tow ISUZU TF SERIES 2004 User Guide

BRAKES 5C-45

P1010008


Important Operations
4. Spring ; shoe hold
Push the shoe hold spring toward the brake shoe and hold it.
Rotate the spring to remove it from the shoe hold pin.


6. Spring ; shoe to shoe, lower
Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.


INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.





Brake drum


Back plate


Brake lining


Wheel cylinder body


Piston

Piston cup

Return spring



Visual check
Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.





Thickness of the Brake Lining
Thickness mm(in)
standard (T) Limit (t)
4

2 5.0 (0.197) 1.0 (0.039)
4

2 HIGH RIDE
4

4 5.0 (0.197) 1.0 (0.039)

ELECTRICAL-BODY AND CHASSIS 8A-5
NOTES FOR WORKING ON ELECTRICAL ITEMS
Battery

BATTERY CABLE
Disconnecting the Battery Cable
1. All switches should be "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result in
a short circuit.














Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order to
connect the battery cables.
CAUTION:
Clean the battery terminal and apply light coat of grease to
prevent terminal corrosion.




CONNECTOR HANDLING
Disconnecting the Connectors
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards you
1.
Other tang locks are released by pressing them forward
2.
Determine which type of tang lock is on the connector being
handled.



Firmly grasp both sides (male and female) of the connector.
Release the tang lock and carefully pull the two halves of the
connector apart.
Never pull on the wires to separate the connectors.
This will result in wire breakage.

ELECTRICAL-BODY AND CHASSIS 8A-7


Pin Tang Lock Type
1. Insert a slender shaft 3 into the connector housing open
end
4.
2. Push the tang lock
8flat (toward the wire side of the
connector).
Pull the wire
6 with pin 7free from the wire side of the
connector.



Connector Pin Insertion
1. Check that the tang lock 8 is fully up.
2. Insert the pin
7 from the connector wire side 9.
Push the pin in until the tang lock closes firmly.
3. Gently pull on the wires
6to make sure that connector pin
is firmly set in place.



Fuse Replacement
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a burn out fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious circuit
damage.



Parts Handling
Be careful for parts handling and any part should not be
dropped or thrown, otherwise short circuit or disorder may
result.



Wiring Harness
1. When assembling the parts, be careful not to bite or wedge
the wiring harness.
2. All electrical connections must be kept clean and tight.

8A-20 ELECTRICAL-BODY AND CHASSIS

Caution:
Never push or tow the vehicle in an attempt to start it.
Extensive damage to the emission system and other
vehicle parts will result.
(Only catalytic converter vehicle)
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the procedure outlined below.
Always be aware of the dangers of sparking.
Failure to follow the following procedure can result in:
a. Serious personal injury, specially to your eyes.
b. Extensive property damage from a battery explosion,
battery acid discharge, or electrical file.
c. Extensive damage to the electronic components o
f
both vehicles.
Do not use a 24 volt booster battery.
Serious damage to the vehicle's electrical system and
electronic components will result.

Jump Starting Procedure
1. Set the parking brake on both vehicles.
2. If one or both vehicles is equipped with a manual
transmission, place the gear shift in the "NEUTRAL"
position.
3. Turn off the ignition on both vehicles.
4. Turn off all vehicle lights and accessories.
5 Be sure that the two vehicles are not touching.

Attach the end of one jumper cable to the booster battery
positive terminal.
6
Attach the other end of the same cable to the discharged
battery positive terminal.
7. Once again, check that the booster battery has a 12 vol
t
rating.
8.
Attach one end of the remaining booster cable to the
booster battery negative terminal.
9.
Attach the other end of the booster cable to a solid ground
(such as the air conditioner compressor mounting bracke
t
or the alternator mounting bracket) in the engine room o
f
the vehicle with the discharged battery.
Be sure that the ground connection is at least 500 mm (20
in) from the discharged battery.

