Isuzu 2CA1 / 3CA1 / 3CB1 engine, repair e-manual

Contents

General

• Engine nomenclature
• Specifications
• Fuel oil, lubricating oil and coolant water
• Engine external views
• Structural description
• Exhaust gas emission regulation
• The emission standard in USA
• Engine identification
• Guarantee conditions for the epa emission standard

Inspection and adjustment

• Periodic maintenance schedule
• Periodic inspection and maintenance procedure
• Check before daily operation
• Inspection after initial 50 hours operation
• Inspection every 50 hours
• Inspection every 250 hours or 3 months
• Inspection every 500 hours or 6 months
• Inspection every 1,000 hours or one year
• Inspection every 2000 hours or 2 years
• Adjusting the no-load maximum or minimum speed
• Sensor inspection
• Oil pressure switch
• Thermo switch
• Water leak check in cooling water system
• Radiator cap inspection
• Thermostat inspection
• Adjusting operation
• Long storage

Troubleshooting

• Preparation before troubleshooting
• Quick reference table for troubleshooting
• Troubleshooting by measuring compression pressure

Disassembly, inspection and reassembly of engines

• Complete disassembly and reassembly
• Introduction
• Special service tools
• Complete disassembly
• Precautions before and during reassembly
• Adjusting operation
• Cylinder head
• Valve seat correction
• Valve guide replacement
• Valve stem seal replacement
• Gear train and camshaft
• Oil seal replacement
• Camshaft bushing replacement
• Cylinder block
• Cylinder bore correction
• Piston pin bushing replacement
• Oil seal replacement (flywheel housing side)

Lubrication system

• Lubrication system diagram
• Trochoid pump components
• Disassembly(reverse the procedure below for assembly)
• Servicing points
• Parts inspection and measurement
• Trochoid pump inspection and measurement

Cooling system

• Cooling water system
• Cooling water pump components
• Disassembly (reverse the procedure below for assembly)

Fuel injection pump / governor

• Introduction
• Fuel injection pump
• Fuel system diagram
• External view and components
• Disassembly procedure
• Reassembly procedure
• Confirmation and adjustment of fuel injection timing
• Confirmation and adjustment of no-load maximum and minimum speed

The specifications of a starting motor and the characteristics

• The specifications and the characteristics
• Specifications
• Characteristics
• The structure of a starting motor and the wiring diagram
• Performance

Alternator

• Alternator
• Specifications
• Structure
• Wiring diagram
• Standard output characteristics
• Inspection
• Troubleshooting

Electric wiring

• Electric wiring diagram
• Alternator
• Starter
• Current limiter
• Section area and resistance of electric wire

Service standards

• Engine tuning
• Engine body
• Cylinder head
• Gear train and camshaft
• Cylinder block
• Lubricating oil system (trochoid pump)

Tightening torque for bolts and nuts

• Tightening torques for main bolts and nuts
• Tightening torques for standard bolts and nuts

Customers reviews