2004 ISUZU TF SERIES oil

TROUBLESHOOTING 6 – 1


SECTION 6
TROUBLESHOOTING


TABLE OF CONTENTS
PAGE PAGE
BASIC INSPECTION PROCEDURE ... 6– 2

1. HARD STARTING ........................... 6– 3

1-1.Starter Motor Inoperative ......... 6– 3

1-2. Starter Motor Operates But
Engine Does Not Turn Over .......... 6– 3

1-3. Engine Turns Over But Does
Not Start Engine ............................. 6– 4

2. UNSTABLE IDLING ........................ 6– 5

3. INSUFFICIENT POWER ................. 6– 6

4. EXCESSIVE FUEL
CONSUMPTION ................................. 6– 7

5. EXCESSIVE OIL CONSUMPTION.. 6– 8

6. OVERHEATING............................... 6– 9

7. WHITE EXHAUST SMOKE ............. 6– 9

8. DARK EXHAUST SMOKE .............. 6– 10

9. OIL PRESSURE DOES NOT RISE . 6– 11

10. ABNORMAL ENGINE NOISE ....... 6– 12

10-1. Engine Knocking.................... 6– 12

10-2. Gas Leakage Noise ................ 6– 12

10-3. Continuous Noise .................. 6– 13

10-4. Slapping Noise ....................... 6– 13

10-5. Excessive Turbocharger
Noise ............................................... 6– 14
11. ROTATING PART WEAR OF
TURBOCHARGER ............................. 6– 14

12. OIL LEAKAGE FROM
TURBOCHRGER ............................... 6– 15

13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER ....................... 6– 15

14. BATTERY CHARGING AND
NOISE PROBLEM.............................. 6– 16

14-1. Battery No Charging .............. 6– 16

14-2. Battery Overcharging ............ 6– 16

14-3. Battery Under Charging......... 6– 17

14-4. Battery Unstable Charging
Current ............................................ 6– 17

14-5. Charging System Noise ......... 6– 18

15. STARTER MOTOR PROBLEM..... 6– 19

15-1. Starter Motor Pinion Engages
to Ring Gear But Engine Does
Not Turn Over ................................. 6– 19

15-2. Incorrect Pinion And Ring
Gear Engagement .......................... 6– 19

15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off ....................................... 6– 20

15-4. Excessive Commutator
Sparking .......................................... 6– 20

6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn
ON ? Go to section
6E “On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —

6 – 8 TROUBLESHOOTING
5. Excessive Oil Consumption
Step Action Value(s) Yes No
1 Does the air cleaner element conditon OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element
2 Does PCV (Positive Crankcase Ventilation) Valve
has problem? — Repair or
replace the
relation parts. Go to Step 3
3 Was the oil pressure value more than normal value? Less than
588 kPa (6.0
kg/cm
2, 85
psi) Repair or
replace the oil
relief valve Go to Step 4
4 Inspect the front and rear crankshaft oil seal.
Was the oil leakage found? —
Replace the
failure part. Go to Step 5
5 Was the oil leakage found from any gasket? — Replace the
wrong gasket Go to Step 6
6 Inspect the valve stem seal, the valve stem and the
valve guide for worn.
Were any worn found? —
Replace the
worn part. Go to Step 7
7 Was the oil leakage found from the turbocharger oil
seal? — Replace the oil
seal. Go to Step 8
8 Was the oil drain pipe of the turbocharger restricted?— Repair or
replace the oil
drain pipe. Go to Step 9
9 Was the oil drain passage in the turbocharger center
housing restricted? — Clean the
center housing Go to Step 10
10 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 11
11 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction
found? (Include radiator cap) — Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the
fan clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump
assembly.
8 Was the restriction by the foreign materials in the
cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. — Clean or
replace the
clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? — Replace the
sealing cap or
replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 2 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
2 Was the PCV (Positive Crankcase Ventilation) valve
working completely? —
Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved

6 – 10 TROUBLESHOOTING
8. Dark Exhaust Smoke
Step Action Value(s) Yes No
1 Was the air cleaner element normal condition? —
Go to Step 2 Clean or
replace the air
cleaner
element
2 Was the EGR valve sticking? — Replace the
EGR valve Go to Step 3
3 Was the injection nozzle pressure or the injection
spray pattern OK? —
Go to Step 4 Replace the
injection nozzle
4 Was the oil leakage found from the turbocharger oil
seal? — Replace the oil
seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted?— Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the
turbocharger center housing restricted? — Clean the
center housing Go to Step 7
7 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 8
8 Does PCV (Positive Crankcase Ventilation) Valve
has problem? — Repair or
replace the
relation parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 11
9. Oil Pressure Does Not Rise
Step Action Value(s) Yes No
1 Was the oil pressure warning lamp working OK? —
Go to Step 2 Replace the oil
pressure
warning lamp
2 Does the oil filter element clog? — Replace the oil
filter element Go to Step 3
3 Does the relief valve open? — Repair or
replace the
relief valve Go to Step 4
4 Does the oil strainer clog? — Clean or
replace the oil
strainer Go to Step 5
5 Was the oil pump working OK? (The pump related
parts worn etc.) —
Go to Step 6 Repair or
replace the oil
pump.
6 Was the rocker arm and/or relation parts worn? — Replace the
rocker arm
and/or relation
parts Go to Step 7
7 Was the camshaft and/or relation parts worn? — Replace the
camshaft
and/or relation
parts Go to Step 8
8 Was the crankshaft and/or relation parts worn? — Replace the
crankshaft
and/or relation
parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved

Table of pressure unit
Pressure kPa (kg/cm
2) 100
(1.0) 980
(10.0)
Resistance ohm 81 30
Electric current A 63.5 106.7

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the
turbocharger? —
Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? — Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged?— Replace the
damaged
gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? — Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? — Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? — Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? — Repair or
replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? — Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/
10W–30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil
feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 15
12. Oil Leakage from Turbocharger
Step Action Value(s) Yes No
1 Inspect the oil leakage area.
Was the oil feed pipe eye bolt loose or the gasket
broken? — Tighten the eye
bolt or replace
the gasket. Go to Step 2
2 Were the V band fixing faces tight? — Tighten band
or replace the
turbocharger Go to Step 3
3 Was there oil leakage from the flange of the turbine
housing? — Replace the
turbocharger Go to Step 4
4 Was there oil leakage from the flange of compressor
housing? — Tighten the bolt
and/or hose
clamp. Go to Step 5
5 Are any DTC stored? — Go to indicated
DTC Solved

13. Insufficient Acceleration and/or Lack of Power due to turbocharger
Step Action Value(s) Yes No
1 Inspect the air or exhaust route.
Was the air and/or exhaust gas piping loose? — Tighten flange
bolts or hose
clamp. Go to Step 2
2 Inspect the work of waste gate valve control.
Was there rust on the linkage rod or pin of the waste
gate valve? —
Replace the
turbocharger Go to Step 3
3 Was air leakage found from the actuator piping? — Repair or
replace the
actuator pipe or
hose/ Go to Step 4
4 Inspect the inside of the turbocharger.
Was the turbine shaft end nut loose? — Replace the
turbocharger Go to Step 5
5 Were the turbine blades bent? — Replace the
turbocharger Go to Step 6
6 Was the turbine wheel rubbing against housing? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved