stop start ISUZU TF SERIES 2004 User Guide

ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.




Engine coolant Filling up procedure
1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.

Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)
50 %

ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.

Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)

9.5 (2.5/2.1)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.

6B – 8 ENGINE COOLING
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolan
t
(EC) level should be between the “MIN" and “MAX" lines o
f
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the “MAX" line.
There should not be any excessive deposit of rust or scales
around the radiator cap or radiator filler hole, and the EC
should also be free from oil.
Replace the EC if excessively dirty.


P1010064
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.

2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do not
remove the cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out unde
r
pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it.
Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.
 Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the radiato
r
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to reduce
the pressure when the coolant has become cooler.

6B – 20 ENGINE COOLING
FAN CLUTCH WITH COOLING FAN
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.


033R300001
Visually inspect for damage, leak (sillicon grease) or other
abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at
the fan clutch portion gets to around 80
C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.



033RY00011
2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80
C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.

6C – 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dus
t
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7.
Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to“Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9.
Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.
Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.













Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected agains
t
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)
NOTE: The anchor of the tank band must be certainly installed
to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–75
When control current flows to the timing control valve
(TCV) coil, the valve needle opens and the fuel annular
chamber flows through the orifice to the feed pump inlet.
Consequently, the pressure of the annular chamber
decreases and the hydraulic stopper is moved to the
retard side.
The timing control valve (TCV) acts as a variable
throttle, using the rapid opening and closing (cycling) of
the valve needle in the timing control valve (TCV).
At normal operation, the TCV controls the pressure
acting on the annular chamber so that the hydraulic
stopper cam move to any position, from the retard
position to the advance position. At this time, the duty
ratio is set by the pump control unit (PSG).
Duty ratio is the ratio of the time that the timing control
valve (TCV) is opened to one complete timing control
valve (TCV) operating cycle. A duty ratio change of
100% to 0% is an advance in injection timing. (The
VP44 displays an ON duty ratio.)The engine control module (ECM) contains
characteristic maps of the start of injection,
corresponding to engine operating conditions (engine
load, engine speed and engine coolant temperature).
The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
injection timing. If there is a difference, the timing
control valve (TCV) is controlled by the duty ratio. (The
actual start of injection timing is determined from the
pump camshaft speed sensor.) (1) Coil
(2) From Annular Chamber
(3) To Feed Pump
(4) Orifice
(5) Valve Needle
Engine Load
Engine Speed
Engine Coolant
TemperatureEngine
Control
Module
(ECM)Pump
Control
Unit
(PSG)
Pump Camshaft
Speed Sensor
Timing
Control
Valve
(TCV)

6E–122 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
35 P0560 A OFF System Voltage Malfunction System voltage of PSG
(pump control unit) is below
4.5V or more than 27V.PSG uses default voltage as
substitute.System voltage of PSG is
between 4.5V and 27V.1. Battery power feed
harness open circuit or
short to ground circuit.
2. PSG (pump control unit)
ground harness open or
p o o r c o n n e c t i o n .
3. Poor connector
c o n n e c t i o n .
4 . B a t t e r y m a l f u n c t i o n .
5. Charge system
m a l f u n c t i o n .
6. Battery jump start cable
misconnect.
7. PSG (pump control unit)
malfunction.——
18 P0561 A OFF Ignition Switch Circuit
MalfunctionThe ECM recognized ignition
switch turn off signal during
ECM is activated.ECM stops engine. No recovery until condition
match in the next ignition key
cycle.1. Ignition switch circuit
open or short to ground
c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. Ignition switch
m a l f u n c t i o n .
4. ECM malfunction.39 —
B OFF Ignition Switch Circuit
MalfunctionIgnition switch circuit is
malfunction.1. Ignition switch circuit
open or short to ground
c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. Ignition switch
m a l f u n c t i o n .
4. ECM malfunction.39 —
- P0602 - Control Module
Programming ErrorECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed.
——
28 P0606 A ON ECU Malfunction Gate Array communication
error.1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
becomes 0mg/strk.No recovery. ECM malfunction.
——
B ON ECU Malfunction 1. Throttle position is below
1 % .
2. Desired injection quantity
is more than 0mg/strk.
3. Engine speed is more
t h a n 2 0 0 0 r p m . MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d . Desired injection quantity is
b e l o w 0 m g / s t r k . 1 . E C M m a l f u n c t i o n .
2. PSG (pump control unit)
malfunction.
—— Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

ENGINE MECHANICAL (6VE1 3.5L) 6A-19
Engine Oil Pressure Check
1. Check for dirt, Fuel or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the “Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the
“ADD" and the “FULL" marks on the oil level
dipstick.
If the oil level does not reach the “ADD" mark on
the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
normal operating temperature (About 80C).
6. Measure the oil pressure.
Oil pressure should be:
392




550 kPa (56.9




80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.

6B-6 ENGINE COOLING (6VE1 3.5L)
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“ MIN" and “MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
“ MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.




P1010064
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiato
r
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a
solution that is 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.

 Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
not vapor or boiling water. To open the radiato
r
cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure when
the coolant has become cooler.

After tightening radiator cap, warm up the engine at
about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolan
t
circulate also into heater water system.
 Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5 –minute idling again and stop the engine.
 When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
cooling system and reservoir tank hose for leakage.
 Pour coolant into the reservoir tank up to “MAX"
line.