Isuzu C22NE, 22LE, 20LE Workshop Manual

WORKSHOP MANUAL

TF SERIES

GASOLINE ENGINE

(C22NE, 22LE, 20LE)

SECTION

6, 6A, 6B, 6C, 6D, 6E, 6F, 6G, 6H & 6J

THIS MANUAL INCLUDES FOLLOWING SECTIONS

SECTION CONTENTS

6 Engine Diagnosis 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel

6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System

6E Driveability and Emissions 6F Engine Exhaust 6G Engine Lubrication 6H Engine Speed Control System

6J Induction

NOTICE

Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section - OA under the headings “GENERAL REPAIR INSTRUCTIONS” and “HOW TO USE THIS MANUAL”.

All material contained in this Manual is based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without prior notice.

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-1

INDEX

SECTION 6

ENGINE DIAGNOSIS

CONTENTS

PAGE

Engine Diagnosis............................................................................................................... 6- 2

Hard Starting ................................................................................................................. 6-2

Engine Compression Test Procedure......................................................................... 6- 3

Rough Engine Idling or Engine Stalling...................................................................... 6- 4

Rough Engine Running ................................................................................................ 6- 5

Hesitation....................................................................................................................... 6- 6

Engine Lacks Power..................................................................................................... 6- 7

Engine Noisy ................................................................................................................. 6- 8

Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9

Troubleshooting Procedure......................................................................................... 6- 9

Abnormal Combustion.................................................................................................. 6-11

Engine Oil Consumption Excessive............................................................................ 6-12

Fuel Consumption Excessive ...................................................................................... 6-13

Oil Problems.................................................................................................................. 6-13

Engine Oil Pressure Check.......................................................................................... 6-13

Malfunction Indicator Lamp ......................................................................................... 6-14

6-2 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Engine Diagnosis

Hard Starting

1.Starting Motor Does Not Turn Over Trouble Shooting Procedure

Turn on headlights and starter switch.

Condition Possible cause Correction

Headlights go out or dim considerably

2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start Spark Test

Disconnect a high tension cable from any spark plug. Connect the spark plug tester (use commercially available tool), crank the engine, and check if a spark is generated in the spark plug tester. Before cranking the engine, make sure that the spark plug tester is properly grounded. To avoid electrical shock, do not touch the high tension cable while the engine is running.

Battery run down or under charged

Terminals poorly connected Clean battery posts and terminals

Starting motor coil circuit shorted Overhaul or replace Starting motor defective Overhaul or replace

Recharge or replace battery

and connect properly

Condition Possible cause Correction

Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace

Ignition timing incorrect Refer to Ignition System Fuel not reaching fuel injector(s)

or engine Valve timing incorrect Adjust Engine lacks compression Refer to item 4 (Engine lacks

No sparking takes place Ignition coil disconnected or

broken Electronic Ignition System with

module Poor connections in engine

harness Engine Control Module cable

disconnected or defective

Refer to item 3 (Trouble in fuel system)

compression) Connect properly or replace

Replace

Correct

Correct or replace

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-3

3.Trouble in Fuel System Condition Possible cause Correction

Starting motor turns over and spark occurs but engine does not start.

4.Engine Lacks Compression Condition Possible cause Correction

Engine lacks compression Spark plug loosely fitted or spark

Fuel tank empty Fill

Water in fuel system Clean Fuel filter clogged Replace filter Fuel pipe clogged Clean or replace Fuel pump defective Replace Fuel pump circuit open Correct or replace Evaporative Emission Control

system circuit clogged Multiport Fuel Injection System

faulty

plug gasket defective Valve timing incorrect Adjust Cylinder head gasket defective Replace gasket Valve incorrectly seated Lap valve Valve stem seized Replace valve and valve guide Valve spring weakened Replace Cylinder or piston rings worn Overhaul engine Piston ring seized Overhaul engine.

Correct or replace

Refer to "Electronic Fuel Injection" section

Tighten to specified torque or replace gasket

Engine Compression Test Procedure

1. Start and run the engine until the engine reaches normal operating 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 opened fully, keep the starter engaged until the compression gauge needle reaches the maximum level. Note the reading.

