clutch ISUZU TF SERIES 2004 Manual Online

ENGINE MECHANICAL 6A – 125







25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque N·m(kg·m/Ib ft)
31 (3.1/23)

Connector the vacuum hose.





025R100008
RTW36ASH000301













26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)

EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)


RTW48ASH001801
26-2. EGR Cooler (EURO III model only)
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct N·m(kg·m/Ib ft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
RTW36ASH000201












28. Clutch Assembly or Flex Plate

6B – 2 ENGINE COOLING

PAGE
Engine coolant change ............................................................................................. 6B - 19
Fan Clutch with Cooling Fan ........................................................................................ 6B - 20
Inspection and Repair ............................................................................................... 6B - 20

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 – 11
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.

Cracks in the water pump body

Coolant leakage from the seal unit

Excessive radial play or abnormal noise in the fan center
when rotate by hand

Excessive thrust play in the fan center (Standard play: less
than 0.2mm)

Cracks or corrosion in the impeller





























Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque N·m(kg·m/lb ft)
20 (2.0/14)

2. Fan Drive Belt and Pulley
1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the
generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt mid-
portion to check the drive belt deflection.
Fan Drive Belt Deflection mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
030R300002


030R300001














3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque N·m(kg·m/lb in)
8(0.8/69)

4. Upper Fan Shroud

6B – 20 ENGINE COOLING
FAN CLUTCH WITH COOLING FAN
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.


033R300001
Visually inspect for damage, leak (sillicon grease) or other
abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at
the fan clutch portion gets to around 80
C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.



033RY00011
2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80
C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.

ENGINE ELECTRICAL 6D – 23


DISASSEMBLY



RTW460LF000201
Disassembly Step
1.
Lead wire
14. Armature
2.
Bolt 15. Bolt
3.
Magnetic switch assembly 16. Bearing retainer
4.
Torsion spring 17. Pinion assembly
5.
Plunger 18. Pinion stopper clip
6.
Dust cover 19. Pinion stopper
7.
Magnetic switch 20. Return spring
8.
Screw 21. Pinion shaft
9.
Through bolt 22. Clutch
10.
Rear cover 23. Dust cover
11.
Motor assembly 24. Shift lever
12.
Brush holder 25. Gear case
13.
Yoke

6D – 28 ENGINE ELECTRICAL
BRUSH AND BRUSH HOLDER
1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)


RTW46DSH004001













RTW46DSH004101
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.





3. Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.

OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
065RY00035


RTW46DSH004401
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.

ENGINE ELECTRICAL 6D – 29
REASSEMBLY



RTW46DLF000601


Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring

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–6 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Circuit Description ..................................... 6E-268
Diagnostic Aids .......................................... 6E-268
Diagnostic Trouble Code (DTC) P0645
(Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low ... 6E-269
Diagnostic Trouble Code (DTC) P0645
(Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High .. 6E-272
DIAGNOSTIC TROUBLE CODE (DTC) P0703
(SYMPTOM CODE A) (FLASH CODE 25)
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
DIAGNOSTIC TROUBLE CODE (DTC) P0703
(SYMPTOM CODE B) (FLASH CODE 25)
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
Circuit Description ..................................... 6E-274
Diagnostic Aids .......................................... 6E-274
Diagnostic Trouble Code (DTC) P0703
(Symptom Code A) (Flash Code 25) Brake
Switch Circuit Malfunction ....................... 6E-274
Diagnostic Trouble Code (DTC) P0703
(Symptom Code B) (Flash Code 25)
Brake Switch Circuit Malfunction ............. 6E-278
DIAGNOSTIC TROUBLE CODE (DTC) P0704
(SYMPTOM CODE 6) (FLASH CODE 57)
CLUTCH SWITCH INPUT CIRCUIT
MALFUNCTION ....................................... 6E-281
Circuit Description ..................................... 6E-281
Diagnostic Aids .......................................... 6E-281
Diagnostic Trouble Code (DTC) P0704
(Symptom Code 6) (Flash Code 57)
Clutch Switch Input Circuit Malfunction ... 6E-282
DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE 1) (FLASH CODE 86)
BAROMETRIC PRESSURE SENSOR
CIRCUIT HIGH INPUT ............................ 6E-285
DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE 2) (FLASH CODE 86)
BAROMETRIC PRESSURE SENSOR
CIRCUIT LOW INPUT ............................. 6E-285
Circuit Description ..................................... 6E-285
Diagnostic Aids .......................................... 6E-285
Diagnostic Trouble Code (DTC) P1105
(Symptom Code 1) (Flash Code 86) Barometric
Pressure Sensor Circuit High Input ......... 6E-285
Diagnostic Trouble Code (DTC) P1105
(Symptom Code 2) (Flash Code 86) Barometric
Pressure Sensor Circuit Low Input .......... 6E-285
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 1) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
CIRCUIT HIGH INPUT ............................ 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 7) (FLASH CODE 21)PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 9) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE D) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH ERROR ....................... 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE E) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
IDLE POSITION SWITCH ERROR ......... 6E-287
Circuit Description ...................................... 6E-288
Diagnostic Aids .......................................... 6E-288
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 1) (Flash Code 21)
Pedal/Throttle Position Sensor
Circuit High Input ..................................... 6E-288
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 7) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage
Supply Circuit High Input ......................... 6E-293
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 9) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input .......................... 6E-295
Diagnostic Trouble Code (DTC) P1120
(Symptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake
Switch Error ............................................. 6E-298
Diagnostic Trouble Code (DTC) P1120
(Symptom Code E) (Flash Code 21)
Pedal/Throttle Position Sensor Idle
Position Switch Error ............................... 6E-300
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ...................................... 6E-302
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ...................................... 6E-302
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE A) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY LOW FUEL
TEMPERATURE ...................................... 6E-302
Circuit Description ...................................... 6E-302
Diagnostic Aids .......................................... 6E-302
Diagnostic Trouble Code (DTC) P1173
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant