replace

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-3 3.Trouble in Fuel System Condition Possible cause Correction Starting motor turns over and spark occurs but engine does not start. Fuel tank empty Fill Water in fuel system Clean Fuel filter clogged Replace filter Fuel pipe clogged Clean or replace Fuel pump defective Replace Fuel pump circuit open Correct or replace Evaporative Emission Control system circuit clogged Correct or replace Multiport Fuel Injection System faulty Refer to "Electronic Fuel Injection" section 4.Engine Lacks Compression Condition Possible cause Correction Engine lacks compression Spark plug loosely fitted or spark plug gasket defective Tighten to specified torque or replace gasket Valve timing incorrect Adjust Cylinder head gasket defective Replace gasket Valve incorrectly seated Lap valve Valve stem seized Replace valve and valve guide Valve spring weakened Replace Cylinder or piston rings worn Overhaul engine Piston ring seized Overhaul engine. Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gauge needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. The pressure difference between the individual cylinders should not exceed 100kPa (14.5 psi).

6-4 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Rough Engine Idling or Engine Stalling Condition Possible cause Correction Trouble in fuel injection system Idle air control valve defective Replace Throttle shutting off incomplete Correct or replace Throttle position sensor circuit open or shorted Correct or replace Fuel injector circuits open or shorted Correct or replace Fuel injectors damaged Replace Fuel pump relay defective Replace Manifold Absolute Pressure Sensor cable disconnected or broken Correct or replace Manifold Absolute Pressure Sensor defective Replace Engine Coolant Temperature Sensor cable disconnected or broken Correct or replace Engine Coolant Temperature Sensor defective Replace Intake Air Temperature sensor cable disconnected or broken Correct or replace Intake Air Temperature sensor defective Replace Knock Sensor (KS) circuits open or shorted Correct or replace KS defective Replace KS Module circuits open or ground Correct or replace KS Module defective Replace Vehicle Speed Sensor circuit open or shorted Correct or replace Vehicle Speed Sensor defective Replace Trouble in emission control system Engine Control Module defective Replace Canister purge solenoid circuit open Correct Canister purge solenoid defective Replace Evaporative Emission Canister Purge control valve defective Replace Trouble in ignition system Refer to Hard Start Troubleshooting Guide Others Engine lacks compression Refer to Hard Start Troubleshooting Guide Valve incorrectly seated Lap valve Air Cleaner Filter clogged Replace filter element Valve timing incorrect Readjust Idle air control valve broken Replace

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-5 Rough Engine Running Condition Possible cause Correction Engine misfires regularly Ignition coil layer shorted Replace Spark plugs fouling Clean or install hotter type plug Spark plug(s) insulator nose leaking Replace Fuel injector(s) defective Replace Engine control module faulty Replace Engine knocks regularly Spark plugs running too hot Install colder type spark plugs Powertrain control module faulty Replace Engine lacks power Spark plugs fouled Clean Fuel injectors defective Replace Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective Correct or replace Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective Correct or replace Engine Control Module faulty Replace Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective Correct or replace Throttle Position Sensor or Throttle Position Sensor circuit defective Correct or replace Knock Sensor or Knock Sensor circuits defective Correct or replace Knock Sensor Module or Knock Sensor Module circuits defective Correct or replace

6-6 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Hesitation Condition Possible cause Correction Hesitation on acceleration Throttle Position Sensor adjustment incorrect Replace throttle valve assembly Throttle Position Sensor circuit open or shorted Correct or replace Excessive play in accelerator linkage Adjust or replace Manifold Absolute Pressure (MAP) Sensor circuit open or shorted Correct or replace MAP Sensor defective Replace Intake Air Temperature (IAT) Sensor circuit open or shorted Correct or replace Knock Sensor (KS) Circuit open or shorted Correct or replace KS defective Replace KS Module circuits open or shorted Correct or replace KS Module defective Replace IAT Sensor defective Replace Hesitation at high speeds (Fuel pressure too low) Fuel tank strainer clogged Clean or replace Fuel pipe clogged Clean or replace Fuel filter clogged Replace Defective fuel pump system Check and replace Fuel Pressure Control Valve leaking Replace Hesitation at high speeds (Fuel injector not working normally) Power supply or ground circuit for Multiport Fuel Injection System shorted or open Check and correct or replace Cable of Multiport Fuel Injection System disconnected or defective Correct or replace Hesitation at high speeds Engine Control Module defective Replace Throttle Position Sensor circuit open or shorted Correct or replace Throttle Position Sensor defective Replace Engine Coolant Temperature Sensor circuit open or shorted Correct or replace Engine Coolant Temperature Sensor defective Replace MAP Sensor cable open or shorted Correct or replace MAP Sensor defective Replace IAT Sensor circuit open or shorted Correct or replace IAT Sensor defective Replace KS Circuit open or shorted Correct or replace KS defective Replace KS Module circuit open or shorted Correct or replace KS Module defective Replace Throttle valve not wide opened Check and correct or replace Air Cleaner Filter clogged Replace filter element Power supply voltage too low Check and correct or replace

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-7 Engine Lacks Power Condition Possible cause Correction Trouble in fuel system Fuel Pressure Control Valve not working normally Replace Fuel injector clogged Clean or replace Fuel pipe clogged Clean Fuel filter clogged or fouled Replace Fuel pump drive circuit not working normally Correct or replace Fuel tank not sufficiently breathing due to clogged Evaporative Emission Control System circuit Clean or replace Water in fuel system Clean Inferior quality fuel in fuel system Use fuel of specified octane rating Engine Control Module supplied poor voltage Correct circuit Throttle Position Sensor cable disconnected or broken Correct or replace Throttle Position Sensor defective Replace Manifold Absolute Pressure Sensor not working normally Replace Intake Air Temperature sensor not working normally Replace Engine Coolant Temperature Sensor circuit open or shorted Correct or replace Engine Coolant Temperature Sensor defective Replace Engine Control Module defective Replace Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element Air duct kicked or flattened Correct or replace Ignition failure - Refer to Hard Start Troubleshooting Guide Heat range of spark plug inadequate Install spark plugs of adequate heat range Electronic Ignition System with module Replace

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ISUZU TF Series C22NE 22LE 20LE Engine Workshop Manual

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