9. Repeat the test with each cylinder. The pressure difference between the individual cylinders should not exceed 100kPa (14.5 psi).

6-4 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Rough Engine Idling or Engine Stalling

Condition Possible cause Correction

Trouble in fuel injection system Idle air control valve defective Replace

Throttle shutting off incomplete Correct or replace Throttle position sensor circuit

open or shorted Fuel injector circuits open or

shorted Fuel injectors damaged Replace Fuel pump relay defective Replace Manifold Absolute Pressure

Sensor cable disconnected or broken

Manifold Absolute Pressure Sensor defective

Engine Coolant Temperature Sensor cable disconnected or broken

Engine Coolant Temperature Sensor defective

Intake Air Temperature sensor cable disconnected or broken

Intake Air Temperature sensor defective

Knock Sensor (KS) circuits open or shorted

KS defective Replace KS Module circuits open or ground Correct or replace KS Module defective Replace Vehicle Speed Sensor circuit open

or shorted Vehicle Speed Sensor defective Replace

Trouble in emission control system

Others Engine lacks compression Refer to Hard Start

Engine Control Module defective Replace

Canister purge solenoid circuit open

Canister purge solenoid defective Replace Evaporative Emission Canister

Purge control valve defective Trouble in ignition system Refer to Hard Start

Valve incorrectly seated Lap valve Air Cleaner Filter clogged Replace filter element Valve timing incorrect Readjust Idle air control valve broken Replace

Correct or replace

Replace

Correct or replace

Replace

Correct or replace

Replace

Correct or replace

Correct

Replace

Troubleshooting Guide

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-5

Rough Engine Running

Condition Possible cause Correction

Engine misfires regularly Ignition coil layer shorted Replace

Spark plugs fouling Clean or install hotter type plug Spark plug(s) insulator nose

leaking Fuel injector(s) defective Replace Engine control module faulty Replace

Engine knocks regularly Spark plugs running too hot Install colder type spark plugs

Powertrain control module faulty Replace

Engine lacks power Spark plugs fouled Clean

Fuel injectors defective Replace Manifold Absolute Pressure (MAP)

Sensor or Manifold Absolute Pressure Sensor circuit defective

Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective

Engine Control Module faulty Replace 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 circuits defective

Knock Sensor Module or Knock Sensor Module circuits defective

Replace

Correct or replace

6-6 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Hesitation

Condition Possible cause Correction

Hesitation on acceleration Throttle Position Sensor

adjustment incorrect Throttle Position Sensor circuit

open or shorted Excessive play in accelerator

linkage Manifold Absolute Pressure (MAP)

Sensor circuit open or shorted MAP Sensor defective Replace Intake Air Temperature (IAT)

Sensor circuit open or shorted Knock Sensor (KS) Circuit open or

shorted KS defective Replace KS Module circuits open or

shorted KS Module defective Replace IAT Sensor defective Replace

Hesitation at high speeds (Fuel pressure too low)

Hesitation at high speeds (Fuel injector not working normally)

Hesitation at high speeds Engine Control Module defective Replace

Fuel tank strainer clogged Clean or replace

Fuel pipe clogged Clean or replace Fuel filter clogged Replace Defective fuel pump system Check and replace Fuel Pressure Control Valve

leaking Power supply or ground circuit for

Multiport Fuel Injection System shorted or open

Cable of Multiport Fuel Injection System disconnected or defective

Throttle Position Sensor circuit open or shorted

Throttle Position Sensor defective Replace Engine Coolant Temperature

Sensor circuit open or shorted Engine Coolant Temperature

Sensor defective MAP Sensor cable open or

shorted MAP Sensor defective Replace IAT Sensor circuit open or shorted Correct or replace IAT Sensor defective Replace KS Circuit open or shorted Correct or replace KS defective Replace KS Module circuit open or shorted Correct or replace KS Module defective Replace Throttle valve not wide opened Check and correct or replace Air Cleaner Filter clogged Replace filter element Power supply voltage too low Check and correct or replace

