Isuzu 4JB1 Instrucciones de funcionamiento e instalación

SERVICE INFORMATION 00 – 3

1.HARD STARTING

1. STARTER INOPERATIVE

Checkpoint Possible cause Correction

Loose battery cable terminal poor

connections due to rusting Clean and/or retighten the battery

cable terminal

Battery discharged or weak Recharge or replace the battery

Battery

Fan belt loose or broken Adjust or replace the fan belt

Fusible link Fusible link shorted Replace the fusible link

Starter switch Defective starter switch or starter relay Replace the starter switch or the

Starter relay

Defective magnetic switch or starter relay Repair or replace the magnetic switch

Starter motor

Defective starter motor Repair or replace the starter motor

2. STARTER MOTOR OPERATES BUT ENGINE DOES NOT TURN OVER

Loose battery cable terminal Clean and/or retighten the battery

cable terminal

Poor connections due to rusting Recharge or replace the battery

Battery discharged or weak Recharge or replace the battery

Battery

Fan belt loose or broken Adjust or replace the fan belt

Defective pinion gear Replace the pinion gear

Defective magnetic switch Repair or replace the magnetic switch

Starter

Brush wear, Weak brush spring Replace the brush and/or the brush

spring

Engine Piston, crank bearing seizure, or other

damage Repair or replace the related parts

00 – 4 SERVICE INFORMATION

3. ENGINE TURNS OVER BUT DOES NOT START

Checkpoint Possible cause Correction

Engine stop

mechanism Defective fuel cut solenoid valve Replace the fuel cut solenoid valve

FUEL IS NOT BEING DELIVERED TO THE INJECTION PUMP

Fuel Fuel tank is empty Fill the fuel tank

Fuel piping Clogged or damaged fuel lines. Loose fuel

line connection Repair or replace the fuel lines

Retighten the fuel line connection

Fuel filter overflow valve does not close Repair or replace the fuel filter

overflow valve

Fuel filter

Clogged fuel filter element Replace the fuel filter element or the

filter cartridge

Fuel system Air in the fuel system Bleed the air from the fuel system

Fuel feed pump Defective feed pump Repair or replace the feed pump

FUEL IS BEING DELIVERED TO THE INJECTION PUMP

Use of the wrong fuel Use the correct fuel

Water particles in the fuel Change the fuel

Fuel

Fuel system Air in the injection pump Bleed the air from the fuel system

Injection nozzle sticking

Injection nozzle

Injection nozzle injection starting pressure

too low

Improper spray condition

Adjust or replace the injection nozzle

Defective fuel injection nozzle resulting in the

fuel drippage after fuel injection Replace the delivery valve

Defective injection pump control rack

operation Repair or replace the injection pump

control rack

Injection pump plunger worn or stuck Replace the injection pump plunger

assembly

Injection pump drive shaft seizure or other

damage Replace the injection drive shaft

Injection pump

Injection pump governor spring seizure Replace the injection pump governor

spring

SERVICE INFORMATION 00 – 5

4. QUICK-ON START SYSTEM

PREPARATION

1 Disconnect the thermoswitch connector.

2. Determine whether or not the glow plugs are receiving power.

a) Make sure that the starter switch is “OFF”.

b) Connect a voltmeter between one of the glow plugs and the cylinder wall.

c) Move the starter switch to the “ON” position.

The voltmeter needle will show the souse voltage (12V) if the glow plugs are receiving power.

If the voltmeter needle does not move, the glow plugs are not receiving power.

3. Perform the troubleshooting procedure.

GLOW PLUGS ARE RECEIVING POWER

Checkpoint Possible cause Correction

Glow plug indicator

light does not turn on Defective indicator light bulb Replace the indicator light bulb

Quick-on start timer Defective quick-on start timer Replace the quick-on start timer

Glow plug indicator

light turns on the 0.3

seconds

Defective quick-on start timer Replace the quick-on start timer

Return the starter switch to the “ON” position

from the “START” position after the engine

starts if the glow plug relay remains on less

than 14 seconds, the quick-on start timer is

defective

Replace the quick-on start timer

Glow plug indicator

light turns on for 3.5

seconds

Move the starter switch from the “OFF”

position to the “ON” position if the glow plug

relay remains on less than 14 seconds, the

quick-on start timer is defective

Replace the quick-on start timer

Thermoswitch Defective thermoswitch Replace the thermoswitch

Glow plug continuity No glow plug continuity Replace the glow plugs

GLOW PLUGS ARE NOT RECEIVING POWER

Glow plug indicator

light does not turn on Broken indicator light fuse Replace the fuse

Quick-on start timer Defective quick-on start timer Replace the quick-on start timer

00 – 6 SERVICE INFORMATION

GLOW PLUGS ARE NOT RECEIVING POWER (Cont’d)

