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VI. Component Failure Analysis

U

L-Series Diesel 38

Fuel System

Nozzle component failure (continued)

Description:

Damage to the nozzle seat and spray hole
sections when the nozzle holder is over
tightened.

Cylinder Block

Description:

Damaged head gasket, cylinder head,
pistons, connecting rods and crankshaft
caused by poor cylinder block casting,
cooling system cavitation, or cooling
system electrolysis.

Description:

Low oil pressure readings or premature
engine bearing wear due to missing internal
oil galley plugs.

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Содержание 3LA

Страница 1: ...lve Adjustment 21 Injector Service 22 24 Injector Pop Off Test 25 Injector Leak Test 26 Glow plug Inspection 26 Hot plug Replacement 27 IV Engine Repair Specifications 3L 28 31 V Engine Repair Specifi...

Страница 2: ...three is the engine service section which illustrates important information regarding fuel injection operation and routine fuel injection service items Section four provides a comprehensive listing of...

Страница 3: ...series apply to engine models in the 11 25 hp range and 25 50 hp range To meet the new CARB standards the pump s injection timing has been changed This eliminates the cost of expensive emission contro...

Страница 4: ...or nozzle check 4 4 Coolant level 4 Coolant leaks 4 Fan belt tension 4 Coolant temperature 4 Coolant replace Replace every 6 months Electrolyte levels 4 Radiator fin cleaning 4 Radiator cap fitting ch...

Страница 5: ...Quiet Single OHV cam that drives injectors intake and exhaust valves less gear driven components Large mesh area on gear driven components Auto thermatic pistons that reduce engine noise at start up a...

Страница 6: ...rt Fuel enters the pressure chamber through the fill port As the plunger rises it closes the fill and spill ports forcing pressurized fuel out the delivery valve to the injector nozzle Any residual fu...

Страница 7: ...a thicker shim the pre stroke is lengthened because the timing sleeve is raised Raising the pump housing changes the start of injection to the last half of the cam lift It also reduces the total numb...

Страница 8: ...e the chamber does not increase because the fuel from the inlet port flows back into the fuel reservoir via the spill port hole Beginning of Injection As the plunger rises it blocks the spill port hol...

Страница 9: ...e timing sleeve fuel pressure continues to rise the delivery valve opens and fuel flows to the injector End of Injection On the return stroke when the plunger helix reaches the timing sleeve s spill p...

Страница 10: ...area to eliminate rocker to bracket contact During disassembly difficulties removing the shafts may be experienced This is due to the slight interference fit in the bracket holes which may be compoun...

Страница 11: ...emble tracks on the fuel pump lobe These are track marks from the fuel pump s roller lifter This is a normal characteristic of this design Camshaft Gear Timing Correct camshaft timing is shown at the...

Страница 12: ...has the engine configuration number cast on the crankshaft for identification Each rod journal has its own set of counter weights to simplify balancing and help reduce crankshaft vibrations Certain L...

Страница 13: ...ins 5 main bearings The caps are identified as detailed below 4L 3L 1 F 1 F 2 2 3 C 3 C 4 R 4 C and a s 5 R has oil pump pick up tube hole The engine block uses cast in place rather than removable lin...

Страница 14: ...available for warranty repairs in standard size only If the engine is out of warranty pistons are available for cylinders bored 010 over Boring the cylinders and use of oversize pistons is not approv...

Страница 15: ...g and replacing the connecting rod assemblies be sure to install the connecting rod with the Isuzu Logo facing the same direction as the piston s forward notch IMPORTANT The rod cap bolts are not to b...

Страница 16: ...ea The sealing bead surrounding the cylinders of the gasket is stainless steel It protects the head gasket from the high cylinder pressures The sealing bead also protects the gasket from the high temp...

Страница 17: ...e The service limit for this engine is 370 psi 26 0 kg cm2 Standard pressure is 441 psi 31 0 kg cm2 Isuzu allows an 8 variance between cylinders on compression tests but there can be no more than a 15...

Страница 18: ...The pump is mounted to the front of the engine block and driven by the crankshaft On the pump s exterior housing there are two lugs machined for dowel pins This enables the pump to be repositioned in...

Страница 19: ...sel 18 Lubrication continued Below is the oil full flow diagram Note the valve opening pressure for the oil filter bypass valve 14 PSI is where the valve begins to open The same is true for the oil pu...

Страница 20: ...cularly in hot spots to the cooling system It is absolutely required that you use a low silicate formula anti freeze Do not add any additional water pump lubricants to the cooling system Refer to the...

Страница 21: ...essurize the pump Then rotate the engine clockwise until fuel quits flowing out of the holder This is the beginning of the injection NOTE Remember that the injection pump uses shims to advance or reta...

Страница 22: ...inder Number 1 2 3 4 Valve Arrangement I E I E I E I E Valve Numbers 4 4 4 4 Loosen the adjuster jam nut insert a 0 40 mm 0 016 feeler gauge in between the rocker tips and the valve stems to adjust th...

Страница 23: ...idue and carbon build up on the surface of the nozzle using Zexel cleaning kit 1057790010 Soak all parts other than the nozzle in cleaning oil Use a soft wire brush to clean excessively dirty parts IM...

Страница 24: ...e nozzle Clean the seat s surface and shaft section using the piece of hardwood from the cleaning kit or a clean soft cloth dipped in oil Likewise clean the spray hole with the special needle also sup...