Replace throttle valve assembly

Correct or replace

Adjust or replace

Correct or replace

Replace

Check and correct or replace

Correct or replace

Replace

Correct or replace

Engine Lacks Power

Condition Possible cause Correction

Trouble in fuel system Fuel Pressure Control Valve not

working normally Fuel injector clogged Clean or replace Fuel pipe clogged Clean Fuel filter clogged or fouled Replace Fuel pump drive circuit not

working normally Fuel tank not sufficiently breathing

due to clogged Evaporative Emission Control System circuit

Water in fuel system Clean Inferior quality fuel in fuel system Use fuel of specified octane rating Engine Control Module supplied

poor voltage Throttle Position Sensor cable

disconnected or broken Throttle Position Sensor defective Replace 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 Engine Control Module defective Replace

Trouble in intake or exhaust system

Ignition failure

Air Cleaner Filter clogged Replace filter element

Air duct kicked or flattened Correct or replace

Heat range of spark plug inadequate

Electronic Ignition System with module

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-7

Replace

Correct or replace

Clean or replace

Correct circuit

Correct or replace

Replace

Correct or replace

Replace

Refer to Hard Start Troubleshooting Guide

Install spark plugs of adequate heat range

Replace

6-8 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Condition Possible cause Correction

Engine overheating Level of Engine Coolant too low Replenish

Thermo switch or fan motor defective

Thermostat defective Replace Engine Coolant pump defective Correct or replace Radiator clogged Clean or replace Radiator filter cap defective Replace Level of oil in engine crankcase

too low or wrong oil in engine Resistance in exhaust system

increased Throttle Position Sensor

adjustment incorrect Throttle Position Sensor circuit

open or shorted Cylinder head gasket damaged Replace Cooling Fan clutch defective Replace Fan belt slipping Adjust tension of V-belt or replace

Engine overcooling Thermostat defective Replace (Use a thermostat set to

Engine lacks compression - Refer to Hard Start Others Tire inflation pressure abnormal Adjust to recommend pressures

Brake drag Adjust Clutch slipping Adjust or replace Level of oil in engine crankcase

too high

Replace

Change or replenish

Clean exhaust system or replace defective parts

Adjust Wide Open Throttle switch setting

Correct or replace

V-belt

open at 92°C (197.6°F))

Correct level of engine oil

Engine Noisy

Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically.

Condition Possible cause Correction

Noise from crank journals or from crank bearings (Faulty crank journals and crank bearings usually make dull noise that becomes more evident when accelerating)

Oil clearance increased due to worn crank journals or crank bearings

Crankshaft out of round Replace crank bearings and

Crank bearing seized Replace crank bearings and

Replace crank bearings and crankshaft or regrind crankshaft and install the over size bearing

crankshaft or regrind crankshaft and install the over size bearing

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-9

Abnormal Noise Due to Hydraulic Lash Adjuster

Should abnormal noise due to the hydraulic lash adjuster trouble be heard immediately after the engine is started, inspect as follows:

Condition Possible cause Correction

Abnormal noise is heard Air contaminated Bleed HLA is spongy Check ball valve broken Repair

Safety valve in cylinder head broken

Valve clearance is not zero HLA inside stick Replace HLA assembly

Replace

Troubleshooting Procedure

Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out.

Condition Possible cause Correction

Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated)

Bearing or crankshaft pin worn Replace connecting rod bearings

and crankshaft or regrind crankshaft and install the under size bearing

Crankpin out of round Replace connecting rod bearings

and crankshaft or regrind crankshaft and install the under

size bearing Connecting rod bent Correct or replace Connecting rod bearing seized Replace connecting rod bearings

and crankshaft or regrind

crankshaft and install the under

size bearing

Troubleshooting Procedure

Abnormal noise stops when the spark plug on the cylinder with defective parts is shorted out.

Condition Possible cause Correction

Piston and cylinder (Faulty piston or cylinder usually makes a combined mechanical thumping noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up)

Piston clearance increased due to cylinder wear

Piston seized Replace piston and cylinder body Piston ring broken Replace piston and cylinder body Piston defective Replace pistons and others

Replace piston and cylinder body

6-10 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Troubleshooting Procedure

Short out each spark plug and listen for change in engine noise.

Condition Possible cause Correction

Piston pin noise (Piston makes noise each time it goes up and down)

Piston pin or piston pin hole worn Replace piston, piston pin and

connecting rod assy

Troubleshooting Procedure

The slapping sound stops when spark plug on bad cylinder is shorted out.

