belt ISUZU TF SERIES 2004 Workshop Manual

6E–264 ENGINE DRIVEABILITY AND EMISSIONS
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE (ECM)
Location
On the intake manifold.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the two connectors from the ECM.
3. Remove four bolts.
4. Remove the ECM from bracket.
Installation Procedure
1. Put on the ECM to the bracket.
2. Tighten the ECM by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
3. Connect the two connectors to the ECM.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
CRANKSHAFT POSITION (CKP) SENSOR
Location
Left-hand side of the cylinder block. (Back of the A/C
compressor)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive belt. Refer to Engine Mechanical
Section.
3. Remove the A/C compressor from engine. Refer to
Engine Mechanical Section.
4. Disconnect connector from the CKP sensor.
5. Loosen a bolt and remove the CKP sensor from the
cylinder block.
NOTE: Use caution to avoid any hot oil that might drip
out.
Installation Procedure
1. Install the CKP sensor to the cylinder block.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolt: 6N·m (0.6kgf·m)
3. Reinstall the A/C compressor to the engine.
4. Reinstall the accessory drive belt.
5. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:

1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I
(DIESEL) I I I I I I I R I I I I I I I R I I I I * P Engine oil (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil (C24SE) Replace every 12,000km * D Engine oil (4JH1-TC) - R - R - R - R - R - R - R - R - R - R * D Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * D Engine oil (4JA1-T) RR R R RR RRRRRRRR R R R RRR * P Engine oil filter (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil filter (C24SE) Replace every 12,000km * D Engine oil filter (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R * D Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination
(GASOLINE) - I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage I I - I - I - I - I - I - I - I - I - I Fuel tank - - - | - - - | - - - | - - - | - - - | P O2 Sensor Replace every 160,000km P Valve clearances (6VE1) Check and adjust if noisy D Valve clearances A - - A - - - A - - - A - - - A - - - A P Spark plugs (C24SE) (for leaded
fuel use) - R - R - R - R - R - R - R - R - R - R
P Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
P Spark plugs (6VE1) Replace every 160,000km Spark plug wire | | - | - | - | - | - | - | - | - | - | Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R Fuel filter (DIESEL) - - R - - R - - R - - R - - R - - R - - Engi ne / Accessory dri ve belt
(GASOLINE) - - - - - - - - - R - - - - - - - - - R
Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (6VE1) - - - - - - - - - R - - - - - - - - - R (C24SE) - | - | - | - | - R - | - | - | - | - R Engine coolant level concentration
(DESEL) I I I I I I I I I R I I I I I I I I I R
Cooli ng sy stem for water l eakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
P Timing belt (C24SE) - - - - - - - - - - - - - - - I - - - - (Replace every 120,000km) P Timing belt (6VE1) Replace every 160,000km CLUTCH Cl utch fl ui d I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I

MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SCHEDULE (For EUROPE)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil (4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * Engine oil filter(4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - I I I I I I I I I I I I I I I I I I I
Valve clearance (4JH1-TC) - - - A - - - A - - - A - - - A - - - A Valve clearance (4JA1-TC) - - A - - A - - A - - A - - A - - A - - * Air cleaner element (4JH1-TC) I I I I I I I R I I I I I I I R I I I I * Air clearance element (4JA1-TC) - - I I I I I I R I I I I I I I I R I I Fuel filter (4JH1-TC) - - R - - R - - R - - R - - R - - R - - Fuel filter (4JA1-TC) - - - - - - - - R - - - - - - - - R - - Engine coolant concentration (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Engine coolant concentration
(4JA1-TC) - - I - - I - - I - - I - - I - - I - - Cooling system for water leakage
(4JH1-TC) - I - I - I - I - I - I - I - I - I - I Cooing system for water leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - CLUTCH Clutch fluid (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch fluid (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Clutch pedal travel and play (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play (4JA1-TC) - - I - - I - - I - - I - - I - - I - - TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * Manual transmission with fluid
(4JA1-TC) - - R - - I - - R - - I - - R - - I - - * Transfer case oil (4JH1-TC) - - - I - - - I - - - I - - - I - - - I * Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Gear control mechanism for
looseness (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Automatic transmission fluid
(4JH1-TC) - - - I - - - I - - - I - - - I - - - I * AT Automatic transmission fluid (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Transfer case oil (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * AT Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - -

MAINTENANCE AND LUBRICATION 0B-9


Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R* Engine oil filter - - - R - - - R - - - R - - - R - - - ROil leakage and contamination - - - I - - - I - - - I - - - I - - - I Idling speed and acceleration - - - I - - - I - - - I - - - I - - - I Fan belt tension and damage - - - I - - - I - - - I - - - I - - - I Exhaust system - - - I - - - I - - - I - - - I - - - I All hoses and pipes in engine
compartment for clog of damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
Valve clearance - - - A - - - A - - - A - - - A - - - A * Air cleaner element - - - I - - - I - - - R - - - I - - - I Fuel filter - - - - - - - - - - - R - - - - - - - - Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid - - - I - - - I - - - I - - - I - - - I Clutch pedal travel and play - - - I - - - I - - - I - - - I - - - I TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* AT Automatic transmissi on fl ui d - - - - - - - - - - - I - - - - - - - - * AT Transfer case oil - - - R - - - I - - - R - - - I - - - R PROPELLER SHAFT Loose connections - - - I - - - I - - - I - - - I - - - I * Universal joints and splines for wear - - - I - - - I - - - I - - - I - - - I 4WD Universal joints and sliding
sleeve - - - L - - - L - - - L - - - L - - - L
FRONT AND REAR AXLE * Differential gear oil (Front and rear) - - - R - - - I - - - R - - - I - - - ROil leakage - - - I - - - I - - - I - - - I - - - I Shift on the fly system Gear oi l - - - - - - - - - - - I - - - - - - - - Front axle shaft rubber boot for
damage - - - - - - - - - - - I - - - - - - - I
Axle case for distortion or damage - - - - - - - - - - - I - - - - - - - I Axle shafts for distortion or damage - - - - - - - - - - - I - - - - - - - I STEERING Power steering fluid - - - I - - - R - - - I - - - R - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I * Steering system for looseness or
damage - - - I - - - I - - - I - - - I - - - I
Power steering hose - - - I - - - I - - - I - - - R - - - I Steering wheel play - - - I - - - I - - - I - - - I - - - I Steeri ng function - - - I - - - I - - - I - - - I - - - I Right and left turning radius - - - - - - - - - - - I - - - - - - - - Wheel al i gnment - - - - - - - - - - - I - - - - - - - - Joi nt ball for oil l eakage or damage - - - I - - - I - - - I - - - I - - - I Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I

1-40 HEATER AND AIR CONDITIONING
COMPRESSOR
REMOVAL AND INSTALLATION (4J ENGINE)





852R300006
Removal Steps
1. Air duct
2. Magnetic clutch harness connector
3. Lock nut
4. Tension adjustment bolt
5. Drive belt
6. Refrigerant line
7. Bolt; compressor to bracket
8. Compressor assembly

Installation Steps
8. Compressor assembly

7. Bolt; compressor to bracket

6. Refrigerant line
5. Drive belt
4. Tension adjustment bolt
3. Lock nut
2. Magnetic clutch harness connector
1. Air duct

HEATER AND AIR CONDITIONING 1-41
Important Operations - Installation

7. Bolt; Compressor to Bracket
N
m (kgf
m/lb
ft)

Torque 44 (4.5/33)



6. Refrigerant Line
N
m (kgf
m/lb
ft)

Torque 11
19 (1.1/9.5
1.9/14)



Compressor Belt
Check the drive belt tension.
Depress the drive belt mid-portion with a 98N (10kg/22Ib)
force.
mm(in.)

Standard deflection 14~17 (0.55~0.67)

1-42 HEATER AND AIR CONDITIONING

REMOVAL AND INSTALLATION (6VE1)



RTW310MF000301

Removal Steps
1. Magnetic clutch harness connector
2. Compressor belt
3. Refrigerant line
4. Bolt; compressor to bracket
5. Compressor assembly

Installation Steps
5. Compressor assembly

4. Bolt; compressor to bracket

3. Refrigerant line

2. Compressor belt
1. Magnetic clutch harness connector

HEATER AND AIR CONDITIONING 1-43
Important Operations - Installation

4. Bolt; Compressor to Bracket
N
m (kgf
m/lb
ft)

Torque 19 (1.9/14)



3. Refrigerant Line
N
m (kgf
m/lb
ft)

Torque 11
19 (1.1/9.5
1.9/14)

RTW310MH000101

2. Compressor Belt
Move compressor belt tensioner to loose side using
wrench, then install serpentine belt to normal position.

1-44 HEATER AND AIR CONDITIONING

REMOVAL AND INSTALLATION (C24SE)

RTW310MF000401

Removal Steps
1. Magnetic clutch harness connector
2. Compressor belt
3. Refrigerant line
4. Bolt; compressor to bracket
5. Compressor assembly

Installation Steps
5. Compressor assembly

4. Bolt; compressor to bracket

3. Refrigerant line

2. Compressor belt
1. Magnetic clutch harness connector

HEATER AND AIR CONDITIONING 1-45
Important Operations - Installation

4. Bolt; Compressor to Bracket
N
m (kgf
m/lb
ft)

Torque 19 (1.9/14)



3. Refrigerant Line
N
m (kgf
m/lb
ft)

Torque 11
19 (1.1/9.5
1.9/14)



2. Compressor Belt
Move compressor belt tensioner to loose side using
wrench, then install serpentine belt to normal position.