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Isuzu c240 manual download. TCM Parts Manual Engine Isuzu C 240 PKJ PE C 240 PJK 1 B 108 Pages

Isuzu c c engine repair manual by mor - Issuu.ISUZU CPW TECHNICAL MANUAL Pdf Download | ManualsLib

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This section provides information and guidance for inspecting, servicing, and installing the engine. For additional information, also refer to end item maintenance manual. The cooling system consists of a radiator, hoses, thermostat, belt driven fan, water pump, and cooling jackets within the engine.

Extremely cold outside temperatures make starting the engine difficult. To improve engine starting, a cold weather starting aid has been provided that features a glow plug for each cylinder. The glow plugs are energized to preheat engine combustion air during engine preheat starting cycle. Purpose of Troubleshooting Table. This section contains troubleshooting information for locating and Correcting operating troubles which may develop in the engine.

Each malfunction for an individual component unit or system is followed by a list of tests or inspections which will help you to determine probable causes and corrective action to take.

Step 1. Troubleshooting per end item maintenance manual. Check for defective starter motor and solenoid. Step 2.

Check for faulty glow plugs. Test glow plugs. Refer to paragraph If glow plugs not defective, do step 2. Replace defective glow plugs. Step 8. Perform engine compression check. If engine defective, repair or replace engine. Check for improper grade of oil. Refer to end item lubrication order. If proper grade of oil, do step 2. If improper grade of oil, refer to end item maintenance manual and change oil and filter.

Defective fuel injection pump. Remove and test fuel injection pump. If fuel injection pump not defective, go to step 6. Replace fuel injection pump. Check fuel injection pump timig. Check for loose or damaged exhaust manifold. Inspect for damaged and attaching hardware. IF not damage or loose, do step 2. Check for defective batteries.

Test batteries. Refer to end item maintenance manual. If batteries not defective, do step 2. Where applicable, prior to performing engine maintenance, ensure bat- teries are disconnecting. If the engine has been operating and coolant is hot, allow engine to cool before you slowly loosen filler cap and relieve pressure from cooling system. Failure to observe this warning could result in severe personal injury.

Remove rocker arm cover and rocker arm assembly, refer to paragraph Remove pushrods, cylinder head assembly and cylinder head gasket, refer to paragraph Check for bent push rods and discard cylinder head gasket. Remove crank shaft pulley and front gear cover, refer to paragraph Install cylinder head assembly and Push rods, refer to paragraph This section provides maintenance for cooling system components.

Components of cooling system not men- tioned in this section can be found in the end item maintenance manual. Discard gasket 3. Lift thermostat 4 from housing. Loosen two hose clamps 10 and remove bypass hose 11 from housing 8 and water pump housing. NOTE : Note location of two shorter screws 6 for use during installation.

Tighten screws to in-lbs 19 Nm. Install bypass hose 11 on housing 8 and water pump housing and secure with two hose clamps Connect outlet hose to outlet pipe 2 and secure with hose clamp.

Inspect pump rotation for abnormal noise, binding, and other abnormal conditions. Inspect pump housing for cracks, corrosion, or any other damage.

Replace pump assembly if inspection reveals any abnormal condition, such as bearing failure, ex- cessive end play, or abnormal rotation. Water Pump This section provides maintenance for fuel system components.

Components of the fuel system not mentioned in this section can be found in end item maintenance manual. Remove and discard two seals 8. Cap openings. Disconnect fuel return line 10 to facilitate removal of fluid passage bolt Remove fluid passage bolt 11 securing fuel tube 13 to fitting on top of filter body Fuel Filter Assembly Do not tighten bolts until fuel tubes have been connected to filter and tightened. Remove caps and install fuel return line Attach fuel tube 13 to fitting on top of filter body 15 with two new seals 12 and fluid passage bolt Failure to observe this caution could damage the equipment.

NOTE Drain fuel into suitable container. Loosen sleeve nut on fuel tubes 1, 2, 3, and 4, FIGURE at fuel injection pump Loosen sleeve nut on fuel tubes 1, 2, 3, and 4 at fuel injector. Fuel lnjectors and Piping If necessary, remove screw 22 , connector 23 , and gasket 24 from holder Discard gasket The nozzle needle valve and nozzle body combinations must not be in- terchanged otherwise, injectors will not operate property.

Cleaning solvent is flammable and toxic to eyes, skin, and respiratory tract. Good general ventilation is nom-rally adequate. Soak all parts except nozzle in a dry cleaning solvent P-D and wipe off all excess residue with a soft cloth.

Dry with compressed air. Assembly Fuel Injector. Install nozzle 21 and retainer nut 20 on holder Install pushrod 19 , spring 18 , and washer 17 in holder Install each fuel injector 11 and temporarity tighten them.

Final tightening will be done after fuel tubes are connected. Cap all openings. Disconnect fuel tubes from top and bottom of fuel feed pump Support weight of fuel injection pump 3 and remove four bolts 1 and two bolts 2 securing pump to engine front plate. Fuel Feed Pump and Timer Assembly Fuel Injection Pump Assembly Tighten cou- pling nut. Remove plug 12 and preformed packing 13 from top of governor housing Remove bolt 14 with retainer 15 and six screws 16 securing housing 17 to end of pump.

By tapping housing 17 lightly with a mallet, separate it from the pump. Remove four screws 16 securing cover Tap governor end of camshaft 18 with a mallet and remove cover 17 using two screwdrivers to pry cover out of housing.

Removing Tappet Typical Be careful not to let plunger 24 come in contact with other parts. Place them in clean diesel fuel in their order of removal. Using mechanical finger through bottom plug hole, remove plunger 24 , lower spring seat 25 and spacer ring 26 aa.

Remove two plate assemblies Loosen four delivery valve bodies Remove delivery valve body 33 and spring Screw extractor into delivery valve Removing Plunger Barrel al. If necessary, remove and retain two bleed screws 40 , two gaskets 41 , three studs 42 , and adapter Feed Pump. Remove gasket 27 and spring Discard gasket. Remove piston Turn pump housing 10 over in vise.

Remove and discard retaining ring Remove tappet 31 from housing and withdraw push rod Diesel fuel is flammable and toxic to eye-s, skin, and respiratory tract. Good general ventilation is normally adequate. Thoroughly wash all disassembled parts in clean diesel fuel.

Check each part carefully. Holding delivery valve seat, close port with finger tip. To check for end play, hold pinion and measure movement of control rack. If wear on working area of control rack and bushing is excessive and play is more than 0. If damaged, replace seat. Check thread damage and keyway groove on both ends. Bearing Removal If defective, replace check valve.

Check piston 29 for damage or cracks. If defective, replace piston. Check tappet 31 rollers, bushing, and pin for excessive wear, flaws, or peeling. Feed Pump Tappet Tuner Assembly. Visually inspect for broken springs. If springs are broken, replace timer assembly. If defective, replace gear. Using feeler gage, check clearance between washer 39 and shim Clearance should be 0. Clamp pump housing in vise, with protected jaws, so tappet opening is facing upward.

Install new retaining ring Turn pump housing over in vise. Install piston 29 and spring Mount pump housing 19, FIGURE in bracket mounted on universal vise Install four plunger barrels 37 so that locating pins in pump housing 19 mate with grooves in barrels Ensure that barrels 37 cannot manually be rotated. Align tappet guide with pump housing guide groove and insert tappet 23 and spacer ring 26 through camshaft opening, refer to FIGURE Tighten screws 72 in-lbs 8.

Apply adhesive and install four plugs 15 in bottom of pump. Tighten plugs 47 ft-lbs 63 7 Nm Place pump in upright position. Refer to end item maintenance manual and install governor mechanism.

Install two plate assemblies 32 to valve bodies Tighten screw 36 in-lbs 4. Perform fuel injection pump test, refer to paragraph Plug feed pump opening with plastic plug. Fill camshaft chamber with engine lubricating oil MIL-L 80 cc. Remove control rack cap and attach measuring device Fuel Pump Test Specifications Install valves 35 , gaskets 36 , springs 34 , and bodies 33 , refer to paragraph N O T E Ensure fuel injection pump is bled of all air before doing following steps.

Set test stand for an inlet pressure of 23 psi 1. Perform feed pump suction test as follows: 1 Install feed pump, paragraph Priming Pump Test aj. Perform feed pump capacity test as follows: N O T E Feed pump can be tested for capacity while installed on engine.

Discon- nect discharge hose and insert in measuring container. Crank engine for 15 seconds. Capacity Test ak. Feed Pump Pressure Test 2 Install plug in discharge port.

There must be no air leakage. Remove coupling from camshaft. Position bracket 8 and new gasket 10 on drive end of housing and secure with four washers 7 new lock- washers 6 , and nuts 5 ap. Refer to end item maintenance manu- Position oil feed tube to side of pump and secure with two new preformed packings 4, FlGURE and fluid passage bolt 3.

Bleed air from fuel system, refer to paragraph Operate engine and check for leaks. Install valve body 33 and tighten to 31 ft-lbs Take care to avoid entry of dirt or foreign particles in fuel injection pump while delivery valve is removed.

Adjustment Procedure. Align timing pointer at timing gear case and middle 18 degrees injection timing notch line on crankshaft pulley. Disconnect injection pipe from delivery valve No. Remove No. This is the correct fuel injection timing. Blow remaining fuel from No. Cartridge Replacement.

Drain lubrication system, refer to end item maintenance manual. Discard used cartridge. Wipe filter head 2 with a clean rag. Oil Filter Install cartridge 1 if necessary, refer to paragraph Service lubrication system, refer to end item maintenance manual. Operate engine and check for leakage. Tag, disconnect, and remove oil pressure sending unit, if supplied. Install oil pressure gage psi. Start engine and check oil pressure relief valve opening. Valve should open between Oil Piping Position fuel injection pump oil pipe 7, FIGURE and secure with four new gaskets 5 , two fluid passage bolts 4 , and bolt 6.

Tighten bolts 4 to 84 in-lbs 9. Position valve rocker oil fuel pipe 3 and secure with two new gaskets 2 and fluid passage bolt 1. Remove oil pan 6 and gasket 6. If not removed, remove drain plug 8 and gasket 9. Replace if damaged. Inspect gasket 2 for deterioration and replace as necessary. Remove oil pan, refer to paragraph Remove crankcase, refer to paragraph Remove two screws 2 securing pump assembly and remove pump.

Disconnect pipe 1 from pump. Standard clearance is 0. Oil Pump Inspections Remove two clamps 4 attaching hose 5 to PCV valve 14 and breather pipe 17 ; remove hose.

PCV Assembly Change Replace if defective. Inspect clamps for deformity, weakness, or other damage. Inspect check valve for damage. Blow into check valve. At one end, air should pass freely.