Condition Possible cause Correction

Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the

tension pulley or replace timing

belt Tensioner bearing defective Replace Timing belt defective Replace Timing wheels defective Replace Timing belt comes in contact with

timing cover

Valve noise Valve and valve guide seized Replace valve and valve guide

Valve spring broken Replace Valve seat off-positioned Correct

Crankshaft noise Crankshaft end play excessive

(noise occurs when clutch is engaged)

Engine knocking Preignition due to use of spark

plugs of inadequate heat range Fuel too low in octane rating Replace fuel Wide Open Throttle enrichment

system failure Selection of transmission gear

incorrect Engine overheating Refer to "Engine Lacks Power"

Others Water pump defective Replace

V-belt slipping Adjust tension of V-belt or replace

Replace timing belt and timing

cover

Replace thrust bearing

Install Spark Plugs of adequate

heat range

Refer to Section 6E

Caution operator or incorrect gear

selection

V-belt

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-11

Abnormal Combustion

Condition Possible cause Correction

Trouble in fuel injection system Fuel pressure control valve

defective Fuel filter clogged Replace Fuel pump clogged Clean or replace Fuel tank or fuel pipe clogged Clean or replace Fuel injector clogged Clean or replace Fuel pump relay defective Replace Power supply cable for fuel pump

loosely connected or defective Manifold Absolute Pressure

Sensor circuit open or shorted Manifold Absolute Pressure

Sensor defective Engine Coolant Temperature

(ECT) Sensor circuit open or shorted

ECT Sensor defective Replace Throttle Position Sensor

adjustment incorrect Throttle Position Sensor defective Replace Throttle Position Sensor connector

loosely connected Vehicle Speed Sensor cable

loosely connected or defective Vehicle Speed Sensor loosely

fixed Vehicle Speed Sensor in wrong

contact or defective Engine Control Module cable

loosely connected or defective

Trouble in emission control system

Trouble in ignition system - Refer to "Engine Lacks Power" Trouble in cylinder head parts Carbon deposits in combustion

Heated Oxygen Sensor circuit open (If applicable)

Heated Oxygen Sensor defective (If applicable)

Signal vacuum hose loosely fitted or defective

ECT Sensor circuit open or shorted

ECT Sensor defective Replace Evaporative Emission Control

system (If applicable)

chamber Carbon deposit on valve, valve

seat and valve guide

Replace

Reconnect, correct or replace

Correct or replace

Replace

Correct or replace

Reconnect

Correct or replace

Fix tightly

Replace

Correct or replace

Replace

Correct or replace

Refer to Section 6E

Remove carbon

6-12 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Engine Oil Consumption Excessive

Condition Possible cause Correction

Oil leaking Oil pan drain plug loose Retighten or replace gasket

Oil pan setting bolds loosened Retighten Oil pan gasket broken Replace gasket Front cover retaining bolts loose or

gasket broken Head cover retaining bolts loose

or gasket broken Oil filter adapter cracked Replace Oil filter attaching bolt loose or

rubber gasket broken Crankshaft front or rear oil seal

defective Oil pressure unit loose or broken Retighten or replace Blow-by gas hose broken Replace hose Engine/Transmission coupling

area

Oil leaking into combustion chambers due to poor seal in valve system

Oil leaking into combustion chambers due to poor seal in cylinder parts

Crank case ventilation, Positive Crankcase Ventilation System malfunctioning

Others Improper oil viscosity Use oil of recommended S.A.E.

Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide Cylinders and pistons worn

excessively

Piston ring gaps incorrectly positioned

Piston rings set with wrong side up Correct Piston rings sticking Rebore cylinder and replace

Piston ring and ring groove worn Replace pistons and others Return ports in oil rings clogged Clean piston and replace rings Positive Crankcase Ventilation

Hose clogged

Continuous high speed driving and or severe usage such as trailer towing

Retighten or replace gasket

Retighten or replace oil filter

Replace oil seal

Rebore cylinder and replace

pistons and others

Correct

pistons and others

Clean

viscosity

Continuous high speed operation

and or severe usage will normally

cause increased oil consumption

ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-13

Fuel Consumption Excessive

Condition Possible cause Correction

Trouble in fuel system Mixture too rich or too lean due to

trouble in fuel injection system Fuel cut function does not act Refer to "Abnormal Combustion"

Trouble in ignition system Misfiring or abnormal combustion

due to trouble in ignition system

Others Engine idle speed too high Reset Idle Air Control Valve

Returning of accelerator control sluggish

Fuel system leakage Correct or replace Clutch slipping Correct Brake drag Correct Selection of transmission gear

incorrect

Refer to "Abnormal Combustion"

Refer to Hard Start or Abnormal

Combustion Troubleshooting

Guide

Correct

Caution operator of incorrect gear

selection

Oil Problems

Condition Possible cause Correction

Oil pressure too low Wrong oil in use Replace with correct engine oil

Relief valve sticking Replace Oil pump not operating properly Correct or replace Oil pump strainer clogged Clean or replace strainer Oil pump worn Replace Oil pressure gauge defective Correct or replace Crankshaft bearing or connecting

rod bearing worn

Oil contamination Wrong oil in use Replace with new engine oil

Oil filter clogged Replace oil filter Cylinder head gasket damage Replace gasket Burned gases leaking Replace piston and piston rings or

Oil not reaching valve system Oil passage in cylinder head or

cylinder body clogged

Replace

rebore cylinders

Clean or correct

Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil.

a. Check the viscosity of the oil. b. Change the oil if the viscosity is outside the

specified standard.

c. Refer to the "Maintenance and Lubrication"

section of this manual.

2. Check the engine oil level. The level should fall somewhere between the "ADD" and the "FULL" marks on the oil level dipstick. If the oil level does not reach the "ADD" mark on the oil level dipstick, engine oil must be added.

3. Remove the oil pressure unit.

4. Install an oil pressure gauge.

5. Start the engine and allow the engine to reach normal operating temperature (About 80°C).

6. Measure the oil pressure.

Oil pressure should be: 150 kPa(21.8 psi) at idle speed.

7. Stop the engine.

8. Remove the oil pressure gauge

9. Install the oil pressure unit.

10. Start the engine and check for leaks.

6-14 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE)

Malfunction Indicator Lamp

The instrument panel "CHECK ENGINE" Malfunction Indicator lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions.

Condition Possible cause Correction

"CHECK ENGINE" MIL does not illuminate at the starting of engine

“CHECK ENGINE” MIL illuminates, and stays on

Bulb defective Replace

MIL circuit open Correct or replace Command signal circuit to operate

self diagnostic system shorted Engine Control Module (ECM)

cable loosely connected, disconnected or defective

ECM defective Replace Deterioration heated oxygen

sensor of internal element Heated oxygen sensor connector

terminal improper contact (If applicable) Heated oxygen sensor lead wire

shorted (If applicable) Heated oxygen sensor circuit open

(If applicable) Deterioration engine coolant

temperature sensor of internal element

Engine coolant temperature sensor connector terminal improper contact

Engine coolant temperature sensor lead wire shorted

Engine coolant temperature sensor circuit open

Throttle position sensor open or shorted circuits

Deterioration of crankshaft position sensor

Crankshaft position sensor circuit open or shorted

Vehicle speed sensor circuit open Correct or replace Manifold absolute pressure sensor

circuit open or shorted Intake air temperature sensor

circuit open or shorted Fuel injector circuit open or shorted Correct or replace ECM driver transistor defective Replace EPROM or ECM Malfunctioning of ECM RAM

(Random Access Memory) or Malfunctioning of ECM PROM (Programmed Read Only Memory)

Correct or replace

Replace

Reconnect properly

Correct

Correct or replace

Replace

Reconnect properly

Correct

Correct or replace

Replace

Correct or replace

Replace EPROM or ECM

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-1

INDEX

SECTION 6A

ENGINE MECHANICAL

CONTENTS

PAGE

General Description......................................................................................................... 6A- 4

ENGINE PICTORIAL.................................................................................................... 6A- 6

Main Data and Specification........................................................................................... 6A-11

