engine remove ISUZU TF SERIES 2004 User Guide

5C-26 BRAKES


A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the master
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinder
and brakes, then the brake system served by the disconnected
pipe must be bled.

1. Set the parking brake completely, then start the engine.
NOTE :
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.

3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation
4. Always use new brake fluid for replenishment.
5. In replenishing rake fluid, take care that air bubbles do no
t
enter the brake fluid.


When the master cylinder is replaced or overhauled, firs
t
bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.


Bleeding the Master Cylinder
6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with
your finger, where the pipe was disconnected then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake
pedal returns completely.
10. Repeat steps 7 through 9 until the brake fluid comes out o
f
the delivery port during step 7.
NOTE : Do not allow the fluid level in the reservoir to go below
the half-way mark.
11. Reconnect the brake pipe (1) to the master cylinder and
tighten the pipe.
12. Depress the brake pedal slowly once and hold it depressed.
13. Loosen the rear wheel brake pipe (1) at the master cylinder.
14. Retighten the brake pipe, then release the brake pedal
slowly.

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

ELECTRICAL-BODY AND CHASSIS 8A-19
Battery-1

BATTERY
Inspection
1. Check the battery terminals 1 for corrosion.
2. Check the battery cables
2 for looseness.
3. Check the battery case
3 for cracks and other damage.
4. Check the battery electrolyte level.

Battery-2

Battery Replacement
1. Disconnect the battery ground cable 1.
2. Disconnect the battery positive cable
2.
3. Remove the battery clamp
3.
4. Remove the battery
Caution:
It is important that the battery ground cable be removed
first.
Removing the battery positive cable first can result in a
short circuit.


Jump Starting the Engine with a Booster Battery
The following description assumes that you are using a booster
battery mounted on a second vehicle.
The listed steps (with some minor modifications) are also
applicable if you are using a naked booster battery or special
battery charging equipment.

ELECTRICAL-BODY AND CHASSIS 8A-21

Caution:
Do not attach the booster cable to the discharged battery
negative terminal.

11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.

ELECTRICAL-BODY AND CHASSIS 8A-105
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
C24SE

Removal
1. Lift both the ECM harness connector locking levers and
remove the two harness connectors form the ECM.
2. Remove the four socket head screws securing the ECM to
the mounting bracket.
3. Remove the ECM from the engine compartment
.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-106 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
6VE1
Removal
1. Pull both the red ECM harness connector locks toward the
front of the vehicle, and remove the two harness connectors
form the ECM.
2. Remove the four hex-head screws securing the ECM to the
common chamber.
3. Remove the ECM from the engine compartment.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

ELECTRICAL-BODY AND CHASSIS 8A-107
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
4JA1-TC / 4JH1-TC


Removal
1. Remove the passenger side front seat – refer to Section 10
CAB.
2. Remove the passenger side front door opening scuff plate.
3. Raise the carpet to gain access to the four hex-head bolts
securing the ECM and ECM cover to the floorpan
.
4. Remove the four hex-head bolts.
5. Pull the two harness connector locks away from the
harness connectors and then remove the connectors form
the ECM.
6. Remove the ECM from the vehicle.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”







Installation
Follow the removal procedure in the reverse order to install the
ECM.
Torque passenger seat securing bolts to the specified value –
refer to Section 10 CAB
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-108 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


FUEL PUMP
Removal
1. Remove the fuel tank.
Refer to the Section 6C-ENGINE FUEL of this Manual.

Disconnect the fuel pipe.





Installation
Follow the removal procedure in the reverse order to install the
fuel pump.
Pay close attention to the important points mentioned in the
following paragraphs.



Rubber Seal
Be absolutely sure that the fuel pump rubber seals correctly
seated.

Connector
Be absolutely sure that the fuel pump connector is securely
connected.
This will prevent a poor contact and an open circuit.

8A-212 ELECTRICAL-BODY AND CHASSIS
Windshield Washer Spray
Be sure that the engine hood is completely closed before
checking the windshield washer spray adjustment.
Windshield Washer Spray Position: Refer to the illustration.

RTW38DSF000201



Connector
Be absolutely sure that the wiper motor connector is securely
connected.
This will prevent a poor contact and an open circuit.


Note:
Windshield wiper arm and blade assembly configurations
are different for the right-hand and left-hand side of the
vehicle.
Be careful not to confuse the right-hand and left-hand side
assemblies.



This illustration is based on RHD model
WASHER TANK MOTOR
Removal
1. Remove the head light.

Refer to the head light in this manual.
2. Remove the inner riner.
3. Pull out the clip washer filler.
4. Remove the washer tank nuts.

8A-278 ELECTRICAL-BODY AND CHASSIS
Low Fuel Indicator Light Inspection
1. Disconnect the fuel tank unit wire connector.
2. Turn the key switch on. Check that the bulb lights.
If operation is not correct, remove and check the bulb or circuit.
or If check whether low fuel turns on fuel input (B-24) at the
time of open and key on.
 meter is check at low fuel
140R300006





Check level sensor operation
1. Remove the fuel tank unit.
2.
Apply battery voltage between terminal (B) and (C) through
a 1.12 watt bulb. Check that the bulb lights.
Note:
It will take a short time for the bulb light.
3. Submerge the sensor in fuel. Check that the bulb goes out.
If operation is not correct, replace the fuel tank unit.

BRAKE SYSTEM WARNING LIGHT
The brake system warning light comes on while the parking
brake is set and the engine run position.
Note:
The parking brake indicator light circuit is designed to
prevent driving of the vehicle with the parking brake on.
It does not indicate the condition of the parking brake
system.



The parking brake switch is in parallel with the brake fluid
switch.



The brake system warning light also comes on when reservoir
brake fluid level falls below the specified limit with the parking
brake released and the engine run position.