ISUZU TF SERIES 2004 Workshop Manual

ENGINE COOLING 6B-11
Radiator
Radiator and Associated Parts



Legend
1 Radiator Hose
2 Drain Plug
3 Fan Guide, Lower
4 Fan Guide
5 Bracket 6 Reserve Tank Hose
7 Reserve Tank
8 Radiator Cap
9 Radiator Assembly


Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain engine coolant (EC).
3. Disconnect radiator inlet hose and outlet hose.
4. Disconnect the reserve tank hose from radiator.
5. Lift out the radiator assembly, taking care not to damage
the radiator core.

6B-12 ENGINE COOLING


Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 88.3 – 103.0
(13.5 – 15.7)
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.
Valve opening vacuum kPa (psi) 1.9 - 4.9
(0.28 - 0.71)



Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all sign of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:

Leakage from the radiator

Leakage from the coolant pump

Leakage from the water hoses

Check the rubber hoses for swelling.
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0

ENGINE COOLING 6B-13

Installation
1. Install radiator assembly, taking care not to damage the
radiator core.
2. Install the radiator assembly.
3. Connect reserve tank hose.
4. Connect radiator inlet hose and outlet hose.
5. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolan
t
change) procedure for filling with engine coolant.

Remove radiator cap.

Fill with engine coolant (EC) to the radiator filler neck.

Fill with EC to the "MAX" line on the reservoir tank.

Start the engine with the radiator cap removed and bring to
operating temperature by running engine at 2,500 - 3,000
rpm for 30 minutes.

By EC temperature gauge reading make sure that the
thermostat is open.

If air bubbles come up to the radiator filler neck, replenish
with EC. Repeat until the EC level does not drop any further.
Install the radiator cap and stop the engine.

Replenish EC to the "MAX" line on the reservoir tank and
leave as it is until the engine gets cool.


After the engine gets cool, start the engine and make sure
there is no water running noise heard from the heater core
while the engine runs at 3000 rpm.

Should water running noise be heard, repeat the same
procedure from the beginning.


Main Data and Specifications
General Specifications
Cooling system Engine Coolant forced circulation
Radiator Tube type corrugated (2 tube in row)
Heat radiation capacity 66.3 kcal/h
Heat radiation area 7.08 m2
Radiator front area 028 m2
Radiator dry (weight) 3.1 kg
Radiator cap valve opening pressure 93.3 – 122.7 kpa
Engine coolant capacity 2.0L
Engine coolant pump Centrifugal type
Thermostat Bypass type
Engine coolant total capacity 5.7lit

6B-14 ENGINE COOLING
SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME


1

5-8840-0277-0


Tester; radiator cap


2

5-8840-2603-0

Adapter; radiator cap

ENGINE FUEL (C24SE) 6C-1
ENGINE
ENGINE FUEL (C24SE)
CONTENTS

General Description............................................. 6C-2
Service Precaution............................................... 6C-3
Fuel Metering........................................................ 6C-4
Fuel Filter............................................................... 6C-5
Removal.............................................................. 6C-5
Inspection........................................................... 6C-6
Installation.......................................................... 6C-6
Inspection........................................................... 6C-6
In-Tank Fuel Filter............................................. 6C-6
Fuel Pump Flow Test....................................... 6C-7
Fuel Pump.............................................................. 6C-8
Fuel Pump and Associated Parts................. 6C-8
Removal.............................................................. 6C-8
Installation.......................................................... 6C-9
Fuel Tube / Quick - Connector Fittings.......... 6C-10
Precautions........................................................ 6C-10
Cautions During Work..................................... 6C-10