CRANK CASE VENTILATION SYSTEM...................................................................... 6A-18

ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-19

OPERATIONS ON ENGINE AGGREGATES.................................................................... 6A-20

Engine Damping Blocks(Engine without Transmission)......................................... 6A-20

Toothed Belt Tension, Check..................................................................................... 6A-23

Toothed Belt Tension, Adjust .................................................................................... 6A-25

Toothed Belt, Replace ................................................................................................ 6A-26

OPERATIONS ON INSTALLED ENGINE......................................................................... 6A-28

Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-28

Gasket, Intake Manifold, Clinder Head...................................................................... 6A-28

Seal Ring, Camshaft Housing, Timing Side.............................................................. 6A-29

Seal Ring, Thermostat Housing, Cylinder Head....................................................... 6A-29

Seal Ring - Front Camshaft Housing, Replace......................................................... 6A-30

Toother Belt Rear Cover............................................................................................. 6A-32

Toother Belt Tension Roller....................................................................................... 6A-33

COMPONENT PARTS ...................................................................................................... 6A-34

Cylinder Head.............................................................................................................. 6A-34

Hydraulic Valve Lifter.................................................................................................. 6A-35

OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-36

Camshaft...................................................................................................................... 6A-36

Camshaft Housing Removal and Installation ........................................................... 6A-37

Cylinder Head.............................................................................................................. 6A-37

Hydraulic Valve Lifers, Replace................................................................................. 6A-39

Camshaft Housing, Replace....................................................................................... 6A-39

6A-2 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

PAGE

Camshaft Housing, Check for Plance Surface......................................................... 6A-41

Cylinder Head, Removal and Installation.................................................................. 6A-41

Cylinder Head, Disassemble and Assemble............................................................. 6A-44

Valve, Grind................................................................................................................. 6A-46

Valve Seating, Mill....................................................................................................... 6A-47

Cylinder Head, Overhaul............................................................................................. 6A-47

Flywheel....................................................................................................................... 6A-48

Starter Ring Gear(Manual Transmission) ................................................................. 6A-49

Seal Ring, Crankshaft................................................................................................. 6A-50

Seal Ring, Crankshaft Rear........................................................................................ 6A-50

Gasket, Oil Pan............................................................................................................ 6A-51

OPERATIONS ON CRANK DRIVE................................................................................... 6A-53

Con-Rod Bearing......................................................................................................... 6A-53

Piston with Con-Rod................................................................................................... 6A-53

Con-Rod....................................................................................................................... 6A-54

Pistion Rings............................................................................................................... 6A-55

OPERATIONS ON REMOVED ENGINE........................................................................... 6A-57

Crankshaft ................................................................................................................... 6A-57

Bearing Free Play Measurement................................................................................ 6A-59

Plastigage Method ...................................................................................................... 6A-59

Micrometer and gauge method.................................................................................. 6A-60

Bypass Valve............................................................................................................... 6A-61

Oil Filter ....................................................................................................................... 6A-61

Oil Pump ...................................................................................................................... 6A-61

Oil Pump Safety Valve ................................................................................................ 6A-62

Oil Pump(Overhaul) .................................................................................................... 6A-63

OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-64

Cylinder Head Safety Valve........................................................................................ 6A-64

OPERATIONS ON COOLING SYSYTEM......................................................................... 6A-65

Cooling System, Check for Leakes ........................................................................... 6A-65

Cooling System, Fill Up and Bleed............................................................................ 6A-65

Refill Coolant............................................................................................................... 6A-66

Ignition Timing, Check................................................................................................ 6A-66

ENGINE EXTERNAL PARTS............................................................................................ 6A-67

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-3

PAGE

Radiator ....................................................................................................................... 6A-67

Thermostat................................................................................................................... 6A-67

Water Pump................................................................................................................. 6A-68

Coating sealing surfaces with Silicone Grease ....................................................... 6A-68

Alternator..................................................................................................................... 6A-68

Starter .......................................................................................................................... 6A-68

V-belt Tension of Alternator....................................................................................... 6A-69

FULE INJECTION SYSTEM.............................................................................................. 6A-70

Map Sensor.................................................................................................................. 6A-70

Pressure Regulator..................................................................................................... 6A-70

ECM (Engine Control Module).................................................................................... 6A-70

