wheel ISUZU TF SERIES 2004 Workshop Manual

6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.


Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0


Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.


015LX113 020R100001
020RY00034
020RY00035

ENGINE MECHANICAL 6A – 115



RTW46ASH002201




















4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracke
t
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.


Injection pump Bracket Bolt Torque (6) N·m(kg·m/lbft)
19 (1.9/14)

Injection pump Bracket Bolt Torque (5) N·m(kg·m/lbft)
40 (4.1/30)



030RY00007














24. Water Pump
1. Apply the recommended liquid gasket or its equivalent
to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.


Water Pump Bolt Torque N·m(kg·m/lbft)
20 (2.0/14)













25.Timing Gear Case Cover
1.
Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.


Gear Case Cover Bolt Torque N·m(kg·m/lbft)
M8 19 (1.9/14)
M12 76 (7.7/56)

























26. Crankshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.


Crankshaft Damper Pulley Bolt Torque N·m(kg·m/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.


014R100014 020R300004

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 – 11
5. Install the filler neck to the body with bolt.
6. Install the inner liner of the wheel house at rear left side.
7. Remove lifter from the fuel tank.
8.
Lower the vehicle.
9.
Tigten the filler cap until at least three clicks.
10.
Connect the battery ground cable.

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.

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

6E–72 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
High Pressure Fuel Circuit
In addition high pressure generating device, the high
pressure circuit also consists of fuel piping, and devices
to set the beginning of injection and fuel injection
quantity.
The main components are as follows.
High pressure generation: Radial Plunger High
Pressure Pump
Fuel distribution: Distributor Head
Beginning of injection timing: Timing Device
Prevention of secondary injection: Constant Pressure
Valve (CPV)
Pump Camshaft Speed Sensor
When the drive shaft rotates, the pump camshaft speed
sensor receives signal form the sensor wheel, and an
electric pulse is sent through the flex ible connecting
harness to the pump control unit (PSG).
From these signals the pump control unit (PSG) can
determine the average pump speed and the momentary
pump speed.
The pump camshaft speed sensor is mounted to the
cam ring. Thus, the relationship between the cam ring
and the pump camshaft speed sensor signal is
constant. (1) Pump Control Unit (PSG)
(2) Distributor Head
(3) High Pressure Solenoid Valve
(4) Constant Pressure Valve (CPV)
(5) Radial Plunger High Pressure Pump
(1) Pump Camshaft Speed Sensor
(2) Sensor Wheel
(3) Pump Camshaft Speed Sensor Retaining Ring
(4) Flex ible Connector Harness
(5) Drive Shaft

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–209
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
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.
If the CKP sensor harness or sensor malfunction is
detected during engine run, DTC P0335 (Symptom
Code B) is stored.
If the CKP sensor harness or sensor malfunction is
detected during engine cranking, DTC P0335
(Symptom Code D) is stored.
If the CKP sensor signal frequency is ex cessively high
or engine over-running, DTC P0335 (Symptom Code E)
is stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the “Engine Speed” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit Malfunction
Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
43 P0335 B ON Crankshaft Position Sensor
Circuit Ma lfunction1. Engine speed is more than
665rpm.
2. CKP sensor pulse width
e rro r.When pump camshaft speed
senso r is OK:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
When pump camshaft speed
senso r is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
D ON Crankshaft Position Sensor
Circuit Ma lfunction1. No pump camshaft speed
se nsor erro r.
2.“Cranksha ft Position Se n-
so r Circuit Ma lfunction
(Symptom Code B)” is not
stored.
3. Engine speed is 0rpm.
4. Do uble d pump camsha ft
speed is more than 50rpm.When pump camshaft speed
senso r is OK:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
Other tha n pump camsha ft
speed sensor is OK:
Fuel inje ctio n qua ntity is
reduced.
E ON Engine Speed Input Circuit
Range/PerformanceEngine spe ed is more tha n
5700rpm.When intermittent malfunction:
1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
When preliminary malfunction:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check

6E –212 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
9 Using the DVM and check the CKP sensor circuit.
1. Ignition “On ”, engine “Off ”.
2. Disconnect the CKP sensor connector.
3. Check the circuit for short to power supply circuit.
If the DVM indicated out of specified value, repair
faulty harness and verify repair.
Is the action complete?
Less than 1V Verify repair —
10 Using the DVM and check the CKP sensor signal. 1. Ignition “On ”, engine “On ”.
2. Measure the CKP output voltage at the sensor and ECM.
Does the tester indicate standard voltage?
If a oscilloscope is available, monitor the CKP sensor
signal. Does the oscilloscope indicate correct wave
form?
Go to Step 13 Go to Step 11
11 Remove the CKP sensor from the flywheel housing and visually check.
Check for the following conditions.
 Objects sticking the CKP sensor.
 Objects sticking the CKP sensor pulser.
If a problem is found, repair as necessary.
Was the problem found? —Verify repair Go to Step 12
12 Check the CKP sensor shield wire for open or short circuit.
Was the problem found? — Repair faulty
harness and verify repair Go to Step 13
Step Action Value(s) Yes No
1
2
VV
E-9
Measurement Point Voltage (V) (AC Range)
At CKP se nso r te rminal 2 & 1 Appro ximate ly 1.1 V a t 2000rpm
At ECM C57 co nnecto r 90 & 98
Cra nksha ft Po sitio n (CKP) Sensor Refe rence Wav e Form
0V 
Mea sure me nt Terminal: 90(+) 98(-)
Measurement Scale: 20V/div 2ms/div
Mea sure me nt Co ndition: Approx imately 2000rpm