Removal............................................................... 6C-10
Reuse of Quick-Connector............................. 6C-11
Assembling Advice........................................... 6C-11
Fuel Pump Relay................................................... 6C-12
General Description.......................................... 6C-12
Fuel Tank................................................................ 6C-13
Fuel Tank and Associated Parts.................... 6C-13
Removal............................................................... 6C-14
Installation.......................................................... 6C-14
Filler Neck............................................................... 6C-15
Removal............................................................... 6C-15
Installation.......................................................... 6C-15
Fuel Gauge Unit.................................................... 6C-15
Removal and Installation................................. 6C-15
Fuel Filler Cap........................................................ 6C-16
General Description.......................................... 6C-16
Inspection............................................................ 6C-16
Main Data and Specifications............................ 6C-17
Special Tool........................................................ 6C-18

6C-2 ENGINE FUEL (C24SE)
General Description

*
*
*

* Applicable to EVAP Emission Control System
** Not applicable to EVAP Emission Control System

ENGINE FUEL (C24SE) 6C-3


When working on the fuel system, there are several things to
keep in mind:


Any time the fuel system is being worked on, disconnect the
negative battery cable except for those tests where battery
voltage is required.


Always keep a dry chemical (Class B) fire extinguisher near
the work area.

Replace all pipes with the same pipe and fittings that were
removed.

Clean and inspect "O" rings. Replace if required.


Always relieve the line pressure before servicing any fuel
system components.

Do not attempt repairs on the fuel system until you have
read the instructions and checked the pictures relating to
that repair.

Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper emission
control system operation.
Its use will also minimize spark plug fouling and extend engine
oil life. Using leaded gasoline can damage the emission control
system and could result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission Control
System. The purpose of the system is to minimize the escape
of fuel vapors to the atmosphere.



Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or othe
r
corrosion inhibitors) on threaded fasteners or fastene
r
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage 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.

6C-4 ENGINE FUEL (C24SE)

Fuel Metering
Engine Control Module (ECM) is in complete control of this fuel
delivery system during normal driving conditions.
The intake manifold function, like that of a diesel, is used only
to let air into the engine. The fuel is injected by separate
injectors that are mounted over the intake manifold.
The Manifold Absolute Pressure (MAP) sensor measures the
changes in the intake manifold pressure which result from
engine load and speed changes, which the MAP senso
r
converts to a voltage output.
This sensor generates the voltage to change corresponding to
the flow of the air drawn into the engine.
The changing voltage is transformed into an electric signal and
provided to the ECM.
With receipt of the signals sent from the MAP sensor, Intake
Air Temperature sensor and others, the ECM determines an
appropriate fuel injection pulse width feeding such information
to the fuel injector valves to effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection system
where the injectors turn on at every crankshaft revolution. The
ECM controls the injector on time so that the correct amount o
f
fuel is metered depending on driving conditions.
Two interchangeable "O" rings are used on the injector tha
t
must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold and
supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the engine
is running. This removes air and vapors from the fuel as well
as keeping the fuel cool during hot weather operation.
The fuel pressure control valve that is mounted on the fuel rail
maintains a pressure differential across the injectors under all
operating conditions. It is accomplished by controlling the
amount of fuel that is recirculated back to the fuel tank based
on engine demand.
See Section "Driveability and Emission" for more information
and diagnosis.

ENGINE FUEL (C24SE) 6C-5
Fuel Filter
Fuel Filter and Associated Parts







Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system fo
r
loose connections or leakage. For the fuel system
diagnosis, see Section "Driveability and Emissions".

(2.4L)
1. Disconnect battery ground cable.
2. Disconnect the quick connector from the fuel filter.
3. Pull off fuel filter from the holder to side member side.
4. Remove the fuel filter.

6C-6 ENGINE FUEL (C24SE)
Fuel Filter
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt o
r
sediment.
Installation
1. Install the filter to holder from side member side.
NOTE: Attend direction of fuel filter. (1) to engine side
(2) to fuel tank side.
NOTE: Verify to hang holder hook to fuel filter.


NOTE: Verify to hang holder hook to fuel filter.




RTW36CSH000301
2. Connect the quick connector from the fuel tube to
the fuel filter.
NOTE: Pull of the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
3. Tighten fuel filler cap until at least one click are
heard.
4. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel
leakage.
In–Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, no
t
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.