section 8 ISUZU TF SERIES 2004 Workshop Manual

6B – 6 ENGINE COOLING



110RS001
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3

122.7 kPa (13.5

17.8 psi) pressure. (No oil cooler provided for M/T)





F06RW005
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system
capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC
See section 0B MAINTENACE AND LUBRICATION.





PTW46BSH000201
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE

6B – 10 ENGINE COOLING

WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.




Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.





031R300003
2. Water Outlet Pipe
1) Disconnect the turbocharger-cooling pipe from outlet pipe.
2) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud

5. Fan and Fan Clutch 1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.

030R300001 7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.

030R300002

ENGINE COOLING 6B – 13
THERMOSTAT
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.

Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.


2. Water Outlet Pipe 3) Disconnect the turbocharger-cooling pipe from outlet pipe.
4) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.

031R300003

Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.


031RY00005
Operating Test of Thermostat
1. Completely submerge the thermostat in water.
2. Heat the water. Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
C (
F)
82 (180)

4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature
C (
F)
95 (203)

Valve Lift At Fully Open Position mm (in)
9.5 (0.37)

FUEL SYSTEM 6C – 1


SECTION 6C
FUEL SYSTEM


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 3
General Description....................................................................................................... 6C - 4
Fuel Flow .................................................................................................................... 6C - 4
Fuel Filter and Water Separator ............................................................................... 6C - 5
Injection Pump ........................................................................................................... 6C - 7
Injection Nozzle ......................................................................................................... 6C - 8
Fuel Tank ........................................................................................................................ 6C - 9
Removal ..................................................................................................................... 6C - 9
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings ........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21

6C – 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW


RTW46CM F000201


The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.

6C – 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dus
t
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7.
Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to“Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9.
Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.
Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.













Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected agains
t
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)
NOTE: The anchor of the tank band must be certainly installed
to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

FUEL SYSTEM 6C – 13

Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.


140R100035

3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4.
Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5.
Discard fuel gauge unit seal (8) because it cannot be
reusable.


Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause o
f
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4.
Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5.
Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7.
Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

6C – 14 FUEL SYSTEM

8.
Check leak.
Methed of leak check.

(1)
Plug end of quick connector and breather hose (Pull of
f
the breather hose from fuel tank) and tighten fuel fille
r
cap until at least one click are heard.
(2)
Apply water soap around the fuel gauge unit seal area.
(3)
Pressure air into the fuel tank from end of breather pipe
at 5psi (34.3 kPa/2.8kgf/cm
2) over 15 seconds.
(4)
Verify no bubbles around the fuel gauge unit seal area.
9.
Install the fuel tank assembly (9).
NOTE: Refer to “Install the fuel tank” in this section.

FUEL SYSTEM 6C – 17
FILLER NECK
Removal
1.
Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2.
Put a marking the following point as the filler neck assembl
y
is restored.


Each joint area of the hose (to restore axial direction and
insertion length of the hose)


Each fasten area of the clamp (to restore axial direction
and position of the clamp)


Each bolt in the clamp (to restore fasten length of bolt in
the clamp)


The band clip (to restore position and fasten length o
f
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.









Installation
1.
Align each marking and restore the following point.


Each joint area of the hose (Restore axial direction and
insertion length of the hose)


Each fasten area of the clamp (Restore axial direction
and position of the clamp)


Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque N·m (kg·m / lb ft)
2.5 (0.25 / 21.7)
filler neck side except flat deck model.


The band clip (Restore position and fasten length of the
band clip)
2.
Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.

FUEL SYSTEM 6C – 19
INJECTION PUMP

REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.



Removal
1. Battery
Remove the battery from the battery tray.



6C-1
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly


P1010003
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.


5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the intake throttle.
6. Fan