Isuzu Engine Mechanical

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Isuzu Trooper LS V6 3.5L Shop Manual
Kansas City, Missouri World Headquarters Web Auto Repair Database (WARD) Education Division: Advanced Technology Career University (ATCU) (Connecting Visions of Goals For The Future) Advance Technology Career University U.S.A. Affiliates in Education Tech Craftsman Career Building Trade School (TCCBTS) Global Education Career Development, 501 (c) (3) Also Known As (GECD) INDEPENDENT COMMERCIAL BUSINESS DIVISION: See ASSEMBLAGE OF RELATED SERVICES In order to offer Tech Craftsman Career Building Trade School's interns/apprentices more than just going to work, becasue that's what TCCBTS is all about, 24 months, working 5 days a week and 8 hours each one of those 5 day weeks, yes, its a school but learning as if it was a job. TCCBTS's goal is to reward our first-year interns/apprentices by expending their experiences so they can show off their skill while still going to school. How? Easy we're going to create and develop several, Independent Commercial Businesses for the interns/apprentices to work before class or after class or both, and allowed to work on weekends and paid $15.00 dollars an hour. Now the interns/apprentices are not only earning real money, but learning on the job skill social by interacting with real customers asking for their experience and help. INDEPENDENT COMMERCIAL BUSINESS DIVISION Review: Assemblage of Auto Related Services to better under each individual commercial businesses. Read and Review ASSEMBLAGE OF RELATED SERVICES Business Intellectural Concept Created by James E. Grow Library of Congress Copy(c) 2015-TXu-1-954607 Certificate of Registration To return back to Tech Craftsman Career Building Trade School's Internship/Apprenticeship website click below: Tech Craftsman Career Building Trade SchoolInternship/Apprenticeship
[Page 1] ENGINE CONTENTS
Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Ignition System Starting and Charging System	Drive-ability and Emissions Engine Exhaust Engine Lubrication Engine Speed Control System Induction
ENGINE MECHANICAL CONTENTS
Service Precaution General Description Engine Diagnosis Cylinder Head Cover L.H. Removal Installation Common Chamber Removal Installation Exhaust Manifold L.H. Removal Installation	Valve Spring, Oil Controller, Valve, Valve Guide Valve Guide Valve Spring, Oil Controller, Valve Guide and Associated Parts Parts Disassembly Inspection and Repair Re-assembly Valve Clearance Adjustments Camshaft Camshaft and Associated Parts Disassembly Inspection and repair Crankshaft Crankshaft and Associated Parts Disassembly Inspection and repair Reassembly Piston and Connecting Rod Piston, Connecting Rod and Associated Parts Disassembly Inspection and repair Reassembly Crankshaft and Main Bearings Removal Installation	Cylinder Block Cylinder Block and Associated Parts Dis-assembly Inspection and repair Re-assembly Main Data and Specification Special Tool Rear Oil Seal Removal Installation Engine Assembly Removal Installation Cylinder Head and Associated Parts Disassembly Clean Inspection and repair Reassembly Piston, Piston Ring and Connecting Rod Removal Installation Valve Stem Oil Controller, Valve Spring and Valve Guide Removal Installation
[Page 2] BATTERY
CONTITION	POSSIBLE CAUSE	CORRECTION
Headlights go out or dim considerable	Battery run down or under charged Terminal poorly connected Starting motor coil circuit shorted Starting motor defective	Recharge or replace battery Clean battery posts and terminal and connect properly Overhaul or replace Overhaul or replace
IGNITION 2.Ignition Trouble----Starting Motor Turns Over But Engine Does Not Start SPARK TEST Disconnect an ignition coil from any spark plug. Connect the spark plug tester 5-0607-0, start the engine, and check if a spark is generated in the spark plug tester. Before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the ignition coil is broken while the engine is running.
CONTITION	POSSIBLE CUASE	CORRECTION
Spark jumps across gap	Spark plug defective Ignition timing incorrect Fuel not reaching fuel injector(s) or engine Value timing incorrect Engine lacks compression<br>	Clean, adjust spark gap or replace Refer to Ignition System Refer to item 3 (Trouble in fuel system) Adjust Refer to item 4 (Engine lacks compression)<br>
No sparking takes place	Ignition coil disconnected or broken Electronic ignition system with module Poor connections in engine harness<br> Power-Train Control Module cable disconnect or defective	Connect properly or replace Replace Correct Correct or replace
3. [Page 3] Trouble in Fuel System
CONDITION	POSSIBLE CAUSE	CORRECTION
Starting motor turns over and spark occurs but engine does not start	Fuel tank empty Water in fuel system Fuel filter clogged Fuel pipe clogged Fuel pump defective Fuel pump circuit open Evaporative Emission Control System circuit clogged Multi-port Fuel Injectiobn System Faulty	Fill Clean Replace Filter Clean or replace Replace Correct or replace Correct or replace Refer to "Electronic Fuel Injection" section
4. Engine Lacks Compression
CONDITION	POSSIBLE CAUSE	CORRECTION
Engine Lacks Compression	Spark plug loosely filter or spark plug gasket defective Valve timing incorrect Cylinder Head gasket defective Valve incorrectly seated Valve spring weakened or broken Cylinder or piston rings worn Piston ring sized	Tighten to specification torque or replace gasket Adjust Replace gasket Lap valve Replace valve and valve guide Overhaul engine
[Page 4] ENGINE COMPRESSION TEST PROCEDURE
1. Start and run the engine until the engine reaches normal operation 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 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary LIMIT; 1000 kPa (145 psi)
Rough engine Idling or Engine Stalling
CONDITION	POSSIBLE CAUSE	CORRECTION
Trouble in fuel injection system	Idle air control valve defective Throttle shutting off incomplete Fuel injector Circuit open or shorted Fuel injector damaged Fuel pump relay defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure Sensor circuit open or poor connections Engine Coolant Temperature Sensor circuit open or poor connection Intake Air Temperature Sensor circuit open or poor connection Intake Air Temperature Sensor defective Knock Sensor (KS) cable broken or poor connections Knock Sensor defective Vehicle Speed Sensor circuit open or shorted Vehicle Speed Sensor defective	Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Correct or replace Replace Correct or replace Replace Correct or replace Replace
[Page 5] Emission Control
Trouble in Emission Control System	Power-Train Control Module Defective Exhaust Gas Recirculation Valve circuit open or poor connections Exhaust Gas Recirculation valve faulty Canister Purge Valve circuit open or poor connections Canister Purge Valve defective Evaporative Emission Canister Purge Control Valve defective Trouble in ignition system	Replace Correct or replace Replace Correct or rteplace Replace Replace Refer to "Hard Start"
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Others	Engine lacks compression Valve incorrect seated Air Cleaner Filter clogged Valve timing incorrect Idle Air Control valve broken Fast idle Solenoid defective Positive Crankcase Ventilation Valve defective or clogged	Refer to "Hard Start" Lap valve Replace filter element Readjust Replace Replace Replace
Rough Engine Running
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Engine Misfiring Periodically	Ignition coil layer shorted Spark plug fouling Spark plug(s) insulator nose leaking Fuel injector(s) defective	Replace Clean or install hotter type plug Replace Replace
[Page 6] Engine Knock
Engine Knock Periodically	Spark plug running too hot Power-Train Control Module Faulty	Install colder type spark plug Replace
Engine Lacks Power	Spark plug fouled Fuel injectors defective Mass Airflow Sensor or Intake Airflow Sensor circuit defective Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective Engine Coolant Temperature Sensor or Engine Temperature Sensor circuit defective Power-Train Control Module faulty Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective Throttle Position Sensor or Throttle Position Sensor circuit defective Knock Sensor or Knock Sensor circuit defective knock Sensor Module or Knock Sensor Module circuit defective	Clean Replace Correct or replace Correct or replace Correct or replace Replace Correct or replace Correct or replace Correct or replace Correct or replace
CONDITION	POSSIBLE CAUSE	CORRECTION
Hesitation on Acceleration	Throttle Position Sensor adjustment incorrect Throttle Position Sensor circuit open or shorted Excessive play in accelerator linkage Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective Manifold Absolute Pressure (MAP) Sensor circuit open or shorted MAP Sensor defective Intake Air Temperature (IAT) Sensor circuit open or shorted Knock Sensor (KS) Circuit open or shorted Knock Sensor defective Knock Sensor Module circuit open or shorted Knock Sensor Module defective Intake Air Temperature Sensor defective	Replace throttle valve assembly Correct or replace Adjust or replace Correct or replace Replace Correct or replace Replace Correct of replace Correct or replace Replace Correct or replace Replace
