fuel pressure ISUZU TF SERIES 2004 Workshop Manual

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green

8A-274 ELECTRICAL-BODY AND CHASSIS





Terminal Connector No. B-23
No. C24SE
1
ABS CONT. (BRAKE)
2


3


4


5


6


7


8


9
BRAKE
10
CHARGE
11
TURN (RIGHT)
12


13


14


15


16


17
ILLUMI (-)
18
ILLUMI (+)

Terminal Connector No. B-24
No. C24SE
1


2
4LO
3
OIL PRESSURE
4


5
4WD
6
CHECK 4WD
7


8


9
SPEED (+)
10
4P OUTPUT
11


12
STARTER
13
TEMP
14
FUEL
15
FRONT FOG
16


17
CHECK ENGINE
18
AIR BAG
19
SEAT BELT
20
BEAM (+)
21
TURN (LEFT)
22
BEAM (-)
23
BEAM (+)
24


25


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

8A-428 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
E-1
(4JH1-TC)
White Oil pressure switch E-10
SilverEngine ground
E-2
(C24SE)
(6VE1)


Magnetic clutch E-11
(6VE1)

Neutral switch
E-3
(4JH1-TC)
Black
Magnetic clutch AC COMP E-11
(4JH1-TC)
Natural
green
Neutral switch
E-4
~
E-5 NOT USED E-12
(6VE1)

Neutral switch
E-6
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-12
(4JH1-TC)
Natural
green
Neutral switch
E-6
(4JH1-TC)

Injector pump E-13
~
E-17 NOT USED
E-7
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-18
(C24SE)

Ignition coil
E-8
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-19
(4JH1-TC)
Blue Thermo meter unit
E-9
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-20
~
E-21 NOT USED
E-9
(4JH1-TC)
Gray T.D.C sensor E-22
(4JH1-TC)
BrownTPS 1 main

TROUBLESHOOTING 6 – 1


SECTION 6
TROUBLESHOOTING


TABLE OF CONTENTS
PAGE PAGE
BASIC INSPECTION PROCEDURE ... 6– 2

1. HARD STARTING ........................... 6– 3

1-1.Starter Motor Inoperative ......... 6– 3

1-2. Starter Motor Operates But
Engine Does Not Turn Over .......... 6– 3

1-3. Engine Turns Over But Does
Not Start Engine ............................. 6– 4

2. UNSTABLE IDLING ........................ 6– 5

3. INSUFFICIENT POWER ................. 6– 6

4. EXCESSIVE FUEL
CONSUMPTION ................................. 6– 7

5. EXCESSIVE OIL CONSUMPTION.. 6– 8

6. OVERHEATING............................... 6– 9

7. WHITE EXHAUST SMOKE ............. 6– 9

8. DARK EXHAUST SMOKE .............. 6– 10

9. OIL PRESSURE DOES NOT RISE . 6– 11

10. ABNORMAL ENGINE NOISE ....... 6– 12

10-1. Engine Knocking.................... 6– 12

10-2. Gas Leakage Noise ................ 6– 12

10-3. Continuous Noise .................. 6– 13

10-4. Slapping Noise ....................... 6– 13

10-5. Excessive Turbocharger
Noise ............................................... 6– 14
11. ROTATING PART WEAR OF
TURBOCHARGER ............................. 6– 14

12. OIL LEAKAGE FROM
TURBOCHRGER ............................... 6– 15

13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER ....................... 6– 15

14. BATTERY CHARGING AND
NOISE PROBLEM.............................. 6– 16

14-1. Battery No Charging .............. 6– 16

14-2. Battery Overcharging ............ 6– 16

14-3. Battery Under Charging......... 6– 17

14-4. Battery Unstable Charging
Current ............................................ 6– 17

14-5. Charging System Noise ......... 6– 18

15. STARTER MOTOR PROBLEM..... 6– 19

15-1. Starter Motor Pinion Engages
to Ring Gear But Engine Does
Not Turn Over ................................. 6– 19

15-2. Incorrect Pinion And Ring
Gear Engagement .......................... 6– 19

15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off ....................................... 6– 20

15-4. Excessive Commutator
Sparking .......................................... 6– 20

6 – 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump
Step Action Value(s) Yes No
1 Check clogged, damaged the fuel piping or the
connector loosen.
Was any problem found? —
Repair replace
problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow
valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved

Incase of the fuel is being delivered to the injection pump
Step Action Value(s) Yes No
1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 5 Bleed the air
3 Was the injection spray condition complete? —
Go to Step 4 Replace the
injection nozzle
4 Was the injection nozzle injection starting pressure
OK? (See below)
Go to Step 5 Replace the
injection nozzle
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? — Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust
valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at
200rpm
Go to Step 11 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element.
2 Was the intake air leakage found from intake
system? — Repair or
replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —
Go to Step 4 Clean or
replace the fuel
filter element.
4 Check the fuel injection pipes.
Does the injection pipes have obstruction or any
damage? — Repair or
replace the fuel
injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Readjust the
injection nozzle
pressure or
replace the
nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 8 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? — Repair or
replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? — Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger
assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger
assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 7
4. Excessive Fuel Consumption
Step Action Value(s) Yes No
1 Was the air cleaner element clogged? — Clean or
replace the air
cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of
the turbocharger? — Repair or
replace the air
intake side of
the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger
4 Was there the fuel leakage? — Repair or
replace the fuel
leakage part. Go to Step 5
5 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 6 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Replace the
injection nozzle
7 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

6A – 4 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JA1T (L) 4JA1TC
Engine type
Combustion chamber type
Cylinder liner type
Timing gear train system Four-cycle, overhead valve, water cooled
Direct injection
Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 93
92 (3.66
3.62)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement cm3 (in3)
Compression ratio (to 1) 2,499(152.4)
18.5
Compression pressure Mpa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) Approximately 239 (527)
Fuel injection order 1 – 3 – 4 - 2
Fuel injection timing BTDC deg 8 -
Specified fuel type
Idling speed rpm

Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
730  25 (A/C Off)
850  25 (A/C ON)
0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed
type) Electronically controled
Injection nozzle type
Injection nozzle opening pressure Hole with 5 orifices

Mpa(kg/cm2/psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2nd (Reference)
25.527.0
(260275 / 3,7023,920) 2nd (Reference)
34.035.5
(347362 / 4,9365,154)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)