ABS ISUZU TF SERIES 2004 Owners 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

8A-336 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION



AUDIO
Refer to Section 9 “ACCESSORIES” for details.


CIGARETTE LIGHTER
Removal
1. Disconnect the battery ground cable.
2. Remove the center cluster ASM.
3. Remove the lighter

1.
4. Disconnect the connector

2.
5. Loosen the ring nut

3 at the back side.
6. Remove the outer case
4.
7. Remove the lighter holder
5 from the bezel.





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



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


ACC SOCKET
Removal
1. Disconnect the battery ground cable.
2. Remove the center cluster ASM.
3. Disconnect the connector.
4. Remove the holder nut
1.
5. Remove the ACC Socket
2

Installation
Follow the removal procedure in the reverse order to install the
lighter.

ELECTRICAL-BODY AND CHASSIS 8A-423


No. Connector face No. Connector face
C-36
Silver
Engine room-LH ; Ground C-54
(6VE1)
(4JH1-TC)
OrangeABS sensor Front-LH
C-37
Black
Brake fluid level switch C-55
BrownThermo AMP
C-38
(4JH1-TC)
Vacuum switch C-56
(C24SE)
ECM
C-39

Parking brake switch (stick type) C-56
(4JA1-TC
4JH1-TC)
ECM-A
C-40
~
C-43 NOT USED C-57
(4JA1-TC
4JH1-TC)
ECM-B
C-44
White
Stop lamp switch C-58
~
C-62 NOT USED
C-45
~
C-49 NOT USED C-63
(6VE1)
(4JH1-TC)
Gray Front Fog lamp-RH
C-50

Condenser fan C-64
(6VE1)
(4JH1-TC)
Gray Front Fog lamp-LH
C-51
~
C-52 NOT USED C-65
~
C-66 NOT USED
C-53
(6VE1)
(4JH1-TC)
Orange ABS sensor Front-RH C-67
(6VE1)
(4JH1-TC)
BlackEHCU

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

6A – 22 ENGINE MECHANICAL
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacturer Remarks
RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C Three Bond
Three Bond
Water Base ThreeBond 1141E
ThreeBond 1215 Three Bond
Three Bond
Solvent ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402 Three Bond
Isuzu
Isuzu
Isuzu
Anaerobic LOCTITE 515
LOCTITE 518
LOCTITE 262 Loctite
Loctite
Loctite Recommended for
transaxle repairs

* RTV : Room Temperature Vulcanizer

Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10
1.25
37 (3.8/28)
2
3M8
1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)




















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

6C – 24 FUEL SYSTEM




6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)





7. Injection Pipe Clip
Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.

Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)

8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.






9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)









10. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming
pump.
2) Connect the fuel hoses to the injection pump.









12. Oil Level Gauge
Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)

ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.


Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside
holes.
2. Use the insertion tool to press the new oil seal into
place. Follow the procedure shown in Figures A, B, C
and D.

Position the oil seal beneath the shaft and the
guide lip.

Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.

After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution





Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.





Take care not to damage the D surface.





Under no circumstances may the original oil seal
be reused.





The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.







RTW46DSF000101

6E–44 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
RELAY A ND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
No .RELAY
(4JA1-TC/4JH1-TC)
X -1 RELAY; TAIL LIGHT
X -2 RELAY; FRT F OG LI GHT
X -3 RELAY; HORN
X -4 RELAY; DIMMER
X -5 RELAY; GLOW
X -6 RELAY; COND, FAN
X -7 RELAY; RR FOG
X -8 RELAY; STARTER
X -9 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-RH (RHD)
X-10 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-LH (RHD)
X -11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
SLOW BLOW FUSE
NO.FUSE
(4JA1-TC/4JH1-TC)
EB-1 10A ECM
EB-2 10A RR FOG
EB-3 15A FRT FOG
EB-4 —
EB-5 10A ILLUMI & TAIL-RH
EB-6 10A TAIL-LH
EB-7 10A H/LIGHT RH-LOW
EB-8 10A H/LIGHT LH-LOW
EB-9 10A TRA ILER
EB-10 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
EB-15 10A HORN
EB-16 10A HAZARD
NO.SLOW BLOW FUSE
4JA1-TC/4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–45
FUSE A ND RELAY LOCATION (LHD & RHD)
FUSE
SLOW BLOW FUSE
RELAYNo. Capacity Indication on label No. Capacity Indication on label
1——12 15A CIGER
2 10A ABS 13 15A AUDIO (+B)
3——14 20A DOOR LOCK
4 15A BACK UP 15 10A METER (+B)
5 15A METER 16 10A ROOM
6 10A TURN 17 10A ANTI THEFT
7 15A ELEC.IG 18 15A STOP
8 15A ENGINE 19 15A ACC SOCKET
9 20A FRT WIPER 20 10A STARTER
10 15A EGR 21 10A SRS
11 10A AUDIO
No. Capacity Indication on label
SBF-10 20A RR DEF
SBF-11 30A POWER WINDOW
Connector No. B-7 B-8 B-40
4JA1-TC, 4JH1-TC REAR
DEFOGGERPOWER
WINDOWACC
SOCKET
FUSE BOX