[Page 7] Hesitation
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Hesitation at High Speed (Fuel pressure to low)	Fuel tank strainer clogged Fuel pipe clogged Fuel filter clogged Defective fuel pump system Fuel Pressure Control Valve leaking	Clean or replace Clean or replace Replace Check and replace Replace
Hesitation at High Speeds (Fuel injector not working normally)	Power supply or ground circuit for Multi-port Fuel injection Shorted or open Fuel Injector defective Cable of Multi-port Fuel Injection System circuit open or poor connections	Check and correct or replace Replace Correct or replace
CONTITION	POSSIBLE CAUSE	CORRECTIONS
Hesitations at High Speeds	Power-Train Control Module defective Throttle Position sensor cable broken o rpoor connections Throttle Position Sensor defective Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Mass Airflow Sensor circuit open or poor connections Mass Airflow Sensor defective MAP Sensor cable broken or poor connections Mass Airflow Sensor defective MAP Sensor cable broken or poor connections MAP Sensor defective IAT Sensor circuit open or poor connections lAT Sensor defective Knock Sensor circuit open or poor connections Knock Sensor defective Throttle valve not fully open Air Cleaner Filter clogged Power Supply voltage too low	Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Correct or replace Replace Check and correct Replace filter element
[Page 8] Hesitation
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Hesitation at High Speed (Fuel pressure to low)	Fuel tank strainer clogged Fuel pipe clogged Fuel filter clogged Defective fuel pump system Fuel Pressure Control Valve leaking	Clean or replace Clean or replace Replace Check and replace Replace
Hesitation at High Speeds (Fuel injector not working normally)	Power supply or ground circuit for Multi-port Fuel injection Shorted or open Fuel Injector defective Cable of Multi-port Fuel Injection System circuit open or poor connections	Check and correct or replace Replace Correct or replace
[Page 9} Hesitation at High Speeds
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Trouble in Fuel System	Fuel Pressure Control Valve not working normally Fuel Injector clogged Fuel pipe clogged Fuel filter clogged or fouled Fuel pump drive circuit not working normally Fuel tank not sufficiently breathing due to Evaporative Emission Control System circuit Water in fuel system Inferior quality fuel in fuel system Power-Train Control Module supplied poor voltage Throttle Position Sensor cable broken or poor connections Throttle Position Sensor defective Mass Airflow Sensor not working normally Manifold Absolute Pressure Sensor not working normally Intake Air Temperature Sensor not working normally Engine Coolant Temperature Sensor circuit open or shorted Engine Coolant Temperature Sensor defective Power-Train Control Module defective	Replace Clean or replace Clean Replace Correct or replace Clean or replace Clean Use fuel of specified octane rating Correct circuit Correct or replace Replace Replace Replace Replace Correct or replace Replace Replace
CONITION	POSSIBLE CAUSE	CORRETIONS
Trouble in Intake or Exhaust System	Air Cleaner Fuel clogged Air duct kinked or flattened	Replace filter element Correct or replace
Ignition Failure	------------------------------------------------------ Troubleshooting Guide Heat range of spark plug inadequate	Refer to "Hard Start"
[Page 10} Engine Overheating
CONTITION	POSSIBLE CAUSE	CORRECTIONS
Engine Overheating	Level of Engine Coolant too low Fan clutch defective Incorrect fan installed Thermostat defective Engine Coolant pump defective Radiator clogged Radiator filter cap defective Level of oil in engine crankcase too low or wrong engine oil Resistance in exhaust system increased Throttle Position Sensor adjustment incorrect Throttle position Sensor circuit open or shorted Cylinder Head gasket damaged	Replenish Replace Replace Replace Correct or replace Clean or replace Replace Change or replenish Change or replace Replace with Throttle Valve ASM Correct or replace Replace
Engine Over Cooling	Thermostat defective	Replace (Use a thermostat set to open at 82� C (180� F)
Engine lacks compression	------------------------	Refer to "Hard Start"
Other	Tire inflation pressure abnormal Brake drag Clutch slipping Level of oil in engine crankcase too high Exhaust Gas Recirculation Valve defective	Adjust to recommended pressure Adjust Adjust or replace Correct level of engine oil Replace
Engine Noisy:Abnormal engine noise often consists of various noise originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically.
