Isuzu N-Series. Service manual — part 297
International Service & Parts
Tokyo, Japan
WORKSHOP MANUAL
N-SERIES
ENGINE 4H SERIES
SECTION 6
SERVICE INFORMATION 00-1
ENGINE 4H SERIES
SECTION 00
SERVICE INFORMATION
Contents
TROUBLESHOOTING . . . . . . . . . . .. 00-2
MAIN DATA AND SPECIFICATIONS . . . . . 00-15
Main Data and Specifications . . . . . . .. 00-15
SERVICE STANDARD. . . . . . . . . . 00-25
SERVICING . . . . . . . . . . . . . . 00-39
FIXING TORQUE. . . . . . . . . . . . 00-56
SPECIAL TOOLS . . . . . . . . . . . . 00-67
Special Tools . . . . . . . . . . . . ... 00-67
00-2 SERVICE INFORMATION
TROUBLESHOOTING
Hard Starting
1. Starter Inoperative
2. Starter Motor Operates But Engine Does Not Turn Over
3. Engine Turns Over But Does Not Start
Checkpoint
Possible cause
Correction
Battery
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
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
Starter motor
Defective magnetic switch or starter relay
Repair or replace the magnetic switch
Defective starter motor
Repair or replace the starter motor
Checkpoint
Possible cause
Correction
Battery
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
Fan belt loose or broken
Adjust or replace the fan belt
Starter motor
Defective pinion gear
Replace the pinion gear
Defective magnetic switch
Repair or replace the magnetic switch
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
Checkpoint
Possible cause
Correction
Engine stop mecha-
nism
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
Fuel filter overflow valve does not close
Repair or replace the fuel filter overflow
valve
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
Fuel
Use of the wrong fuel
Use the correct fuel
Water particles in the fuel
Charge the fuel
Fuel system
Air in the injection pump
Bleed the air from the fuel system
SERVICE INFORMATION 00-3
4. Quick-on Start System
Injection nozzle
Injection nozzle sticking
Replace the injection nozzle
Injection nozzle injection starting pressure
too low
Improper spray condition
Adjust or replace the injection nozzle
Injection pump
Defective fuel injection nozzle resulting in
the fuel drippage after fuel injection
Replace the delivery valve
Defective injection pump control rack oper-
ation
Repair or replace the injection pump con-
trol 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 governor spring seizure
Replace the injection pump governor
spring
Check point
Possible cause
Correction
Glow plug indicator
light does not turn on
1. Defective Fusible link wire
Replace the fusible link wire
2. Broken indicator light fuse
Replace the indicator light fuse
3. Defective indicator bulb
Replace the indicator light bulb
Preheating system
dose not work
1. Defective fusible link wire shorted
Replace the fusible link wire
2. Defective glow plug relay connector
Replace or Repair glow plug relay connec-
tor
3. Defective glow plug connector
Replace or Repair glow plug connector
4. Defective quick-on start timer connec-
tor
Replace or Repair quick-on start timer
connector
Preheating time to long
or to short
1. Defective thermo switch include defec-
tive wiring harness
Replace thermo switch
2. Defective glow plug
Replace glow plug
3. Defective timer unit
Replace timer unit
Checkpoint
Possible cause
Correction
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