oil pressure ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 3438 of 4264
3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
If the pressure recorded is within 9300-9800 kPa
(95-100 kg/cm
2/1350-1420 psi), the pump is
functioning within its specifications.
If the pressure recorded is higher than 9800 kPa
(100 kg/cm
2/1420 psi), the valve in the pump is
defective.
If the pressure recorded is lower than 9300 kPa (95
kg/cm
2/1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the powe
r
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and fron
t
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
Inspect belt for tightness.
Inspect pulley for looseness or damage. The pulle
y
should not wobble with the engine running.
Inspect hoses so they are not touching any othe
r
parts of the vehicle.
Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130
F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.
Page 3451 of 4264
POWER-ASSISTED STEERING SYSTEM 3B-21
Power Steering Pump and Associated Parts (C24SE)
RTW33BLF000801
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible
(4) Bolt
(5) Connector, Pressure switch
Removal
1. Remove the drive belt.
2. Remove the pulley
3. Place a drain pan below the pump.
4. Disconnect the suction hose.
5. Disconnect the flexible hose.
6. Disconnect the oil pressure switch connector.
7. Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
Torque: 34-46 N·m (3.5-4.7 kg·m/25-34 lb ft)
2. Connector the oil pressure switch connector.
3. Install the flexible hose.
Tighten the eye bolt to specified torque.
Torque: 49-59 N·m (5.0-6.0 kg·m/36-43 lb ft)
4. Install the pulley and tighten the bolt to the specified
torque.
Torque: 69-88 N·m (7.0-9.0 kg·m/51-65 lb ft)
5. Install the drive belt.
6. Connect the suction hose, then fill and bleed
system.
Refer to Bleeding the Power Steering System in this
section.
Page 3453 of 4264
POWER-ASSISTED STEERING SYSTEM 3B-23
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent). Be
careful not to expose the oil seal of shaft assembl
y
to solvent.
2. Remove the bolt, suction pipe and O-ring.
Remove the O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.
6. Remove the snap ring.
7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the fron
t
housing.
10. Remove two O-rings.
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Page 3454 of 4264
3B-24 POWER-ASSISTED STEERING SYSTEM
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail. The parts with minor scores may be reused after
lapping the face.
Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Needle bearing fitting
face must be free from damage and wear.
O-ring, Oil Seal, Retaining Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N
m (2.2-2.7 kg
m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 7.8-12 N
m (0.8-1.2 kg
m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N
m (5.0-7.0 kg
m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N
m (1.5-2.0 kg
m/11-14 lb ft)
Page 3456 of 4264
3B-26 POWER-ASSISTED STEERING SYSTEM
Power Steering Pump and Associated Parts (6VE1)
RTW33BLF000701
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible
(4) Bolt
(5) Connector, Pressure switch
Removal
1. Remove the drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Disconnect the oil pressure switch connector.
6. Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
Torque: 31-63 N·m (3.2-6.4 kg·m/23-46 lb ft)
2. Connector the oil pressure switch connector.
3. Install the flexible hose.
Tighten the eye bolt to specified torque.
Torque: 49 - 59 N·m (5.0 – 6.0 kg·m/36 - 43 lb ft)
4. Install the drive belt.
5. Connect the suction hose, then fill and bleed
system.
Refer to Bleeding the Power Steering System in this
section.
Page 3457 of 4264
POWER-ASSISTED STEERING SYSTEM 3B-27
Power Steering Pump Disassembled View
RTW43BMF000301
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin
(12) Cam
(13) Pump Cartridge Assembly
(14) O-ring
(15) Snap Ring
(16) Rear Housing
(17) Bolt
(18) Spring
(19) Relief Valve
(20) O-ring
(21) Connector
(22) Bush
(23) Pressure Switch Assembly
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent). Be
careful not to expose the oil seal of shaft assembl
y
to solvent.
2. Remove the bolt, suction pipe and O-ring.
Remove the O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the pressure switch assembly.
5. Remove the bolt, rear housing and O-ring.
6. Remove the snap ring.
7. Remove the shaft assembly.
8. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
9. Remove the pump cartridge assembly from the front
housing.
