engine ISUZU TF SERIES 2004 Workshop Manual

HEATER AND AIR CONDITIONING 1-97



YES

Disconnect the condenser fan relay connector
condenser fan.
YES


Is there battery voltage between the engine
room harness connector terminal NO. 3 (C-
24) and ground? Open circuit between the condenser
fan relay No.4 (X-6) 4JAH No. 3 (X-
13) and engine room harness
connector terminal No. 4 (X-14).
NO

Is there continuity between the relay terminal
No. 4 (X-6) and engine room harness connector
terminal No.4 (C-24)?
YES

connect the A/C thermo relay connector.
Open circuit between the No. EB-13
fuse and engine room harness
connector terminal No. 4 (C-24).
NO
YES

Is there battery voltage between the engine
room harness connector terminal No.3 (C-55)
dd?
Open circuit between the engine room
harness connector terminal No. 2 (C-
24) and the engine room harness
connector terminal No. 2 (C-55).
NO
YES

Is there continuity between the engine room
harness connector terminal No.1 (C-55) and
ground (C-109) ? Open circuit between the No. EB-13
fuse and engine room harness
connector terminal No. 3 (C-55).
NO


Disconnect the electronic themostat.


Is there continuity between the engine room
harness connector terminal No. 2 (C-55) and the
engine room harness connector terminal No. 2
(C-24)?
Open circuit between the engine
room harness connector terminal
No. 4 (X-15) and the engine room
harness connector terminal No. 1(C-
24).
NO

1-100 HEATER AND AIR CONDITIONING



Replace
YES


Are the A/C thermo (X-15), heater & A/C (X-11)
and A/C compressor (X-14) relay OK?


Are the No. SBF 8 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES


Is the pressure switch (C-24) OK?
YES


Are the A/C switch (B-57) and the fan switch (B-13)
OK?
NO
YES


Is there continuity between the engine harness
connector terminal No.1 (E-2) and engine room
harness connector terminal No.2 (X-14)?

Disconnect the A/C compressor relay.


Turn the ignition switch "ON" (Engine is running)


A/C switch and fan control knob (fan switch "ON")
NO
Replace
NO
Defective switch or insufficient
refrigerant
NO
NO
Does the magnetic clutch
operate?
YES
Replace


Disconnect the magnetic clutch connector.

Is there battery voltage between the engine room
harness connector terminal No.1 (E-2) and ground?
Defective compressor
YESNO
Defective magnetic clutch

HEATER AND AIR CONDITIONING 1-101



Open circuit between the No. EB-13
fuse and engine room harness
connector terminal No.1 (X-14).
NO
YES


Is there battery voltage between the engine room
harness connector terminal No.1 (X-14) and
ground?
YES


Disconnect the A/C thermo relay.
YES


Is there continuity between the ECM harness
connector terminal No. 14 (C-56) and engine
room harness connector terminal No.4 (X-14)?
Open circuit between the No. EB-13
fuse and engine room harness
connector terminal No. 3 (X-14).
NO


Is there battery voltage the engine room harness
connector terminal No.3 (X-14) and ground?
YES


Is there continuity between the ECM harness
connector terminal No. 26 (C-56) and engine
room harness connector terminal No. 1 (X-15)?Open circuit between the ECM
harness connector No.14 (C-56) and
engine room harness connector
terminal No. 4 (X-14).
NO
YES

Is there battery voltage between the engine room
harness connector terminal No. 2 (X-15) and
ground?
Open circuit between the ECM
harness connector No. 26 (C-56) and
the engine room harness connector
terminal No. 1 (X-15).
NO
YES


Is there continuity between the engine room
harness connector terminal No. 3 (X-15) and the
engine room harness connector terminal No. 1 (C-
24
).
Open circuit between the No. EB-13
fuse and engine room harness
connector terminal No. 4 (X-15).
NO


Disconnect the ECM harness connector.