8A-106 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
6VE1
Removal
1. Pull both the red ECM harness connector locks toward the
front of the vehicle, and remove the two harness connectors
form the ECM.
2. Remove the four hex-head screws securing the ECM to the
common chamber.
3. Remove the ECM from the engine compartment.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





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



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-132 ELECTRICAL-BODY AND CHASSIS

Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
Wire damage will result.


AIMING OF HEADLIGHT
Check and adjust the inflation pressures, clean the headlight,
park the vehicle on a level surface and insure that vehicle is at
curb weight.


VERTICAL ADJUSTMENT
Use a screwdriver for vertical adjustment.



HORIZONTAL ADJUSTMENT
Use a screwdriver horizontal adjustment.


Installation
To install, follow the removal steps in the reverse order.
Noting the following point:
1. After installing the headlight, be sure to adjust the headligh
t
aim.

HEADLIGHT ADJUSTMENT
Preparation
Place the vehicle with 1 person in driver seat on a level surface
and check to see if the inflation pressure of the tires is correct,
the lenses are clean, the battery is sufficiently charged, and
adjust to place vehicle by using the screen.
1. Set a vertical screen on a level surface.
2. Toward the screen
1from the bulb center mark of the
headlight, extend parallel lines to the floor. Mark point
A
and B on the screen at the intersection of parallel line and
the screen.
3. Draw vertical lines through point
A and B on the screen.

8A-174 ELECTRICAL-BODY AND CHASSIS

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



Bulb
Be absolutely sure that each bulb is correctly installed.
This will prevent a poor contact and an open circuit.

SIDE TURN LIGHT
Removal
1. Remove the lens 1.

Pull the light/bulb toward you while pushing the ligh
t
housing in the rear direction of the vehicle to release its
lock.

Remove the socket by turning it counterclockwise.
2. Pull the bulb
2 to remove it.


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



Bulb
Be absolutely sure that the side turn light bulb is correctly
installed.
This will prevent a poor contact and an open circuit.
















REAR COMBINATION LIGHT
Turn Signal Light
Removal
1. Open the rear gate.
2. Remove the screws.
3. Remove the rear combination light assembly.

4. Turn the bulb 1 counterclockwise to remove it.

ELECTRICAL-BODY AND CHASSIS 8A-357


(5) If there is a place where the voltage suddenly changes to
0V, there is a broken wire between there and the powe
r
side.
(6) Move the tester probe from the position where the voltage
changes to 0V toward the power side and find where the
voltage suddenly increases.



REPAIR OF BROKEN HEAT WIRE
(1) Clean broken wire tips with white gasoline.
(2) Place masking tape along both sides of wire to be repaired.



(3) Thoroughly mix the repair agent (Dupont paste No. 4817 or
equivalent).
(4) Using a fine tip brush, apply a small amount to the wire.
(5) After a couple of minutes, remove the masking tape.
(6) Allow to stand at least 24 hours.

6A – 34 ENGINE MECHANICAL



RTW46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8)
is aligned with the pointer.

Injection Timing : BTDC 8  2

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket
bolts.
11. Adjust the injection pump setting angle.
When large than standard
value When smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.

ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80C (158 - 176F).


4. Disconnect the engine control cable from the control
lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730  25 rpm


Idling Speed Adjustment
1. Loosen the idling set screw lock nut
on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt
.
3. Lock the engine set nut

with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.

6A – 52 ENGINE MECHANICAL


RTW36ASH000801
Idler Gear "A" End Play Measurement
Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measured value exceeds the specified limit, the
thrust collar must be replaced.

Idler Gear End Play mm (in)
Standard Limit
0.07 (0.0028) 0.2 (0.0079)





4JA1T(L)
040R300009
14. Idle Gear Shaft
15. Crankshaft Timing Gear



4JA1TC/4JH1TC RTW36ASH001301
16. Injection Pump
1. Remove the injection pump cover (4JA1TC/4JH1TC
only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.

NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.









17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0

18. Crank Case

19. Oil Pump With Oil Pipe

015RY00001