low oil pressure ISUZU KB P190 2007 Workshop Workshop Manual

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-343
Excessive Smoke (Black Smoke)
ChecksAction
Definition:
Black smoke under load, idle or start up hot or cold.
Preliminary Check • Ensure the vehicle has an actual problem.
• Inspect the ECM grounds for being clean, tight, and in their proper locations.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or restricted. Replace as necessary.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Inspect the programmed fuel injector ID code for each cylinder.
• Inspect the Scan Tool Data List in this section.
• Inspect the Service Bulletin.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the Scan Tool
Data List in this section.
• Compare the Coolant Temperature with the Intake Air Temperature (IAT) and Fuel Temperature (FT) parameters on a cold engine condition. If the difference among
temperature reading is more than 5 °C (9 °F) on a cold engine, check for high
resistance in each circuit or for a skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT may indicate
a higher than normal intake air temperature if the ignition switch is being ON.
• Observe the MAF parameter for a skewed or slow MAF sensor.
• Observe the Fuel Rail Pressure (FRP) Sensor parameter with the engine OFF. The FRP Sensor should read 0.9 to 1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1 minute. If not, check for high
resistance in each circuit or for a skewed sensor.
• Observe the Fuel Rail Pressure and Desired Fuel Rail Pressure parameter between idle and W.O.T. (accelerator pedal full travel) in Neutral. Fuel Rail Pressure
parameter should follow within ±5 MPa ( ±725 psi) quick enough.
• Observe the Barometric Pressure (BARO) parameter. The BARO parameter should indicate near surrounding barometric pressure. Refer to Altitude vs. Barometric
Pressure. (Standard output)
• Observe the Boost Pressure and BARO with ignition ON and engine OFF. Both parameters should be within the 7.0 kPa (1.0 psi) each other. (High output)
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Fuel injectors. Remove the injectors and visually inspect.
• Perform the Cylinder Balance Test with a scan tool.
• Perform the Pilot Injection Control with a scan tool.
• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
• A restriction or damaged at MAF sensor.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer to turbocharger inspection in the Engine Mechanical section.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-345
Excessive Smoke (White Smoke)
ChecksAction
Difinition:
White smoke under load, idle or start up hot or cold.
Preliminary Check • Ensure the vehicle has an actual problem.
• Inspect the ECM grounds for being clean, tight, and in their proper locations.
• Inspect the fuel quality (cetane index).
• Inspect the programmed fuel injector ID code for each cylinder.
• Inspect the Scan Tool Data List in this section.
• Inspect the Service Bulletin.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the Scan Tool
Data List in this section.
• Compare the Coolant Temperature with the Intake Air Temperature (IAT) and Fuel Temperature (FT) parameters on a cold engine condition. If the difference among
temperature reading is more than 5 °C (9 °F) on a cold engine, check for high
resistance in each circuit or for a skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT may indicate
a higher than normal intake air temperature if the ignition switch is being ON.
• Observe the Fuel Rail Pressure (FRP) Sensor parameter with the engine OFF. The FRP Sensor should read 0.9 to 1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1 minute. If not, check for high
resistance in each circuit or for a skewed sensor.
• Observe the Fuel Rail Pressure and Desired Fuel Rail Pressure parameter between idle and W.O.T. (accelerator pedal full travel) in Neutral. Fuel Rail Pressure
parameter should follow within ± 5 MPa ( ± 725 psi) quick enough.
• Observe the Accelerator Pedal Position (APP). APP parameter should change linearly from 0 to 100% according to the accelerator pedal operation.
• Observe the Boost Pressure and Barometric Pressure (BARO) with ignition ON and engine OFF. Both parameters should be within the 7.0 kPa (1.0 psi) each other.
• Crankshaft position (CKP) sensor is tight and the sensor rotor is not damaged.
Fuel System Checks • If excessive smoke is present, check for a stuck open fuel injector. Inspect for fuel
leakage into the combustion chamber.
• Fuel injectors. Remove the injectors and visually inspect.
• Perform the Cylinder Balance Test with a scan tool.
• Perform the Pilot Injection Control with a scan tool.
• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
• A restriction or damaged at MAF sensor.
• Perform the Swirl Control Solenoid Test with a scan tool. Inspect the diaphragm valve operation when it commanded ON/ OFF.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Oil leak from turbocharger. Refer to turbocharger inspection in the Engine Mechanical
section.

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6-8 ENGINE DIAGNOSIS (C24SE)
Condition Possible cause Correction
Engine overheating Level of Engine Coolant too low Replenish
Thermo switch or fan motor
defective Replace
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 Change or replenish

Resistance in exhaust system
increased Clean exhaust system or replace
defective parts
Throttle Position Sensor
adjustment incorrect Adjust Wide Open Throttle switch
setting
Throttle Position Sensor circuit
open or shorted Correct or replace

Cylinder head gasket damaged Replace
Cooling Fan clutch defective Replace
Fan belt slipping Adjust tension of V-belt or replace
V-belt
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 92 °C (197.6 °F))
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 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 Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crankshaft out of round Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crank bearing seized Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing


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6-12 ENGINE DIAGNOSIS (C24SE)
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 Retighten or replace gasket

Head cover retaining bolts loose
or gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace
Oil filter attaching bolt loose or
rubber gasket broken Retighten or replace oil filter

Crankshaft front or rear oil seal
defective Replace oil seal

Oil pressure unit loose or broken Retighten or replace
Blow-by gas hose broken Replace hose
Engine/Transmission coupling
area Replace oil seal
Oil leaking into combustion
chambers due to poor seal in
valve system Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion
chambers due to poor seal in
cylinder parts Cylinders and pistons worn
excessively Rebore cylinder and replace
pistons and others
Piston ring gaps incorrectly
positioned Correct

