fuel pump ISUZU TF SERIES 2004 Workshop Manual

8A-28 ELECTRICAL-BODY AND CHASSIS

RELAY LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
RHD





















NO. RELAY (C24SE) RELAY (6VE1) RELAY
(4JA1-TC/4JH1-TC)RELAY (4JA1-L)
X-1 RELAY; TAIL LIGHT
  
X-2 RELAY; FUEL PUMP
 RELAY; FRT FOG RELAY; FRT FOG
LIGHT
X-3 RELAY; HORN
  
X-4 RELAY; DIMMER
  
X-5 RELAY; FOG LIGHT
 RELAY; GLOW RELAY; GLOW
X-6 RELAY; STARTER
 RELAY; COND, FAN RELAY; CSD
X-7 RELAY; COND, FAN
 RELAY; RR FOG

X-8
  RELAY; STARTER RELAY; STARTER
X-9 RELAY; HAZARD-RH
  
X-10 RELAY; HAZARD-LH
  
X-11 RELAY; HEATER
  
X-12 RELAY; HEAD
LIGHT   
X-13
 RELAY; ECM MAIN
 RELAY; COND, FAN
X-14 RELAY; A/C COMP
  
X-15 RELAY; THERMO
  

ELECTRICAL-BODY AND CHASSIS 8A-29

RELAY LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
LHD





















NO. RELAY (C24SE) RELAY (6VE1) RELAY
(4JA1-TC 4JH1-TC)RELAY (4JA1-L)
X-1 RELAY; TAIL LIGHT
  
X-2 RELAY; FUEL PUMP
 RELAY; FRT FOG RELAY; FRT FOG
LIGHT
X-3 RELAY; HORN
  
X-4 RELAY; DIMMER
  
X-5 RELAY; FRT FOG
LIGHT RELAY; FOG LIGHT RELAY; GLOW RELAY; GLOW
X-6 RELAY; STARTER
 RELAY; COND, FAN RELAY; CSD
X-7 RELAY; COND, FAN
 RELAY; RR FOG

X-8
  RELAY; STARTER

X-9
  SHORT
CONNECTOR
(with cooler) 
X-10
   
X-11 RELAY; HEATER
  
X-12 RELAY; HEAD
LIGHT   
X-13
 RELAY; ECM MAIN
 RELAY; COND, FAN
X-14 RELAY; A/C COMP
  
X-15 RELAY; THERMO
  

ELECTRICAL-BODY AND CHASSIS 8A-31
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
RHD

FUSE 
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
EB-1 15A ECM 20A ECM 10A ECM 
EB-2 
10A ECM (B) 10A RR FOG 
EB-3 15A FRT FOG
10A TCM 15A FRT FOG 
EB-4 10A ACG (S) 15A FRT FOG  10A ACG (S)
EB-5 10A ILLUMI  10A ILLUMI & TAIL-RH10A ILLUMI
EB-6 10A TAIL  10A TAIL-LH 10A TAIL
EB-7 10A H/LIGHT-RH  10A H/LIGHT RH-LOW10A H/LIGHT RH
EB-8 10A H/LIGHT-LH  10A H/LIGHT LH-LOW10A H/LIGHT LH
EB-9 20A FUEL PUMP 10A O2 SENSOR 10A TRA ILER 
EB-10 10A O2 SENSOR 20A FUEL PUMP 10A AC G (S) 
EB-11 
10A H/LIGHT RH-HIGH 
EB-12 
10A H/LIGHT LH-HIGH
EB-13 10A A/C 
 
EB-14 10A 4WD
10A 4WD  
EB-15 10A HORN   
EB-16 15A HAZARD 10A HAZARD  

SLOW BLOW FUSE
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
SBF-1 100A MAIN 
80A MAIN 
SBF-2  
20A COND, FAN 
SBF-3  
60A GLOW 20A COND, FAN
SBF-4 20A COND, FAN 
30A ECM 50A GLOW
SBF-5 40A IG 1   
SBF-6 
40A ABS-1  
SBF-7 
30A ABS-2  
SBF-8 30A BLOWER   
SBF-9 50A IG 2

