Table Of Content

WORKSHOP MANUAL TBR SERIES ENGINE (cid:215) 4JA1-NA 4JA1-L MODELS SECTION 6 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 - 0A 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. Applicable Model : TBR54 This manual is applicable to 2000 year model and later vehicles. THIS MANUAL INCLUDES FOLLOWING SECTIONS SECTION CONTENTS 6 Troubleshooting 6A Engine Mechanical 6B Engine Cooling 6C Fuel System 6D Engine Electrical 6F Exhaust System TROUBLESHOOTING 6-1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS PAGE Hard Starting....................................................................................................................... 6- 3 Starter Inoperative......................................................................................................... 6- 3 Starter Motor Operates But Engine Does Not Turn Over ........................................... 6- 4 Engine Turns Over But Does Not Start........................................................................ 6- 5 Unstable Idling.................................................................................................................... 6- 8 Insufficient Power............................................................................................................... 6-11 Excessive Fuel Consumption............................................................................................ 6-15 Excessive Oil Consumption............................................................................................... 6-17 Overheating......................................................................................................................... 6-18 White Exhaust Smoke........................................................................................................ 6-20 Dark Exhaust Smoke.......................................................................................................... 6-21 Oil Pressure Does Not Rise............................................................................................... 6-22 Abnormal Engine Noise..................................................................................................... 6-24 Turbocharger...................................................................................................................... 6-27 6-2 TROUBLESHOOTING Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems. 1.This Section is divided into ten Sub-Sections. Refer to the Table of Contents. 2.Each troubleshooting chart has three headings arranged from left to right: Example: 3.Easily checked areas are presented at the beginning of the troubleshooting chart. Procedures become more complex as the chart progresses. 4.It is suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle. 5.It is possible that a seemingly apparent engine problem is not related to the engine. For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a slipping clutch instead of an engine malfunction. Refer to the other troubleshooting charts if required. 6.Optional equipment and variations are included in the troubleshooting charts. If the vehicle you are servicing is not equipped with a particular option or variation noted in the "Checkpoint" frame, disregard the frame and move on to the next one. TROUBLESHOOTING 6-3 1. HARD STARTING 1. STARTER INOPERATIVE Checkpoint Trouble Cause Countermeasure Loose battery cable terminals NG Clean and/or retighten the Battery Poor connections due to battery cable terminals rusting NG Battery discharged or weak Recharge or replace the battery NG Fan belt loose or broken Adjust or replace the fan belt OK NG Main fuse Main fuse shorted Replace the main fuse OK NG Defective starter switch or Replace the starter switch or Starter switch starter relay the starter relay OK NG Defective magnetic switch or Repair or replace the magnetic Starter motor starter relay switch NG Repair or replace the starter Defective starter motor motor 6-4 TROUBLESHOOTING 2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure Loose battery cable terminals NG Clean and/or retighten the Battery Poor connections due to battery cable terminals rusting NG Battery discharged or weak Recharge or replace the battery NG Fan belt loose or broken Adjust or replace the fan belt OK NG Starter motor Defective pinion gear Replace the pinion gear NG Repair or replace the magnetic Defective magnetic switch switch NG Brush wear Replace the brush and/or the Weak brush spring brush spring OK NG Piston, crank bearing seizure, Repair or replace the related Engine or other damage parts TROUBLESHOOTING 6-5 3. ENGINE TURNS OVER BUT DOES NOT START Checkpoint Trouble Cause Countermeasure NG Defective fuel cut solenoid Replace the fuel cut solenoid Engine stop mechanism valve valve FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP NG Fuel Fuel tank is empty Fill the fuel tank OK Repair or replace the fuel lines NG Clogged or damaged fuel lines Fuel piping Retighten the fuel line Loose fuel line connections connections OK NG Fuel filter overflow valve does Repair or replace the fuel filter Fuel filter not close overflow valve NG Replace the fuel filter element Clogged fuel filter element or the fuel filter cartridge OK NG Bleed the air from the fuel Fuel system Air in the fuel system system OK NG Repair or replace the feed Fuel feed pump Defective feed pump pump 6-6 TROUBLESHOOTING FUEL IS BEING DELIVERED TO THE INJECTION PUMP Checkpoint Trouble Cause Countermeasure NG Fuel Use the wrong fuel Use the correct fuel NG Water particles in the fuel Change the fuel OK NG Bleed the air from the fuel Fuel system Air in the injection pump system OK NG Injection nozzle Injection nozzle sticking Replace the injection nozzle NG Injection nozzle injection Adjust or replace the injection starting pressure too low nozzle Improper spray condition OK NG Defective fuel injection nozzle Injection pump resulting in fuel drippage after Replace the delivery valve fuel injection NG Injection pump plunger worn or Replace the injection pump stuck plunger assembly Continued on the next page TROUBLESHOOTING 6-7 Checkpoint Trouble Cause Countermeasure Continued from the previous page NG Injection pump drive shaft Replace the injection pump Injection pump seizure or other damage drive shaft NG Injection pump governor spring Replace the injection pump seizure governor spring

Description:
operation. Adjust or replace the control lever. NG. Defective injection timing. Adjust the injection timing. Repair or replace the injection pump timer. NG.
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Isuzu Diesel Engine 4JA1 Workshop Manual Section 6 PDF

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Preview Isuzu Diesel Engine 4JA1 Workshop Manual Section 6

WORKSHOP MANUAL TBR SERIES ENGINE (cid:215) 4JA1-NA 4JA1-L MODELS SECTION 6 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 - 0A 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. Applicable Model : TBR54 This manual is applicable to 2000 year model and later vehicles. THIS MANUAL INCLUDES FOLLOWING SECTIONS SECTION CONTENTS 6 Troubleshooting 6A Engine Mechanical 6B Engine Cooling 6C Fuel System 6D Engine Electrical 6F Exhaust System TROUBLESHOOTING 6-1 SECTION 6 TROUBLESHOOTING TABLE OF CONTENTS PAGE Hard Starting....................................................................................................................... 6- 3 Starter Inoperative......................................................................................................... 6- 3 Starter Motor Operates But Engine Does Not Turn Over ........................................... 6- 4 Engine Turns Over But Does Not Start........................................................................ 6- 5 Unstable Idling.................................................................................................................... 6- 8 Insufficient Power............................................................................................................... 6-11 Excessive Fuel Consumption............................................................................................ 6-15 Excessive Oil Consumption............................................................................................... 6-17 Overheating......................................................................................................................... 6-18 White Exhaust Smoke........................................................................................................ 6-20 Dark Exhaust Smoke.......................................................................................................... 6-21 Oil Pressure Does Not Rise............................................................................................... 6-22 Abnormal Engine Noise..................................................................................................... 6-24 Turbocharger...................................................................................................................... 6-27 6-2 TROUBLESHOOTING Refer to the following troubleshooting charts to quickly pinpoint and repair engine problems. 1.This Section is divided into ten Sub-Sections. Refer to the Table of Contents. 2.Each troubleshooting chart has three headings arranged from left to right: Example: 3.Easily checked areas are presented at the beginning of the troubleshooting chart. Procedures become more complex as the chart progresses. 4.It is suggested that you work from the beginning of the troubleshooting chart. Do not start from the middle. 5.It is possible that a seemingly apparent engine problem is not related to the engine. For example, the engine may appear to have insufficient power. This could be caused by dragging brakes or a slipping clutch instead of an engine malfunction. Refer to the other troubleshooting charts if required. 6.Optional equipment and variations are included in the troubleshooting charts. If the vehicle you are servicing is not equipped with a particular option or variation noted in the "Checkpoint" frame, disregard the frame and move on to the next one. TROUBLESHOOTING 6-3 1. HARD STARTING 1. STARTER INOPERATIVE Checkpoint Trouble Cause Countermeasure Loose battery cable terminals NG Clean and/or retighten the Battery Poor connections due to battery cable terminals rusting NG Battery discharged or weak Recharge or replace the battery NG Fan belt loose or broken Adjust or replace the fan belt OK NG Main fuse Main fuse shorted Replace the main fuse OK NG Defective starter switch or Replace the starter switch or Starter switch starter relay the starter relay OK NG Defective magnetic switch or Repair or replace the magnetic Starter motor starter relay switch NG Repair or replace the starter Defective starter motor motor 6-4 TROUBLESHOOTING 2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER Checkpoint Trouble Cause Countermeasure Loose battery cable terminals NG Clean and/or retighten the Battery Poor connections due to battery cable terminals rusting NG Battery discharged or weak Recharge or replace the battery NG Fan belt loose or broken Adjust or replace the fan belt OK NG Starter motor Defective pinion gear Replace the pinion gear NG Repair or replace the magnetic Defective magnetic switch switch NG Brush wear Replace the brush and/or the Weak brush spring brush spring OK NG Piston, crank bearing seizure, Repair or replace the related Engine or other damage parts TROUBLESHOOTING 6-5 3. ENGINE TURNS OVER BUT DOES NOT START Checkpoint Trouble Cause Countermeasure NG Defective fuel cut solenoid Replace the fuel cut solenoid Engine stop mechanism valve valve FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP NG Fuel Fuel tank is empty Fill the fuel tank OK Repair or replace the fuel lines NG Clogged or damaged fuel lines Fuel piping Retighten the fuel line Loose fuel line connections connections OK NG Fuel filter overflow valve does Repair or replace the fuel filter Fuel filter not close overflow valve NG Replace the fuel filter element Clogged fuel filter element or the fuel filter cartridge OK NG Bleed the air from the fuel Fuel system Air in the fuel system system OK NG Repair or replace the feed Fuel feed pump Defective feed pump pump 6-6 TROUBLESHOOTING FUEL IS BEING DELIVERED TO THE INJECTION PUMP Checkpoint Trouble Cause Countermeasure NG Fuel Use the wrong fuel Use the correct fuel NG Water particles in the fuel Change the fuel OK NG Bleed the air from the fuel Fuel system Air in the injection pump system OK NG Injection nozzle Injection nozzle sticking Replace the injection nozzle NG Injection nozzle injection Adjust or replace the injection starting pressure too low nozzle Improper spray condition OK NG Defective fuel injection nozzle Injection pump resulting in fuel drippage after Replace the delivery valve fuel injection NG Injection pump plunger worn or Replace the injection pump stuck plunger assembly Continued on the next page TROUBLESHOOTING 6-7 Checkpoint Trouble Cause Countermeasure Continued from the previous page NG Injection pump drive shaft Replace the injection pump Injection pump seizure or other damage drive shaft NG Injection pump governor spring Replace the injection pump seizure governor spring

Description:
operation. Adjust or replace the control lever. NG. Defective injection timing. Adjust the injection timing. Repair or replace the injection pump timer. NG.
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