ECT............................................................................................................................... 6A-71

Idle Air Control(IAC) Valve.......................................................................................... 6A-71

Ignition Coil ................................................................................................................. 6A-71

Crank Position Sensor................................................................................................ 6A-72

FUEL INJECTOR.............................................................................................................. 6A-73

Knock Sensor.............................................................................................................. 6A-73

Oxygen Sensor............................................................................................................ 6A-74

Throttle Valve Position Sensor.................................................................................. 6A-74

Acclelerator Pedal and Cable..................................................................................... 6A-74

Air Cleaner Filter......................................................................................................... 6A-75

Spark Plug Thread ...................................................................................................... 6A-75

TECHNICAL DATA ........................................................................................................... 6A-76

Recommended Troque Values................................................................................... 6A-87

SPECIAL SERVICE TOOL................................................................................................ 6A-88

6A-4 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

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.



A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation.



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.



At the time of installation, they should be installed in the same locations and with the same mating surfaced as when removed.



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.



The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft pulley.

General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-5

contributing to reliable engine performance:



When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick up unit.



The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.



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 cast iron. The crankshaft is supported by five bearings. The bearing cap is made of nodular cast iron.

Cylinder Head

The cylinder head is made of aluminum alloy casting with a spark plug in the center.

Valve Train

Valve system is a single over head camshaft. The valves clearance adjustment are hydraulic. Hydraulic valve lifter adjustment, no adjustment necessary.

Intake Manifold

The intake manifold is made of aluminum alloy.

Exhaust Manifold

The exhaust manifold is made of high Si-Mo nodular iron.

Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.

Crankshaft and Bearings

The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.

6A-6 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

ENGINE PICTORIAL

Front View

“4WD OIL PAN”

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-7

Inlet Side View

“4WD OIL PAN”

6A-8 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

Rear View

“4WD OIL PAN”

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-9

Exhaust Side View

“4WD OIL PAN”

6A-10 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

Top View

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-11

Main Data and Specifications

Engine - General C22NE 22LE 20LE

Engine type Four-cycle, water cooled cross-flow with

single over head camshaft Micro-computer

control, fuel injection Combustion chamber type (Volume) Hemispherical (43.3cm3) <-- <-Timing train system Belt drive <-- <-No.of cylinders-bore × stroke mm (in) 4-86.0×94.6 (3.39×3.72) <-- 4-86.0x94.6 (3.39x3.72) Bore Spacing (C/L to C/L) 93.0 mm Firing Order 1-3-4-2 <-- <-Bore×Stroke 86.0×94.6mm 86.0×86.0 Total piston displacement cm3 (in3) 2,198 (134.39) 1,998 (122.16) Combustion Chamber Volume 43.3 cm No.of piston ring compression ring : 2 ,oil ring :1 Compression pressure kg/cm2 (psi/pa) 17.8 (253/1746) Ignition timing (BTDC) No adjustment Idling speed :rpm (WO/AC,W/AC)

Acoff Valve clearances (At cold) Intake mm (in) 0 (0) (Hydraulic valve lash adjustment) Exhaust mm (in) 0 (0) ( " ) Intake valves Open at (BTDC) deg 29 <-- <-Close at (ABDC) deg 65 <-- <-Exhaust valves Open at (BBDC) deg 66 <-- <-Close at (ATDC) deg 29 <-- <-Ignition system Fully transistorized battery ignition Distributor type Not applicable, Electronic Spark Timing control Distributor advance type Not applicable, Electronic Spark Timing control Spark plug type RN9YC4 Spark plug gap mm (in) 1.0--1.1 (0.039--0.043) Lubrication system Lubricating method Fully flow pressure circulation Special engine oil (API grade) SE,SF,SG or SH grade Oil pressure kg/cm2 (psi/Pa) rpm 1.5 (21.3/147)/825 (SAE 10W-30/API SE grade) engine oil after

warm-up Oil pump type Gear Oil filter type Cartridge full flow Oil capacity lit. (US/UK gal.) with Oil Filter change 4.5litres

without Oil Filter change 4.25 (1.07/0.93) litres Cooling system Radiator type Corrugated fin with reserve tank Coolant capacity lit. (US/UK gal.) 2.3 (0.66/0.55) Water pump type Centrifugal Thermostat Wax pellet with jiggle hole Fuel system Electronically controlled Multi Port Fuel Injection System Fuel pump type Electric