8A-32 ELECTRICAL-BODY AND CHASSIS
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
LHD

FUSE  Saudi Arabia
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
EB-1 15A ECM 20A ECM 10A ECM 
EB-2 
10A ECM (B) 10A RR FOG 
EB-3 15A FRT FOG
10A TCM 15A FRT FOG 
EB-4 10A ACG (S) 15A FRT FOG  10A ACG (S)
EB-5 10A ILLUMI & TAIL-RH  10A ILLUMI & TAIL-RH 
EB-6 10A TAIL-LH  10A TAIL-LH

EB-7 10A H/LIGHT-RH 10A H/LIGHT-RH
10A H/LIGHT-RH-LOW
 10A H/LIGHT RH-LOW
10A H/LIGHT-RH-LOW
EB-8 10A H/LIGHT-LH 10A H/LIGHT-LH
10A H/LIGHT-LH-LOW
 10A H/LIGHT LH-LOW
10A H/LIGHT-LH-LOW
EB-9 20A FUEL PUMP 10A O2 SENSOR 10A TRA ILER 
EB-10 10A O2 SENSOR 20A FUEL PUMP 10A AC G (S) 
EB-11
10A H/LIGHT-RH-HIGH
10A H/LIGHT RH-HIGH 
EB-12 10A H/LIGHT-LH-HIGH
10A H/LIGHT LH-HIGH 
EB-13 10A A/C 
 
EB-14 10A 4WD
10A 4WD  
EB-15 10A HORN   
EB-16 15A HAZARD 10A HAZARD  
SLOW BLOW FUSE
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
SBF-1 100A MAIN 
80A MAIN 
SBF-2  
20A COND, FAN 
SBF-3  
60A GLOW 20A COND, FAN
SBF-4 20A COND, FAN 
30A ECM 50A GLOW
SBF-5 40A IG 1   
SBF-6 
40A ABS-1  
SBF-7 
30A ABS-2  
SBF-8 30A BLOWER   
SBF-9 50A IG 2

8A-108 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


FUEL PUMP
Removal
1. Remove the fuel tank.
Refer to the Section 6C-ENGINE FUEL of this Manual.

Disconnect the fuel pipe.





Installation
Follow the removal procedure in the reverse order to install the
fuel pump.
Pay close attention to the important points mentioned in the
following paragraphs.



Rubber Seal
Be absolutely sure that the fuel pump rubber seals correctly
seated.

Connector
Be absolutely sure that the fuel pump connector is securely
connected.
This will prevent a poor contact and an open circuit.

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

8A-432 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
F-1
White
Fuel filter


F-2
White
Fuel pump & sensor


F-3
NOT USED


F-4
Gray
ABS sensor


F-5
Gray
Rear combination lamp-RH


F-6
Gray
Rear combination lamp-LH


F-7
Gray
License plate lamp


F-8
Black
Rear fog light – RH


F-9
Black
Rear fog light - LH

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)

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)

6A – 6 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JH1TC
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type
Timing gear train system Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 95.4
104.9 (3.76
4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter
Compression ratio (to 1) 2,999
18.3
Compression pressure MPa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) MT : Approximately 249 (549)
AT : Approximately 236 (520)
Fuel injection order 1 – 3 – 4 - 2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm
700
25 (A/C OFF)
800
25 (A/C ON)
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
Injection pump type 0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

BOSCH distributor VP44 type
Injection nozzle type
Injection nozzle opening pressure
MPa(kg/cm
2/psi)Hole with 5 orifices

1st 19.5 (199/2,828)
2nd (Reference) 34.335.8 (350365/4,9805,197)
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)
Oil pump type
Oil filter type Gear
Cartridge paper element
Oil capacity lit (US/UK gal)
6.2 (1.64/1.36) (For 4
2)
7.0 (1.85/1.54) (For 4
4)
Oil cooler type Water cooled