oil ISUZU TF SERIES 2004 Workshop Manual

6D – 12 ENGINE ELECTRICAL
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.

ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting. Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter mm (in)
Standard Limit



RTW06DSH000101
31.6 (1.245) 30.6 (1.183)















If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.

3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20 C (68 F) ohms
Standard 3.8



RTW46DSH001001







RTW46DSH001101
4. Check for continuity between the slip rings and the
rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.

ENGINE ELECTRICAL 6D – 13
STATOR COIL ASSEMBLY
1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal “N” and the Coil Ends
(Reference) ohms
Standard 0.1

066RY00022 2. Check for continuity between each stator coils and the
stator core.
If there is continuity, the stator coils must be replaced.
066RY00023


RTW46DSH004801
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference) mm (in)

Standard Limit
25 (1.0) 6.5 (0.25)



RTW46DSH001201
Rectifier


Tester wire
E BAT
U, V, and WN ⊕  U, V, and WN⊕ 
⊕ ----- Conductivity ⊕ ----- No
conductivity

No
conductivity -----
 Conductivity -----
Negative side diode check Positive side diode check

ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.


Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside
holes.
2. Use the insertion tool to press the new oil seal into
place. Follow the procedure shown in Figures A, B, C
and D.

Position the oil seal beneath the shaft and the
guide lip.

Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.

After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution





Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.





Take care not to damage the D surface.





Under no circumstances may the original oil seal
be reused.





The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.







RTW46DSF000101

ENGINE ELECTRICAL 6D – 19


RTW46DSH000401
Important Operations
2. Rear rotor bearing

Re-use improper parts.


5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.



RTW46DSH002101







3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque Nm (kgm/lbft)
83.3  98.0 (8.5  10.0 / 61  72)





RTW46DSH006001
Remove the tape from the splines.









RTW46DSH004901
The rear ball bearing is pressed into the wheel eccentric
groove. The bearing ring projects from the groove.

During installation, rotate the bearing to the point of
minimum bearing ring projection.

Inspect the rear cover bearing box and replace it if it is
damaged.

ENGINE ELECTRICAL 6D – 21




RTW06DSH000201











9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque Nm (kgm/lbft)
3.1  3.9 (0.32  0.41 / 2.6  3.5)


11. Vaccum Pump
To install the generator -

1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the
3 generator fixing points.
3. Twist the fixing points down and to the left to align
them with the middle of the center plate and the rotor.




RTW46DSH006101
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.



RTW46DSH002401
Install the vacuum pump housing.
Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.



RTW46DSH002501













Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque Nm (kgm/lbft)
5.9  6.9 (0.6  0.7 / 5.2  6.1)

ENGINE ELECTRICAL 6D – 27


RTW46DSH003701
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two
commutator segments.
2 Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the commutator.
If there is not, the armature must be replaced.




RTW46DSH003801
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.



RTW46DSH003901
2. Use the circuit tester to check the field winding
continuity.
1 Hold one circuit tester probe against the “M”
terminal lead wire.
2 Hold the other circuit tester probe against the field
winding brush.
There should be continuity.
If there is no continuity, the yoke must be replaced.

6D – 32 ENGINE ELECTRICAL


MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).





RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.




RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.




RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.

6E–66 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Throttle Position Sensor (TPS)
The TPS is a potentiometer connected to throttle shaft
on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
delivery based on throttle valve angle.
Crankshaft Position (CKP) Sensor
The CKP sensor is located on top of the flywheel
housing of the flywheel and fix ed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
ex citer ring and is used to determine the engine speed
and engine cylinder top dead center (TDC). (1) Throttle Position Sensor (TPS)
(2) Idle Switch

1 2
Characteristic of TPS -Reference-
0 0.51 1.52 2.53 3.54 4.5
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pedal Position (%) (Tech2 Readin
g
Output Voltage (V)
(1) Crankshaft Position (CKP) Sensor
(2) Fly wheel with sensor slot

1 2

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–73
The pump camshaft speed sensor signal is utilized for
the following purposes.
To determine the momentary angular position of the
cam ring.
To calculate the actual speed of the fuel injection pump.
To determine the actual timing plunger position.
The pump camshaft sensor signal has a tooth gap, and
the crankshaft position (CKP) sensor on the flywheel
housing is used as a reference signal of engine top
dead center (TDC) for the start timing of fuel delivery or
injection which is to be set.High Pressure Solenoid Valve
Fuel injection quantity control is performed from the
beginning of pressure delivery at the beginning of cam
lift until the high pressure solenoid valve opens at the
end of pressure delivery.
This interval is called the pressure delivery interval.
Accordingly, the interval that the high pressure solenoid
valve is closed determines the fuel injection quantity
(high pressure fuel supply ends when the high pressure
solenoid valve opens).
-Cam Ring Angle
Sensor -Pump Speed
Wheel -Timer PositionPump
Control
Unit
(PSG)Pump
Camshaft
Speed
Sensor
(1) Valve Needle
(2) Magnet Anchor
(3) Coil
(4) High Pressure Passage

6E–74 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
When current from the pump control unit (PSG) flows to
the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
When the fuel injection quantity demanded by the
engine is reached, the current to the coil is cut and the
valve needle re-opens the valve seat.
As a result of this, a path is opened for the fuel in the
high pressure passage to the low pressure circuit and
the pressure decreases. With a decrease in injection
pressure the nozzle closes and injection ends.Timing Control Valve (TCV)
The pressure of the fuel fed from the feed pump is
adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
The timing plunger is connected to the cam ring by a
ball pin. Ax ial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing. (1) Valve Needle
(2) Coil
(1) Cam Ring
(2) Servo Valve
(3) Timer Piston
(4) Outlet
(5) Feed Pump
(6) Inlet
(7) Fuel Suction
(8) Ball Pin
(9) Annular Chamber
(10) Hydraulic Stopper
(11) Return Passage
(12) Timing Control Valve (TCV)