section table ISUZU TF SERIES 2004 Repair Manual

MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
TABLE OF CONTENTS
PAGE
Maintenance Schedule (For GENERAL EXPORT) ......................................................... 0B- 2
Maintenance Schedule (For EUROPE) ........................................................................... 0B- 5
Severe Conditions Maintenance Schedule (For GENERAL EXPORT) ........................ 0B-11
Severe Conditions Maintenance Schedule (For EUROPE) .......................................... 0B-12
Recommended Fluids and Lubricants (For GENERAL EXPORT)................................ 0B-13
Recommended Fluids and Lubricants (For EUROPE).................................................. 0B-15
Oil Viscosity Chart ........................................................................................................... 0B-16

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service .......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor ...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier ................................................................................................................... 1- 39
Removal and Installation ............................................................................................ 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE) ...................................................................... 1- 40
Removal and Installation (6VE1) ................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Removal and Installation ............................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Removal and Installation ............................................................................................ 1- 57
Disassembly and Reassembly ................................................................................... 1- 59
Evaporator (With A/C)...................................................................................................... 1- 60
Removal and Installation ............................................................................................ 1- 60
Disassembly and Reassembly ................................................................................... 1- 61

HEATER AND AIR CONDITIONING 1-83

AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE CORRECTION
No cooling or
insufficient
cooling
1. Magnetic clutch does not run


Refer to “MAGNETIC CLUTCH”
troubleshooting in this section
2. Compressor is not rotating properly

Drive belt loosened or broken

Adjust the drive belt to the specified
tension or replace the drive belt


Magnetic clutch face is not clean and
slips
Clean the magnetic clutch face or replace




Incorrect clearance between magnetic
drive plate and pulley

Adjust the clearance (Refer to
“COMPRESSOR OVERHAUL”



Compressor oil leaks from shaft seal or
shell

Replace the compressor




Compressor seized

Replace the compressor

3. Insufficient or excessive charge of
refrigerant

Discharge and recover refrigerant.
Recharge to specified amount.
4. Leaks in the refrigerant system




Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient radiation


Clean the condenser or replace as
necessary


Check radiator or condenser fan function

6. Temperature control link unit of the heater
unit defective

Repair the link unit

7. Unsteady operation due to foreign
substance in expansion valve

Replace the expansion valve

8. Poor operation of electronic thermostat


Check electronic thermostat and replace
as necessary
Insufficient
velocity
of cooling air

1. Evaporator clogged or frosted


Check evaporator core and replace or
clean the core
2. Air leaking from cooling unit or air duct

Check evaporator and duct connection,
then repair as necessary

3. Blower motor does not rotate prop-erly


Refer to “FAN CONTROL KNOB (FAN
SWITCH)” troubleshooting in this section

* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,
RECYCLING, EVACUATING AND CHARGING” in this section.

HEATER AND AIR CONDITIONING 1-85

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Discharge
(High)
pressure
gauge
abnormally
high Reduced or no air flow through
the condenser


Condenser clogged or dirty


Radiator (condenser) fan
does not operate properly

Clean


Check cooling fan
operation
No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)




Excessive refrigerant in
system





Check sight glass.
(See “Reading Sight
Glass”)


Discharge and
recover refrigerant.
Recharge to specified
amount
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28 PSI) quickly

Air in system


Evacuate and charge
refrigerant system
Discharge
(High)
pressure
gauge
abnormally
low Insufficient cooling and excessive
bubbles in the sight glass







Insufficient refrigerant in
system







Check sight glass.
(See “Reading Sight
Glass”)

Check for leaks


Discharge and
recover refrigerant.
Recharge to specified
amount
Low pressure gauge indicates
vacuum

Clogged or defective
expansion valve

Replace the
expansion valve
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum
Restriction caused by debris
or moisture in receiver/drier


Check system for
restriction and
replace receiver/drier

After turning off air conditioning,
high and low pressure gauge
balanced quickly


Compressor seal defective


Poor compression due to
defective compressor
gasket

Replace or repair
compressor
Suction
(Low)
pressure
gauge
abnormally
high Low pressure gauge is lowered
after condenser is cooled by
water


Excessive refrigerant in
system



Discharge and
recover refrigerant
Recharge to specified
amount
Low pressure hose temperature
around the compressor refrigerant
line connector is lower than
around evaporator



Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve


Expansion valve opens too
long

Replace the
expansion valve




After turning off air conditioning,
high and low pressure gauge is
balanced quickly

Compressor gasket is
defective


Replace


Air conditioning turns off before
passenger compartment is
sufficiently
cool
Electronic thermostat
defective

Check the electronic
thermostat and
replace as necessary


* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.

MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION
(MSG MODELS)
TABLE OF CONTENTS
PAGE
Main Data and Specifications .................................................................................... 7B - 2
General Description.................................................................................................... 7B - 3
Torque Specification .................................................................................................. 7B - 4
Repair Kit .................................................................................................................... 7B - 6
Removal and Installation ........................................................................................... 7B - 7
Disassembly ............................................................................................................... 7B - 15
Inspection and Repair ............................................................................................... 7B - 25
Reassembly ................................................................................................................ 7B - 29
Special Service Tool .................................................................................................. 7B - 42

MANUAL TRANSMISSION 7B1-5

Rear Oil Seal (4





2)
Disassembled View
220R300030
Legend

(1) Rear Propeller Shaft (2) Rear Oil Seal

Removal
1. Raise and support vehicle with suitable jack stands.
2. Remove propeller shaft flange yoke bolts and nuts
at the differential side.
3. Remove center bearing from crossmenber.
4. Remove prepeller shaft from the transmission main
shaft spline.
Refre to the section “Rear Propeller Shaft”.
5. Use a screwdriver to pry the rear oil seal from the
rear cover.

Installation
1. Install a new oil seal (2) using the installer 5-8522-
0050-0.



220RS044
2. Insert the splined yoke into the transimission
mainshaft spline.
3. Install the propeller shaft flange yoke to the drive
pinion flange.

11A-32 IMMOBILIZER SYSTEM

Diagnostic Trouble Code (DTC) list with ECM





Immobilizer Control Unit (ICU)
DTC
Description Note
B0001
REPLACE ELECTRONIC CONTROL UNIT
(ECU) (IMMOBILIZER FAULT) This error code appears if a RAM /ROM Error was
detected or the EEPROM is defect.
B0002 IMMOBILIZER NOT PROGRAMMED Immobilizer control unit is not programmed.
B0003 TRANSPONDER KEY PROBLEM

Reading of Transponder information failed with ignition
on transponder has a fault.


Hardware fault in reading circuit.
B0004
IMMOBILIZER COIL CIRCUIT (ANTENNA
COIL FAULT) Immobilizer coil has a fault.
B0005 COMMUNICATION LINE W VOLTAGE LOW Short circuit to ground or open circuit.
B0006 COMMUNICATION LINE W VOLTAGE HIGH Short circuit to 12V.
B0007 NO ENGINE REQUEST RECEIVED No ECM Challenge.
B0008 WRONG TRANSPONDER KEY Incorrect security code response received.
B0009 NO TRANSPONDER KEY PROGRAMMED Transponder security code table empty
B0010 UNKNOWN TRANSPONDER KEY Transponder security code not valid.






Engine Control Module (ECM: Gasoline Engine {6VE1, C24SE})

DTC Description
Note
P1626 No Response From Immobilizer Refer to Engine Control system section
P1631 Received Response Was Not Correct Refer to Engine Control system section
P1648 Received Incorrect Security Code Refer to Engine Control system section
P1649 Security Code & Security Key Not
Programmed Refer to Engine Control system section






Engine Control Module (ECM: Diesel Engine {4JH1-TC, 4JA1-TC})

DTC Description Note
P1610 Seeds and Key File Destroyed Refer to Engine Control system section
P1611 Wrong Security Code Entered Refer to Engine Control system section
P1612/
P1613 Immobilizer No or Wrong Signal Refer to Engine Control system section
P1649 Wrong Transponder Key Refer to Engine Control system section

