coolant ISUZU TF SERIES 2004 Workshop Manual

8A-276 ELECTRICAL-BODY AND CHASSIS


Connector No. B-24
Terminal Connector place SOUTH
AFRICA SAUDI
ARABIA ISRAEL EC UK OTHER
1
SEDIMENTER
2
4LO
3
OIL PRESS
4
4WD
5
CHECK 4WD
6
GLOW
7
POWER DRIVE
8








9
SPEED (+)
10
4P OUTPUT
11
TACHO
12
STARTER
13
TEMP
14
FUEL
RR FOG


15
FRONT FOG






16
ABS CONT. (ABS)
17
CHECK ENGINE
18
AIR BAG
SEAT BELT 19
LOW COOLANT





CRUISE SET



20
BEAM (+)




21
TURN (LEFT)
22
BEAM (-)
BEAM (+)


23
FRONT FOG




24
3rd START (A/T)
25








26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN

ELECTRICAL-BODY AND CHASSIS 8A-429


No. Connector face No. Connector face
E-23
(4JH1-TC)
Gray TPS 2 main E-44
Gray Vehicle speed sensor
E-24
~
E-29 NOT USED E-45
(4JH1-TC)
Gray 2WD-4WD switch
E-30
(4JH1-TC)
Gray A/T speed sensor E-46
(4JH1-TC)
BrownH-L neutral switch
E-31
(4JH1-TC)
Gray Turbine sensor E-47
~
E-48 NOT USED
E-32
~
E-34 NOT USED E-49
(4JH1-TC)
Glow plug
E-35
(4JH1-TC)
(C24SE)
Black Motor actuator E-50

NOT USED
E-36
~
E-40 NOT USED E-51
(6VE1)
Fuel injector
E-41
(4JH1-TC)
Black Coolant temp sensor E-51
(4JH1-TC)
BlackInhibiter switch
E-42
Natural
green
Backup lamp switch E-52
(6VE1)
Fuel injector
E-43
Natural
green
Backup lamp switch E-53
(6VE1)
Ignition coil

6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn
ON ? Go to section
6E “On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction
found? (Include radiator cap) — Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the
fan clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump
assembly.
8 Was the restriction by the foreign materials in the
cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. — Clean or
replace the
clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? — Replace the
sealing cap or
replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 2 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
2 Was the PCV (Positive Crankcase Ventilation) valve
working completely? —
Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved

ENGINE MECHANICAL 6A – 1


SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit ........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43

ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.




Engine coolant Filling up procedure
1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.

Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)
50 %

6A – 28 ENGINE MECHANICAL


Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage. The testing pressure must not exceed the
specified pressure.

Testing Pressure kPa(kg/cm
2 /psi)
150 (1.5/21)



Radiator Cap Inspection
The radiator filler cap is designed to maintain coolant
pressure in the cooling system at 103 kPa(1.05 kg/cm2,
15psi).
Check the radiator filler cap with a radiator filler cap tester.
The radiator filler cap must be replaced if it fails to hold the
specified pressure during the test procedure.
Radiator Cap Valve Opening Pressure
kPa(kg/cm
2 /psi)
90 – 120 (0.9 – 1.2/13 – 17)

Negative Valve (Reference) kPa(kg/cm2 /psi)
1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)
030LX003
030LX002

6A – 32 ENGINE MECHANICAL









































COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 C (158 – 176 F).
2. Remove the following parts.
 Leak off pipe
 Injection nozzle holder bracket
 Injection nozzle holder
3. Install the following parts.
 Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
 Injection nozzle holder bracket

Injection nozzle holder bracket Bolt Torque
N·m (kg·m /lb·ft)
37 (3.8/27)

Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0


4. Turn the engine over with the starter motor and take
the compression gauge reading.

Compression Pressure MPa (kg/cm
2 /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)




5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
F06XL056
901R100003

6A – 34 ENGINE MECHANICAL



RTW46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8)
is aligned with the pointer.

Injection Timing : BTDC 8  2

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket
bolts.
11. Adjust the injection pump setting angle.
When large than standard
value When smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.

ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80C (158 - 176F).


4. Disconnect the engine control cable from the control
lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730  25 rpm


Idling Speed Adjustment
1. Loosen the idling set screw lock nut
on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt
.
3. Lock the engine set nut

with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.

ENGINE MECHANICAL 6A – 39

18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.

TPS connector

Oil pressure switch connector

Thermo switch connector

Injection pump connector

Engine earth

Thermometer unit connector

TDC sensor
2) Remove the clips fixing engine harness.
P1010009