light ISUZU TF SERIES 2004 Owners Manual

8A-422 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
C-1
Gray
Side turn lamp-RH C-22
Front turn lamp-RH
C-2
Silver
Engine room-RH ground C-23
NOT USED
C-3
(6VE1)
(4JH1-TC)

INT Relay C-24
Triple pressure switch
C-4
Light-
blue
Front wiper motor C-25
NOT USED
C-5
~
C-16 NOT USED C-26
Black
Head lamp-LH
C-17
Gray
Front wiper motor C-27
Clearance lamp-LH
C-18

Clearance lamp-RH C-28
~
C-29 NOT USED
C-19
Black
Head lamp-RH C-30

BlackEngine hood switch
C-20
(6VE1)
(4JH1-TC)

Horn ; high note C-31
~
C-34 NOT USED
C-21
Black
Horn ; Low note C-35
Gray Side turn lamp-LH

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

CRUISE CONTROL SYSTEM 8B-3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAIN SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS
SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHER WISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a faster, use ONLY the
exact part number for that application. Dealer will call out those fasteners that require a replacement after
removal. Dealer will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and joint Clamping force, and may damaged the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to
parts and systems.

General Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received.
When the main switch “AUTO CRUISE” is turned on with the vehicle in the running mode, the battery voltage is
applied to the control unit. When a signal from the control unit while the vehicle is in this state, the cruise control
actuator is activated to operate the system. Also, while the system is operating, the “AUTO CRUISE” indicator light
in the meter assembly lights up.





LTW48BSH000101
1. SET/COAST Switch Function
1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at
which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the
stored speed.
2. COAST-down Function: When the SET/COAST switch is kept on while the vehicle in running, the vehicle
decelerates during that time. The speed at which vehicle is running when the control switch is pressed in the
memory, and the vehicle automatically returns to the stored speed.
3. Tap-down Function: When the SET/COAST switch is pressed and released instantaneously while the
vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the
vehicle was running when the SET/COAST was released last is stored in the memory, and the vehicle
automatically returns to this stored speed.

CRUISE CONTROL SYSTEM 8B-7
Cruise Control Main Switch



Removal
1. Disconnect the battery ground cable.


RTW3A0SH001301
2. Remove the side ventilation grille.



RTW3A0SH001401
3. Disconnect the switch connector and push the lock from the
backside of the side ventilation grille to remove the cruise
control main switch.


Installation
To install, follow the removal steps in the reverse order, noting
the following point.
1. Push in the switch with your fingers until it locks securely.

Cruise Control Switch (Combination Switch)


Removal and Installation
Refer to the Lighting Switch (Combination Switch) removal and
installation steps of Lighting System in Body and Accessories
section.

8B-10 CRUISE CONTROL SYSTEM
Diagnosis
The cruise control unit uses the cruise main indicator light and diagnosis the failure, when the control unit detects
abnormality on the table below.

PART POSSIBLE CAUSE DETECTION PERIOD DTC
Actuator Motor system short circuit Energizing motor 1-1
Clutch system short circuit Energizing clutch 1-2
Clutch system open circuit Energizing clutch 1-2
Mechanical defect Cruise controlling 1-3
Close side of motor system open circuit Cruise controlling 1-1
Cruise control unit Close side of motor system open circuit While starter sw on 1-4
Clutch output abnormality While starter sw on 1-4
Vehicle speed sensor Signal of vehicle speed disconnection Cruise controlling 2-1
Signal of vehicle speed abnormality Cruise controlling 2-1
Switch Turning on switch at all times While starter sw on 3-1
Turning on switch at the same time While starter sw on 3-1
DTC : Diagnostic Trouble Code

DTC Display Condition
1. With the vehicle stationary and the ignition ON, activate the ‘Cruise Cancel’ switch three times within 2 seconds.
2. If there are no DTC’s stored in the Cruise control unit, the LED on the Cruise Main switch will blink rapidly (2Hz).
3. Any DTC’s stored in the Cruise control unit will be displayed by the CRUISE SET warning lamp in the meter
cluster.
4. Read the set DTC’s by referring to then charts on this page.

NOTE:

The DTC display mode will be aborted if either the vehicle speed rises above 10km/h or the RESUME switch is
operated.

The control module stores the DTC in a ‘volatile’ memory – that is the memory is only active while the ignition is
ON.
Turning the ignition to the OFF position will clesr any stored DTC’s.

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.



RTW36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0


RTW36ASH000101


4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
130RY00003
6A-6

ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
With oil filter
replacement Without oil
filter
replacement
4
2
4
4
(4JA1L/TC)6.2 (1.64/1.36) 5.2  4.2
(1.37  1.11
/ 1.14  0.92) 4.5  3.5
(1.19  0.93
/ 0.99  0.77)
4
2
(4JH1TC)
6.2 (1.64/1.36) 5.2  4.2
(1.37  1.11
/ 1.14  0.92) 4.5  3.5
(1.19  0.93
/ 0.99  0.77)
4
4
(4JH1TC) 7.0 (1.85/1.54) 6.2  5.2
(1.64  1.37
/ 1.36  1.14) 5.3  4.3
(1.72  1.14
/ 1.17  0.95)

9. Start the engine and check for oil leakage from the
main oil filter.
6A-7




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.






RTW46ASH000501








2. Clean the fuel filter cartridge fitting faces.
This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench : 5-8840-0253-0 (J-22700)





6. Operate the priming pump until the air discharged
completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.
041RY00009

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several
times and check for fuel leakage.
5. Check the water separator indicator light. It should be
off.



Except EURO III model
RTW46ASH002901




For EURO III model
RTW46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is
felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait until
the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and
crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


014RY00015
8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.


014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360.
14. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
15. Adjust the clearances for the remaining valves as
shown in the illustration.

ENGINE MECHANICAL 6A – 33
INJECTION TIMING ADJUSTMENT
(4JA1T(L) only)
1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.





2. Bring the piston in the No. 1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark.
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
RTW46ASH000601
3. Disconnect the injection pipe from the injection pump
4. Remove one bolt from the distributor head.
5. Install the static timing gauge.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)

6. Rotate the crankshaft to bring the piston in the No. 1
cylinder to a point 30 - 40 BTDC.
7. Set the timing gauge needle to zero.
8. Move the crankshaft pulley slightly in both directions to
check that the gauge indication is stable.