[Page 11] Noise from Journals
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Noise from crank journals or from crank bearings. (Faulty crank journals and crank bearings usually making dull noise that becomes more evident when accelerating)	Oil clearance increased due to worn crank journals or crank bearings Crankshaft out or round Crank bearing seized	Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearings Replace crank bearing and crankshaft or regrind crankshaft and install the undersize bearings Crank bearing seized. Replace crank bearings and crankshaft or regrind crankshaft and install the undersizebearing
Troubleshooting Procedure: Short out each spark plug in sequence using the insulate spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops with spark plug is shorted out
[Page 12] ]Noise from Journals
SERVICE PROCAUTION	CAUTION
WARNING: If so equipped with a supplemental restraint system (SRS), refer tot he SRS component and wiring location view in order to determine whether you are performing service on or near the SRS components or the SRS wiring. When you are performing service on or near the SRS component or the SRS wiring, refer to the SRS service information. Failture to follow warnings could result in possible air bag deployment, personal injury, or otherwise unneeded SRS system repairs	Always use the correct fastener in the proper location. When you replace a fastener, use only the exact part number for that application, Isuzu will call out those fasteners that require a replacement after removal. Isuzu will also call out the fasteners that require thread lockers or thread sealant, Unless otherwise specified, DO NOT USE supplemental coatings (paints, greases, or other corrosion inhibitors) pm threaded fasteners or fastener joint interfaces. generally, such coatings adversely affect the fasteners torque and joint clamping force, and may damage the fastener. When you install fasteners , sue the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
GENERAL DESCRIPTION
ENGINE CLEANLINESS AND CARE An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. 1. A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. 2. Whenever valve train components, pistons,piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. 3. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. 4. Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. 5. The six cylinders of this engine are identified by numbers; Right Side Cylinder 1,3 and 5, Left Side Cylinders 2,4, and 6, as counted from crankshaft pulley side to flywheel side.
GENERAL INFORMATION OF ENGINE SERVICE
The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance: 1. When raising or supporting the engine for any reason, do not use a jack under the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick-up unit. 2. The 12-volt electrical system is capable of damaging circuits. When performing any work when electrical terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery. 3. Any time the intake air duct or air cleaner is removed,the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.
CYLINDER BLOCK
The cylinder block is made of aluminum die-cast casting the 75* V-type six cylinders. It has a rear plate integrated structure and employs a deep shirt. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width of No. 3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron on and each bearing cap uses four bolts and two sided bolts.
ENGINE DIAGNOSIS
[Page 13] HEADLIGHTS GO OUT OR DIM
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Headlights go out or dim considerably	Battery run down or under charged Terminals poorly connected Starting motor coil circuit shorted Starting motor defective	Recharge or replace battery Clean battery posts and terminal and connect properly Overhaul or replace Overhaul or replace
2. Ignition Trouble--starting Motor Turns Over But Engine Not Start SPARK TEST Disconnect an ignition coil from any spark plug. Connect the spark plug tester, start engine, and check if a spark is generated in the spark plug tester. before starting the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the part where insulation of the ignition coil is broken while the engine is running.
CONDITION	POSSIBLE CAUSE	CORRECTIONS
Spark jumps across gap	Spark plug defective Ignition timing incorrect Fuel not reaching fuel injector(s) or engine Valve timing incorrect Engine lacks compression	Clean, adjust spark gap or replace refer to Ignition System Refer to item #3 (Trouble in fuel system) Adjust Refer to item #4 (Engine lacks compression)
No sparking takes place	Ignition coil disconnected or broken Electronic Ignition system with module Poor connections in engine harness Power-Train Control Module cable disconnect or defective	Connect properly or replace Replace Correct

Kansas City, Missouri World Headquarters Web Auto Repair Database (WARD)