825

 

6A-12 ENGINE MECHANICAL (C22NE, 22LE, 20LE)

Engine - General C22NE 22LE 20LE

Fuel pressure kg/cm2 (psi/Pa) 3.4 (48.4/334) <-- <-Fuel filter type Cartridge paper element Air cleaner type Dry paper element <-- <-Battery Type/V-Ax No. of units 50D20L (STD) 34B19L

46B24L Alternator Capacity V-A(W) 12-70 (840) <-- <-Starter Output V-kW 1.2-1.4 <-- <-Exhaust system CO Adjustment (1) Applicable to Open Loop System (Not equipped H2OS)

(2) Not applicable to Closed Loop System (Equipped H2OS) Compression Ratio (with Tolerance) 9.2:1±0.3 8.6:1±0.3 8.8:1±0.3 Cylinder Head Material Aluminum Alloy (gravity cast) Cylinder Block Material Cast Iron No.of Mounting Points (including trans.) 3 Engine Installation Angles-Longitudinal 3° 30'

-Lateral 7° 50' (towards exhaust side)

Overall Dimensions (L × W × H):

- TF (2.2Litre/2WD) 610×550×744 mm

- TF (2.2Litre/4WD) 610×550×708 mm

- TF (2.0Litre/2WD) 610×550×734 mm

Engine Weight - TF (2.2Liter/Man) 136kg

- TF (2.0Liter/Man) 134kg Camshaft Type SOHC No.of Valves per Cylinder - Inlet 1

- Exhaust 1 Spark Plug Location Side Port Arrangement Cross Flow Working Principle Spark Ignition 4-stroke

ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-13

Valve System C22NE 22LE 20LE

Actuation Type Direct-acting Inverted Bucked Tappet Valve Clearance Adjustment Hydraulic Valve Rotor Type None Inlet-Valve Material Chromium Alloyed Steel

-Seat Insert Material Sintered Iron

Exhaust-Valve Material Head:Cr-Mn-Ni Alloyed

Shaft:Cr-Si Alloyed&Cr plated

-Seat Insert Material Sintered Iron Valve Spring Material GME 06 100-C1 Valve Guide Material QS 13 MR 00 Valve Seal Type Lip

Water Pump C22NE 22LE 20LE

Type Centrifugal Drive-Material&Type HNBR Toothed-belt Bearing Type Double Row Ball Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C22NE 22LE 20LE

Type Bypass

Oil Pump & Filter C22NE 22LE 20LE

Type Gear Pump Location Front of Engine Drive Direct Crankshaft Driven Filter Type Full Flow with Bypass for blocked filter

Oil&Oil Reservoir C22NE 22LE 20LE

Reservoir-Description&Location 1-piece below Engine Reservoir Material Aluminium Alloy (pressure cast) Replacement Oil Fill Volume

-With FIlter change 4500 cm

-without Filter change 4250 cm

3 3

Recommended Oil-Run-in 10W/30SG

-Service (above-18°C) 10W/40SG

-Service (below-18°C) 5W/30SG

Oil Classification API&CCMC

Ignition Components C22NE 22LE 20LE

Spark Plugs Conventional Type Electronic Spark Control No.of Coils&Type 2 Solid State Coil Location Engine-mounted Ignition Lead Type Inductive (hi-resistance)

+ 480 hidden pages

Isuzu C22NE, 22LE, 20LE Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Engine Diagnosis

Hard Starting

Engine Compression Test Procedure

Rough Engine Idling or Engine Stalling

Rough Engine Running

Hesitation

Engine Lacks Power

Engine Noisy

Abnormal Noise Due to Hydraulic Lash Adjuster

Troubleshooting Procedure

Abnormal Combustion

Engine Oil Consumption Excessive

Fuel Consumption Excessive

Oil Problems

Engine Oil Pressure Check

Malfunction Indicator Lamp

GENERAL DESCRIPTION

ENGINE PICTORIAL

Main Data and Specifications