Страница 25: ...o center the nozzle in the retaining nut For reassembly torque specifications see Appendix Nozzle Holder Tightening Standards NOTE Use a flare nut crowfoot socket on the torque wrench When installing...

Страница 26: ...eck the opening pressure When the pressure gauge pointer decreases rapidly read pop off value Refer to engine s specification sheet for values An Indirect Injection will have lower readings than a Dir...

Страница 27: ...replace any nozzle that doesn t meet the criteria Glow Plug Inspection The following procedure tests the resistance value of the glow plug NOTE The test can be performed on or off the engine Total glo...

Страница 28: ...the hot plug knock ball 1 with the cylinder head groove 2 and tap it temporarily into position with a plastic hammer NEW PLUG Place a 1 thick metal plate over the top of the hot plug and press fit the...

Страница 29: ...Fan Belt Deflection Tension 8 0 mm 12 mm 0 3 0 5 in Glow Plug Resistance 0 7 0 9 These specifications vary depending upon the type of equipment in which the engine is being installed Only use API clas...

Страница 30: ...urface to the top of the valves Specification is for both intake and exhaust valves Short Block Specifications Standard Service Limit Main Bearing Bore Diameter 55 98 mm 2 2039 in 56 0 mm 2 2047in Cyl...

Страница 31: ...must not be reused New bolts only Clarification On the second step turn 60 and no less but up to an additional 30 Short Block Specifications Kg m lb ft Crankshaft Bearing Cap 8 5 9 5 61 5 68 7 Rod Bea...

Страница 32: ...d TB1207C Oil Seal Retainer TB1207C Connecting Rod Bolts Engine Oil Cylinder Head Bolts Engine Oil Main Cap Bolts Engine Oil Head Gasket Exhaust Gasket Oil Pump O ring Engine Oil Oil Strainer O ring E...

Страница 33: ...BTDC Fan Belt Deflection Tension 8 0 mm 12 mm 0 3 0 5 in Glow Plug Resistance 0 7 0 9 These specifications vary depending upon the type of equipment in which the engine is being installed Only use API...

Страница 34: ...head surface to the top of the valves Specification is for both intake and exhaust valves Short Block Specifications Standard Service Limit Main Bearing Bore Diameter 55 98 mm 2 2039 in 56 0 mm 2 2047...

Страница 35: ...owing sequence Bolts must not be reused New bolts only Clarification On the second step turn 60 to 90 Short Block Specifications Kg m lb ft Crankshaft Bearing Cap 8 5 9 5 61 0 69 0 Rod Bearing Cap 4LB...

Страница 36: ...d TB1207C Oil Seal Retainer TB1207C Connecting Rod Bolts Engine Oil Cylinder Head Bolts Engine Oil Main Cap Bolts Engine Oil Head Gasket Exhaust Gasket Oil Pump O ring Engine Oil Oil Strainer O ring E...

Страница 37: ...irectly related to combustion gases passing through the nozzle holder spring chamber Problem can be avoided be routine inspection of the nozzles Description Broken coil due to oxidation caused by mois...

Страница 38: ...ustion chamber Description Nozzle seat damage caused by metal contaminants in the fuel that pressed onto the seat area The condition can cause leaks or distorted spray patterns from improper nozzle se...

Страница 39: ...tions when the nozzle holder is over tightened Cylinder Block Description Damaged head gasket cylinder head pistons connecting rods and crankshaft caused by poor cylinder block casting cooling system...

Страница 40: ...excessive piston to wall clearance Creates piston slap sound Description Seized piston skirt due to insufficient piston to wall clearance a k a piston galling Description Failed piston due to lack of...

Страница 41: ...onent Failure Analysis U L Series Diesel 40 Piston Failure Description A wrist pin seized in this bore due to a previously used bent wrist pin or damaged piston pin bore Description Normal piston skir...

Страница 42: ...VII Appendix Miscellaneous Service Information U L Series Diesel 41 NOZZLE...

Страница 43: ...VII Appendix Miscellaneous Service Information U L Series Diesel 42...

Страница 44: ...VII Appendix Miscellaneous Service Information U L Series Diesel 43...

Страница 45: ...VII Appendix Miscellaneous Service Information U L Series Diesel 44...

Страница 46: ...olts or leaking gaskets 4 Check the intake and exhaust systems for restriction i e dirty air cleaner collapsed hose or crushed exhaust pipe 5 Check the fuel system i e air in the fuel dirty fuel inlet...

Страница 47: ...re more than 2 in The manometer pickup tube is inserted into the oil level gauge tube from which the level gauge has been removed Do not insert the tube into the oil Do not attempt to seal engine open...

Страница 48: ...mG G 3 max B Heptane Insoluble Wt 3 max Resin Insoluble Wt Reference 1 max Ash Sulfate Wt Reference 0 5 max Diesel Fuel Content Wt 5 max Water Content Wt 5 max Worn Metal particle Fe PPM 150 Worn Meta...

Страница 49: ...B EPA and other applicable emission standards well into the future If one looks at the global automotive picture it is estimated that fully 90 percent of the vehicular diesel engines will be direct in...

Страница 50: ...d for an extra measure of noise reduction Isuzu feels it has accomplished something with respect to sound quality as well as sound level Both the 3LD2 and the 4LE2 direct injected diesels are naturall...

Страница 51: ...__________________________________________________________________ __________________________________________________________________________ __________________________________________________________...

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