Isuzu N-Series. Manual — part 476
Engine Mechanical (4HK1-TC) 6A-9
Trouble Shooting
Engine does not turn over
Engine turns over but does not start
Condition
Possible Cause
Correction
Starter motor does not rotate
Dead or weak battery
Charge or
Replace battery
Incomplete circuit
Connect
Repair
Starter relay
Replace starter relay
Starter motor brushes stuck, worn,
or broken
Replace brushes
Starter motor internal damage
Repair motor
Starter motor not meshed with
flywheel
Ring gear abrasion
Replace ring gear
Pinion gear abrasion
Replace pinion gear
Magnetic switch (starter motor) not
properly adjusted
Adjust
Starter motor pinion meshed with
ring gear but does not rotate
Dead or weak battery
Charge battery
Replace battery
Insufficient contact pressure
between starter motor brushes and
commutator
Adjust pressure
Armature (starter motor) stuck
Repair armature
Engine internal damage (Seizure)
Repair engine
Condition
Possible Cause
Correction
Fuel is not delivered to fuel supply
pump
Air in fuel system
Bleed air from fuel system
Air entering fuel pipe
Replace pipe and bleed air from
fuel system
Empty fuel tank
Replenish fuel
Clogged strainer (fuel suction)
Clean or replace strainer
Clogged fuel pipe
Clean or replace pipe
Use of wrong fuel for prevailing
temperatures
Drain existing fuel and replace with
appropriate fuel
Clogged fuel filter
Replace filter
Fuel is delivered to fuel supply
pump
Loose injection pipe connections
Tighten connections
Loose or broken electrical
connectors
Tighten and/or replace connectors
Bad rotational sensor
Replace sensor
Engine control system malfunction
System diagnosis
Insufficient or unstable fuel delivery
volume
Air in fuel system
Bleed air from fuel system
Feed pump malfunction
Repair pump
Loose or broken electrical
connectors
Tighten and/or replace connectors
Clogged fuel filter
Replace filter
Engine control system malfunction
System diagnosis
6A-10 Engine Mechanical (4HK1-TC)
Excessive black exhaust smoke
Excessive white exhaust smoke
Condition
Possible Cause
Correction
Bad injection timing
Engine control system malfunction
System diagnosis
Bad injection nozzle condition
Carbon deposit at nozzle tip
Clean nozzle tip
Sticking nozzle
Replace fuel injector assembly
Engine control system malfunction
System diagnosis
Insufficient compression pressure
Excessive valve clearance
Adjust clearance
Sticking valve stem (valve open)
Repair or replace valve
Damaged valve spring
Replace spring
Valve seat abrasion
Repair valve seat
Compression leakage due to
damaged piston ring
Replace piston ring
Damaged gasket
Replace gasket
Piston scoring
Replace piston
Fuel condition
Water in fuel
Drain existing fuel and replace with
new fuel
Poor fuel quality
Drain existing fuel and replace with
new fuel
Poor engine aspiration
Clogged intake pipes
Clean or replace pipes
Clogged air cleaner element
Clean or replace element
Malfunction detected by engine
control system
Defective sensor
Replace sensor
Engine control system malfunction
System diagnosis
EGR valve and/or intake throttle
valve malfunction
Intake throttle valve sticking
Repair or replace valve
EGR valve sticking
Repair or replace valve
Exhaust brake valve sticking
Repair or replace valve
Engine control system malfunction
System diagnosis
Turbocharger malfunction
Damaged turbocharger fan
Replace turbocharger
Rough turbocharger shaft rotation
Replace turbocharger
Oil leakage from oil seal
Replace turbocharger
Defective booster sensor
Replace sensor
Condition
Possible Cause
Correction
Bad injection timing
Engine control system malfunction
System diagnosis
Malfunction detected by engine
control system
Engine control system malfunction
System diagnosis
Control unit malfunction
Replace unit
Defective sensor
Replace sensor
Insufficient compression pressure
Excessive valve clearance
Adjust clearance
Sticking valve stem (valve open)
Repair or replace valve
Damaged valve spring
Replace spring
Valve seat abrasion
Repair valve seat
Compression leakage due to
damaged piston ring
Replace piston ring
Damaged gasket
Replace gasket
Piston scoring
Replace piston
Engine Mechanical (4HK1-TC) 6A-11
Engine knocking
Abnormal engine rotation
Abnormal battery charging
Fuel condition
Water in fuel
Drain existing fuel and replace with
new fuel
Excessive oil consumption
Worn or damaged piston ring(s)
Replace ring(s)
Defective valve stem oil seal
Replace oil seal
Defective turbocharger oil seal
Replace turbocharger
Clogged turbocharger oil return
pipe
Repair pipe
Condition
Possible Cause
Correction
Bad timing
Engine control system malfunction
System diagnosis
Malfunction detected by engine
control system
Defective sensor
Replace sensor
Control unit malfunction
Replace unit
Engine control system malfunction
System diagnosis
Fuel condition
Poor quality fuel
Drain existing fuel and replace with
new fuel
Poor engine aspiration
Clogged intake pipes
Clean or replace pipes
Engine control system malfunction
System diagnosis
Engine break-down
Foreign material in cylinders
Engine overhaul
Scored pistons and/or bearings
Replace pistons and/or bearings
Condition
Possible Cause
Correction
Engine speed cannot be increased
Engine control system malfunction
System diagnosis
Defective control unit
Replace unit
Engine speed unstable
Defective control unit
Replace unit
Engine control system malfunction
System diagnosis
Clogged fuel filter element
Replace element
Defective fuel injector nozzle(s)
Replace fuel injector assembly
Water in fuel
Drain existing fuel and replace with
new fuel
Air in fuel system
Bleed air from fuel system
Exhaust brake valve sticking
Repair or replace valve
Turbocharger malfunction
Damaged turbocharger fan
Replace turbocharger
Rough turbocharger shaft rotation
Replace turbocharger
Defective booster sensor
Replace sensor
Condition
Possible Cause
Correction
No
charging
Open or shorted wiring and/or
connectors
Repair or replace wiring and/or
connectors
Defective generator
Repair or replace generator
Defective battery
Replace battery
Condition
Possible Cause
Correction
6A-12 Engine Mechanical (4HK1-TC)
Turbocharger Troubleshooting
Insufficient
charging
Open or shorted wiring and/or
connectors
Repair or replace wiring and/or
connectors
Defective generator
Repair or replace generator
Loose generator drive belt
Adjust belt tension or replace belt
Defective battery
Replace battery
Excessive charging
Shorted wiring
Repair or replace wiring
Defective generator
Repair or replace generator
Defective battery
Replace battery
Condition
Possible Cause
Correction
Engine has less than normal power
Air leakage from intake pipe rubber
hose
Repair
Air leakage from inlet cover
Repair
Clogged intercooler cooling section
Clean
Clogged air cleaner element
Clean or replace
Exhaust brake valve stuck
Repair or replace
Turbine and housing contact
(Interference)
Replace
Excessive carbon deposit near
turbine exhaust port that interferes
with turbine
Clean or repair
Rough turbine shaft rotation
Repair or replace
Damaged turbine fan
Repair or replace
Blue exhaust smoke
Oil leakage from turbocharger oil
seal
Repair or replace
Clogged turbocharger oil return
pipe
Repair
Clogged center housing oil
passages
Repair or replace
Engine oil deterioration
Change engine oil
Noisy turbocharger operation
Gas leakage from intake or exhaust
system
Repair
Turbine and housing contact
(Interference)
Repair or replace
Damaged turbine fan
Replace
Turbine shaft bearing abrasion or
scoring
Repair or replace
Excessive rotating part wear
Engine oil deterioration
Change engine oil
Clogged turbocharger oil feed pipe
Repair
Low engine oil pressure
Repair
Condition
Possible Cause
Correction
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