10. Remove two O-rings.
Page 3458 of 4264
3B-28 POWER-ASSISTED STEERING SYSTEM
Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When par
t
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finge
r
nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.
O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connecto
r
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
Page 3459 of 4264
POWER-ASSISTED STEERING SYSTEM 3B-29
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten i
t
to specified torque.
Torque: 22-26 N
m (2.2-2.7 kg
m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten i
t
to specified torque.
Torque: 7.8-12 N
m (0.8-1.2 kg
m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N
m (5.0-7.0 kg
m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N
m (1.5-2.0 kg
m/11-14 lb ft)
Page 3552 of 4264
3C-60 FRONT SUSPENSION
Checkpoint Trouble Cause Countermeasure
Steering linkage and steering
gearReplaceWorn
AdjustImproper OK
NG NG
OKTire pressure Continued from the previous page
Steering unit fixing bolts and
linkageRetightenLoose
Adjust or replaceIncorrect adjustment or
abrasion OK
NG NG
OKFront wheel bearing
Lubricating oil and grease to
steering linkageReplaceInsufficient NG OK
Page 3681 of 4264
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)
CONTENTS
Service Precaution .................................................
7A2-2
General Description ...............................................
7A2-2
Electronic Control Diagram ...............................
7A2-3
Transmission Control Module (TCM) (1/2) ......
7A2-4
Transmission Control Module (TCM) (2/2) ......
7A2-5
TCM Point Table .................................................
7A2-6
TCM Voltage & Resistance Check Sheet .......
7A2-7
Control System Diagram ....................................
7A2-9
Control and Functions ........................................
7A2-10
Gear Shift Control 3rd start ...............................
7A2-10
Mode Type ...........................................................
7A2-10
Mode Selection ....................................................
7A2-10
Comparison of mode ..........................................
7A2-11
3rd start Mode .....................................................
7A2-11
Backup Mode .......................................................
7A2-11
Functions of Input / Output Components ........
7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................
7A2-13
High speed CAN bus ..........................................
7A2-13
Diagnosis .................................................................
7A2-13
Electronic Diagnosis ...........................................
7A2-13
Check Trans Indicator ........................................
7A2-13
On Board Diagnostic Check ..............................
7A2-13
"Check Trans" Check .........................................
7A2-14
Tech 2 OBD Connection ....................................
7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............
7A2-30
16 - Terminal Data Link Connector (DLC) ......
7A2-31
Clear DTC ............................................................
7A2-32
DTC Check ..........................................................
7A2-32
TCM Precaution ..................................................
7A2-32
Information On TCM ...........................................
7A2-32
TCM Diagnostic Trouble Codes ........................
7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ...........................................
7A2-34
DTC P0602 (FLASHING CODE 63)
Transmission Control Module (TCM)
Programming Error ................................................
7A2-36
DTC P0705 (FLASHING CODE 17)
Transmission Range Sensor Circuit
Malfunction .............................................................
7A2-38
DTC P0712 (FLASHING CODE 15)
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................
7A2-42
DTC P0713 (FLASHING CODE 16)
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................
7A2-45
DTC P0717 (FLASHING CODE 14)
Input Speed Sensor Signal Error .........................
7A2-48
DTC P0722 (FLASHING CODE 11)
Output Speed Sensor Signal Error .....................
7A2-51
DTC P0743 (FLASHING CODE 33)
Torque Converter Clutch Electrical .....................
7A2-54
DTC P0748 (FLASHING CODE 35)
Pressure Control Solenoid Electrical ..................
7A2-57
DTC P0753 (FLASHING CODE 31)
Shift Solenoid S1 Electrical ..................................
7A2-60
DTC P0758 (FLASHING CODE 32)
Shift Solenoid S2 Electrical ..................................
7A2-63
DTC P1767 (FLASHING CODE 67)
ECM CAN Invalid ...................................................
7A2-66
DTC P1790 (FLASHING CODE 61)
Transmission Control Module ROM
Checksum Error .....................................................
7A2-69
DTC P1791 (FLASHING CODE 62)
Transmission Control Module RAM
Error .........................................................................
7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................
7A2-73