IMMOBILIZER SYSTEM 11A-35

Step Action Value(s) Yes No
10 Review and record for scan tool Failure Records data
and DTCs.
Was the action complete? 
Go to Step 11 
11 Following the DTC is stored.
Are there DTC B0001 or B0055 stored?
Go to applicable
DTC table after
Go to Step 12 Go to Step 12
12 Clear the DTCs by "Clear the Information "with scan
tool.
Did the DTCs Cleared? 
Go to Step 12 
13 Select "Display DTCs" with the scan tool.
Are any DTCs stored? 
Go to applicable
DTC table Go to Step 14
14 1. Key position is "ON," engine "OFF."
2. Observe the check engine lamp.
Note: If a key switch is turned ON, check engine lamp
will turn on and a check engine lamp will be turned off
after a few seconds.
Is the check engine lamp "flash"? 
Go to Step 15
Go to Step 20
15 Check the engine control system.
If a problem is found, repair as necessary.
(Refer to section 6E: system check and DTCs)
IMPORTANT:
The replacement ECM must be
programmed the immobilizer data by scan tool.
(Except 4JA1-L Engine)
Was the action complete? 
Go to Step 16 
16 Check the key.
Is a key peculiar to a vehicle? 
Go to Step 18
Go to Step 17
17 Change into a peculiar key.
IMPORTANT:
If replace the key,
after replace lock
cylinders, perform the following below the items.

Replace the keys and key cylinders.

Program the immobilizer system.
(Refer to "Important information on Programming")
Was the action complete? 
Go to Step 18 
18 Check the immobilizer programming functions.


Immobilizer control unit (ICU).


Engine control module (ECM).


Transponder (Key).
If a problem is found, repair as necessary.
(Refer to "Important information on Programming")
Was the action complete? 
Go to Step 19

19 Operate the DTCs by "Clear the Information" with
scan tool.
Was the action complete? 
Go to Step 20 
20 Attempt to start the engine.
Did the engine start? 
System OK
Refer to
Diagnostic Aids

ANTITHEFT SYSTEM 11B – 37
Antitheft System Check
Step Action Value (s) Yes No
1
2
3
4
5
6
7
8
91. Key position is “ACC”, shut all doors and
bonnet.
2. Observe the antitheft lamp.
Note: When a key switch is “ACC”, antithft
lamp will turn on and a antitheft lamp (LED)
will be flashing after 10 seconds.
Is the antitheft lamp "ON” or flashing?
1. Key position is “ON”, engine “OFF”.
2. Observe the antitheft lamp.
3. Key position is turned “ACC”.
4. Check the antitheft lamp will be turned
flashing and lamp will be turned ACC after 10
seconds.
Is the antitheft lamp flashing?
1. Key position is “OFF”.
2. Install the Tech-2.
3. Key position is “ON” or “OFF”.
4. Attempt to display antitheft data with the
Tech-2.
Does the Tech-2 display antitheft data?
1. Key position is “OFF”, disconnect the
antitheft control unit (ACU).
2. Check the DLC (Data Link Connector) circuit
for an open, short to ground, or short to
voltage.
Also, check the DLC ignition feed circuit for an
open or short to ground and the DLC ground
circuit for an open.
Was a problem found?
Repair or replace the DLC (Data Link Connector)
circuit.
Was the action complete?
1. Check the ACU ground circuit for an open, or
short to voltage. Also, check the ACU ignition
feed circuit for an open or short to ground
and the ACU ground circuit for an open.
2. If a problem is found, repair as necessary.
Was the problem found?
Replace the antitheft control unit (ACU).
IMPORTANT: The replacement ACU must be
programmed the antitheft data by Tech-2.
Was the action complete?
Select “Display DTCs” with the Tech-2.
Are any DTCs stored?
1. Observe the antitheft data list on Tech-2.
2. If a problem is found, repair as necessary.
Was the problem found?—
—
—
—
—
—
—
—
—Go to Step 2
Go to
DTC table
Go to Step 9
Go to Step 5
Go to Step 3
Verfy repair
Go to Step 8
Go to applicable
DTC table
System OKGo to
“No antitheft
lamp”
Go to Step 3
Go to Step 4
Go to Step 6
—
Go to Step 7
—
—
Go to
applicable
section

FRONT ALIGNMENT 3A-1
SECTION 3A
FRONT ALIGNMENT
TABLE OF CONTENTS
PAGE
Front End Alignment Inspection and Adjustment .......................................................... 3A- 2
General Description ..................................................................................................... 3A- 2
Inspection .....................................................................................................................3A- 3
Alignment for 4




2 (Except High Ride Suspension) .......................................................3A- 4
Alignment for 4




2 (High Ride Suspension) and 4




4 ......................................................3A- 10