Disconnect the pressure switch?
Open circuit between the engine harness
connector terminal No.1 (E-3) and engine
room harness connector terminal No.2 (X-
14).
NO

1-102 HEATER AND AIR CONDITIONING



YES


Disconnect the condenser fan relay connector condenser
fan.
YES

Is there battery voltage between the engine room
harness connector terminal NO. 3 (C-24) and ground?Open circuit between the condenser fan
relay No.3 (X-7) and engine room harness
connector terminal No. 4 (X-14).
NO

Is there continuity between the relay terminal No. 3 (X-7)
and engine room harness connector terminal No.4 (C-
24)?
YES
Open circuit between the No. EB-13 fuse
and engine room harness connector
terminal No. 4 (C-24).
NO
YES


Is there continuity between the engine room harness
connector terminal No. 2 (C-55) and the engine room
harness connector terminal No. 2 (C-24)?
Open circuit between the engine room
harness connector terminal No. 4 (CX-15)
and the engine room harness connector
terminal No. 1 (C-24).
NO


Disconnect the pressure switch.


Is there continuity between the engine room harness
connector terminal No. 4 (X-15) and the engine room
harness connector terminal No. 1 (C-24).
Open circuit between the No. EB-13 fuse
and engine room harness connector
terminal No. 2 (X-15).
NO


Connect the A/C thermo relay connector.


Disconnect the electronic thermostat.

HEATER AND AIR CONDITIONING 1-103



YES


Disconnect the A/C switch.


Is there battery voltage between the chassis side
harness connector terminal No. 6 (B-57) and ground?
Open circuit between the engine room
harness connector terminal No. 2 (C-24)
and the engine room harness connector
terminal No. 2 (C-55).
NO YES


Is there battery voltage between the engine room
harness connector terminal No. 3 (C-55) and ground?
Open circuit between the No. EB-13 fuse
and engine room harness connector
terminal No. 3 (C-55).
NO YES


Is there continuity between the engine room harness
connector terminal No. 1 (C-55) and ground (C-109)?
Open circuit between the engine room
harness connector No. 1 (C-55) and ground
(C-109).
NO
YES


Is the electronic themostat OK? Open circuit between the No. EB-13 fuse
and the chassis side harness connector
No. 4 (C-55).
NO
YES


Defective ECM Replace electronic thermostat
NO

MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before
you begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.

MSG MODEL 7B-9

Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.





Starter Motor
Remove the starter motor motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the transmission
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative
efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.

MSG MODEL 7B-11
Important Operations - Installation
Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
installation procedure.





Transmission
1. Apply a thin coat of molybdenum disulfide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into
position behind the engine.





4. Slowly operate the transmission jack to raise the
transmission until the rear of the transmission is at the
same level as the No.3 crossmember
1 .
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3
crossmember and the floor panel
2 .



6. Slowly raise the transmission jack until the front of the
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be the
same.
7. Install the gear control box the transmission.
8. Align the top gear shaft spline with the clutch drive plate
spline.
9. Install the transmission to the engine.
Tighten the transmission nuts and bolts as shown in the
figure.

MSG MODEL 7B-13





Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Torque N

m (kgf

m/lb

ft)
78 (8.0 / 58)




Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque N

m (kgf

m/lb

ft
)
78 (8.0 / 58)

Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.



Rear Propeller Shaft (Single Shaft Type)
1. Insert the splined yoke 1 with the propeller shaft into the
transmission main shaft spline
2 .
2. Install the propeller shaft flange yoke
3 to the drive pinion
side.
3. Tighten the propeller shaft flange yoke bolt to the specified
torque.
Propeller Shaft Flange Yoke Bolt Torque N
m (kgf
m/lb
ft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)



Rear Propeller Shaft (Dual Shaft Type)
1. Place the center bearing and retainer 1 together with the
1st propeller shaft
2 and 2nd propeller shaft 7 on the No.4
crossmember
3.
2. Insert the splined yoke
4into the transmission main shaft
spline
5.
3. Tighten the center bearing retainer bolts
6 to the specified
torque.
Center Bearing Retainer Bolt Torque N

m (kgf

m/lb

ft)
60.8 (6.2 / 44.8)



4. Connect the 2nd propeller shaft
7 and drive pinion side 8.
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque N

m (kgf

m/lb

ft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)

7B-14 MSG MODEL



Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the
2nd exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.

Gear Shift Lever
1. Replenish the transmission case with the specified engine
oil.
Transmission Case Oil lit(US gal.)
1.55 (0.41)

2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified
torque.
Shift Lever Cover Bolt Torque N

m(kgf

m/lb

ft)
19.6 (2.0 / 14.5)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.



Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.



Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.



Battery Cable
Connect the negative (-) cable to the battery terminal.