Piston rings set with wrong side
up Correct

Piston rings sticking Rebore cylinder and replace
pistons and others
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Crank case ventilation, Positive
Crankcase Ventilation System
malfunctioning Positive Crankcase Ventilation
Hose clogged Clean
Others
Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving
and or severe usage such as
trailer towing Continuous high speed operation
and or severe usage will normally
cause increased oil consumption


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ENGINE DIAGNOSIS (C24SE) 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 Refer to "Abnormal Combustion"

Fuel cut function does not act Refer to "Abnormal Combustion"
Trouble in ignition system Misfiring or abnormal combustion
due to trouble in ignition system Refer to Hard Start or Abnormal
Combustion Troubleshooting
Guide
Others Engine idle speed too high Reset Idle Air Control Valve
Returning of accelerator control
sluggish Correct

Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear
incorrect 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 Replace
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
rebore cylinders
Oil not reaching valve system Oil passage in cylinder head or cylinder body clogged 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.

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ENGINE MECHANICAL (C24SE) 6A-11
Main Data and Specifications
Engine - General C24SE
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) 4-87.5 ×100.0 (3.44 ×3.93)
Bore Spacing(C/L to C/L) 93.0 mm (3.66 in)
Firing Order 1-3-4-2
Bore×Stroke mm (in) 87.5 ×100.0 (3.44 ×3.93)
Total piston displacement cm3 (in3) 2,405(146.80)
Combustion Chamber Volume 43.3cm3
No. of piston ring Compression ring: 2, Oil ring: 1
Compression pressure kg/cm2 (psi/pa) 12.2-16.3 (174-232/1200-1600)
Ignition timing (BTDC) No adjustment
Idling speed: rpm(W O/AC,W /AC) A/C off 825
Valve clearances (At cold)
Intake mm (in) 0 (0) (Hydraulic valve lash adjustment)
Exhaust mm (in) 0 (0) ( " )
Open at (BTDC) deg 17°30’
Close at (ABDC) deg 76°30’
Exhaust valves
Open at (BBDC) deg 58°30’
Close at (ATDC) deg 35°30’
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 4-4.6 (56.9-65.4/400-450)
Oil pump type Gear
Oil filter type Cartridge full flow
Oil capacity lit. (US/UK gal.) 4.25
Cooling system
Radiator type Corrugated fin with reserve tank
Coolant capacity lit.
(US/UK gal.) 2.3 (0.66/0.55)
W ater pump type
Centrifugal
Thermostat W ax pellet with jiggle hole

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ENGINE MECHANICAL (C24SE) 6A-13
Valve System C24SE
Actuation Type Direct-acting Inverted Bucked Tappet
Valve Clearance Adjustment Hydraulic
Valve Rotor Type None
Inlet-Valve Material Chromium Alloyed Steel
-Seat Insert MaterialSintered Iron
Exhaust-Valve Material Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated
-Seat Insert MaterialSintered Iron
Valve Spring Material GME 06 100-C1
Valve Guide Material QS 13 MR 00
Valve Seal Type Lip

Water Pump C24SE
Type Centrifugal
Drive-Material &Type HNBR Toothed-belt
Bearing Type Double Row Ball
Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C24SE
Type Bypass

Oil Pump & Filter C24SE
Type Gear Pump
Location Front of Engine
Drive Direct Crankshaft Driven
Filter Type Full Flow with Bypass for blocked filter

Oil & Oil Reservoir C24SE
Reservoir-Description & Location 1-piece below Engine
Reservoir Material Aluminum Alloy (pressure cast)
Replacement Oil Fill Volume
-W ith Filter change4.25liters
-W ithout Filter change 4.00liters
Recommended Oil-Run-in 10W /30SG
-Service (above-18°C) 10W /40SG
-Service (below-18°C) 5W /30SG
Oil Classification API&CCMC

Ignition Components C24SE
Spark Plugs Conventional
Type Electronic Spark Control
No. of Coils &Type 2 Solid State
Coil Location Engine-mounted
Ignition Lead Type Inductive (hi-resistance)



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ENGINE MECHANICAL (C24SE) 6A-59






Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx. 15mm/0.6in.).







Oil Filter
Removal
1. Remove oil filter using commercially available tool.

Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.



Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil pump from cylinder block, and oil pressure switch from
oil pump.










Clean
Sealing surfaces

Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.

Tighten (Torque)
Oil pressure switch to oil pump - 30 N ⋅m (3.2 kgf ⋅m)
Oil pump to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil intake pipe to oil pump - 8 N ⋅m (0.8 kgf ⋅m)
Intake pipe bracket to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)


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ENGINE MECHANICAL (C24SE) 6A-77
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change* (litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating temperature (>70°C oil and
approx. 80 °C coolant)
450 - 500 kpa
Oil drain plug M14 × 1.5


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6A-78 ENGINE MECHANICAL (C24SE)
Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 8


Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10
°
°°
°
C
Quantity in litres Up to-20
°
°°
°
C
Quantity in litres Up to-30
°
°°
°
C
Quantity in litres Up to-40
°
°°
°
C
Quantity of litres
(in litres) Water (80%) An ti -
Freeze (20%) Water
(66%) An ti -
Freeze (34%) Water
(56%) An ti -
Freeze (44%) Water
(48%) An ti -
Freeze (52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8


Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm


Radiator cap

Boiling point 123°C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)


Thermostat

Start of opening 92°C
Fully opened 107°C
Type Bypassed


Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W /O catalytic converter system)
*** Ignition timing adjustment not possible.

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