Checkpoint Possible cause Correction

Defective glow plug relay

The glow plug relay does not turn on after the

starter switch is moved from the “OFF”

position to the “ON” position

Replace the glow plug relay

Defective quick-on start timer Replace the quick-on start timer

Defective glow plug relay wiring harness Repair or replace the wiring harness

Glow plug indicator

light turns on for 3.5

seconds

Defective fusible link or wiring harness

The glow plug relay turns on when the starter

switch is moved from the “OFF” position to

the “ON” position

Replace the fusible link or the wiring

harness

2. UNSTABLE IDLING

Checkpoint Possible cause Correction

Idling system Idling improperly adjusted Adjust the idling

Fast idling speed Defective fast idling speed control device Repair or replace the fast idling speed

control device

Accelerator control

system Accelerator control system improperly

adjusted Adjust the accelerator control system

Fuel system leakage or blockage Repair or replace the fuel system

Air in the fuel system Bleed the air from the fuel system

Fuel system

Water particles in the fuel system Change the fuel

Fuel filter Clogged fuel filter element Replace the fuel filter element or the

fuel filter cartridge

Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump

Injection nozzle sticking Replace the injection nozzle

Injection nozzle

Injection nozzle injection starting pressure

too low

Improper spray condition

Adjust or replace the injection nozzle

Injection pump Defective delivery valve resulting in fuel

drippage after fuel injection Replace the delivery valve

SERVICE INFORMATION 00 – 7

Checkpoint Possible cause Correction

Injection timing improperly adjusted Adjust the injection timing

Insufficient injection volume Adjust the injection volume

Defective idle spring Replace the idle spring

Defective governor lever operation Repair or replace the governor lever

Regulator valve improperly adjustment Adjust or replace the regulator valve

Broken plunger spring Replace the plunger spring

Worn plunger Replace the plunger assembly

Injection pump

(Cont’d)

Worn cam disc Replace the cam disc

Valve clearance Valve clearance improperly adjusted Adjust the valve clearance

Compression pressure Blown out cylinder head gasket. Worn

cylinder liner.

Piston ring sticking

Replace the related parts

3. INSUFFICIENT POWER

Checkpoint Possible cause Correction

Air cleaner Clogged air cleaner element Clean or replace the air cleaner

element

Fuel Water particle in the fuel Replace fuel

Fuel filter Clogged fuel filter element Replace the fuel filter element or the

fuel filter cartridge

Fuel feed pump Defective fuel feed pump Repair or replace the fuel feed pump

Injection nozzle sticking Replace the injection nozzle

Injection nozzle

Injection nozzle injection starting pressure

too low

Improper spray condition

Adjust or replace the injection nozzle

Fuel injection pipes Fuel injection pipes damaged or obstructed Replace the fuel injection pipes

00 – 8 SERVICE INFORMATION

Checkpoint Possible cause Correction

Defective regulating valve Repair or replace the regulating valve

Defective delivery valve Replace the delivery valve

Defective timer Repair or replace the timer

Worn cam disc Replace the cam disc

Improper control lever operation Adjust or replace the control lever

Defective injection timing Adjust the injection timing

Repair or replace the injection pump

timer

Weak governor spring Replace the governor spring

Injection pump

Worn plunger Replace the plunger assembly

Compression pressure Blown out cylinder head gasket. Worn

cylinder liner.

Piston ring sticking

Replace the related parts

Valve clearance Valve clearance improperly adjusted Adjust the valve clearance

Valve spring Valve spring weak or broken Replace the valve spring

Exhaust system Exhaust pipe clogged Clean the exhaust pipe

Full load adjusting

screw seal Open and improperly set adjusting screw

seal Adjust and reseal the adjusting screw

SERVICE INFORMATION 00 – 9

4. EXCESSIVE FUEL CONSUMPTION

Checkpoint Possible cause Correction

Fuel system Fuel leakage Repair or replace the fuel system

related parts

Air cleaner Clogged air cleaner element Clean or replace the air cleaner

element

Idling speed Poorly adjusted idling speed Adjust the idling speed

Injection nozzle Injection nozzle injection starting pressure

too low

Improper spray condition

Adjust or replace the injection nozzle

Fuel injection timing Fuel injection timing improperly Adjust the fuel injection timing

Injection pump Defective Delivery valve resulting is fuel

drippage after fuel injection Replace the delivery valve

Valve clearance Valve clearance improperly adjusted Adjust the valve clearance

Compression pressure Blown out cylinder head gasket. Worn

cylinder liner.

Piston ring sticking

Replace the related parts

Valve spring Valve spring weak or broken Replace the valve spring

5. EXCESSIVE OIL CONSUMPTION

Checkpoint Possible cause Correction

Engine oil Engine oil unsuitable

Too much engine oil Replace the engine oil

Correct the engine oil level

Oil seal and gasket Oil leakage from the oil seal and/or the

gasket Replace the oil seal and/or the gasket

Air breather Clogged air breather Clean the air breather

Intake and exhaust

valve Worn valve stems and valve guides Replace the intake and exhaust

valves and the valve guides

00 – 10 SERVICE INFORMATION

6. OVERHEATING

Checkpoint Possible cause Correction

Cooling water Insufficient cooling water Replenish the cooling water

Fan clutch Oil leakage from the fan clutch Replace the fan clutch

Fan belt Fan belt loose or cracked causing slippage Replace the fan belt

Radiator Defective radiator cap or clogged radiator

core Replace the radiator cap or clean the

radiator core

Water pump Defective water pump Repair or replace the water pump

Cylinder head and

cylinder body sealing

cap

Defective sealing cap resulting in water

leakage Replace the sealing cap

Thermostat Defective thermostat Replace the thermostat

Cooling system Cooling system clogged by foreign material Clean the foreign material from the

cooling system

Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing

7. WHITE EXHAUST SMOKE

Checkpoint Possible cause Correction

Cooling water Insufficient cooling water Replace the cooling water

Fuel Water particles in the fuel Replace the fuel

Fuel injection timing Delayed fuel injection timing Adjust the fuel injection timing

Compression pressure Blown out cylinder head gasket. Worn

cylinder liner.

Piston ring sticking

Replace the related parts

Inlet and exhaust valve

Valves seals Defective valve seals.

Worn valves stems and valve guides Replace the valve seals, the valves,

and the valve guides

SERVICE INFORMATION 00 – 11

8. DARK EXHAUST SMOKE

Checkpoint Possible cause Correction

Air cleaner Clogged air cleaner element Clean or replace the air cleaner

element

Injection nozzle Injection nozzle injection starting pressure

too low

Improper spray condition

Adjust or replace the injection nozzle

Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing

Defective delivery valve resulting in fuel

drippage after fuel injection Replace the delivery valve

Injection pump

Excessive injection volume Adjust the injection volume

9. OIL PRESSURE DOES NOT RISE

Checkpoint Possible cause Correction

Engine oil Improper viscosity engine oil.

Insufficient engine oil Replace the engine oil

Correct the engine oil volume

Oil pressure gauge or

unit

Oil pressure indicator

light

Defective oil pressure gauge or unit

Defective indicator light

Repair or replace the oil pressure

gauge or unit

Replace the indicator light

Oil filter Clogged oil filter element Replace the oil filter element or the oil

filter cartridge

Relief valve and by-

pass valve Relief valve sticking and/or weak by-pass

valve spring Replace the relief valve and/or the by-

pass valve spring

Clogged oil pump strainer Clean the oil pump strainer

Oil pump

Worn oil pump related parts Replace the oil pump related parts

Rocker arm shaft Worn rocker arm bushing Replace the rocker arm bushing

Camshaft Worn camshaft and camshaft bearing Replace the camshaft and the

camshaft bearing

Crankshaft and

bearings Worn crankshaft and bearings Replace the crankshaft and/or the

bearings

00 – 12 SERVICE INFORMATION

10. ABNORMAL ENGINE NOISE

1. ENGINE KNOCKING

Check to see that the engine has been thoroughly warmed up before beginning the troubleshooting procedure.

Checkpoint Possible cause Correction

Fuel Fuel unsuitable Replace the fuel

Fuel injection timing Fuel injection timing improperly adjusted Adjust the fuel injection timing

Injection nozzle Improper injection nozzle starting pressure

and spray condition Adjust or replace the injection nozzle

Compression pressure Blown out head gasket

Broken piston ring

Replace the head gasket or the piston

ring

2. GAS LEAKAGE NOISE

Exhaust pipes Loosely connected exhaust pipes. Broken

exhaust pipes Tighten the exhaust pipe connections

Replace the exhaust pipes

Injection nozzles

and/or glow plugs Loose injection nozzles and/or glow plugs Replace the washers

Tighten the injection nozzles and/or

the glow plugs

Exhaust manifold Loosely connected exhaust manifold and/or

glow plugs Tighten the exhaust manifold

connections

Cylinder head gasket Damaged cylinder head gasket Replace the cylinder head gasket

3. CONTINUOUS NOISE

Fan belt Loose fan belt Readjust the fan belt tension

Cooling fan Loose cooling fan Retighten the cooling fan

Water pump bearing Worn or damaged water pump bearing Replace the water pump bearing

Generator or vacuum

pump Defective generator or vacuum pump Repair or replace the generator or the

vacuum pump

Valve clearance Clearance improperly adjust Adjust the valve clearances

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