brake ISUZU TF SERIES 2004 Workshop Manual

6B-6 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 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 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.
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 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
at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the engine is
cold.
6. Block the drive wheels and firmly apply the parking brake.
Shift an automatic transmission to "P" (Park) or a manual
transmission to neutral.
7. Remove the radiator cap. Start the engine and warm it up a
t
2,500 - 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck and the
EC level has gone down, replenish with the EC. Repeat this
procedure until the EC level does not go down. Then stop
the engine and install the radiator cap. Let the engine cool
down.
9. After the engine has cooled, replenish with EC up to the
"MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000 rpm,
make sure there is no running water sound from the heate
r
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.

ENGINE ELECTRICAL 6D1-5











































Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly rinse
the affected area with clean tap water.
Never allow metal tools or jumper cables to come in contact
with the positive battery terminal, or any other metal surface of
the vahicle. This will protect against a short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vahicle is equipped with an automatic transmission,
place the selector level in the "PARK" position.
If the vehicle is equipped with a manual transmission, place
the shift lever in the "NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is completely
clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive terminal
of the booster battery.

Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing the
charging procedure.
Be sure that the booster battery has a 12 volt rating.
4.
Attach one end of the remaining cable to the negative
terminal of the booster battery.

Attach the other end of the same cable to a solid engine
ground (such as the air conditioning compressor bracket o
r
the generator mounting bracket) of the vehicle with the
discharged battery.
The ground connection must be at least 450 mm (18 in.)
from the battery of the vehicle whose battery is being
charged.
WARNING: NEVER ATTACH THE END OF THE JUMPER
CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories have
been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in
reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.

ENGINE DRIVEABILITY AND EMISSIONS 6E–233
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in
this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM.
Refer to section 11 “Immobilizer System-ECM replacement” for the ECM/Immobilizer linking procedure.
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagosis.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Check the “Ignition coil” fuse (15A) and “ECM” fuse
(15A).
Was a fuse blown?—Verify repair Go to Step 5
5 1. Ignition ON
2. Use a DVM to verify that battery voltage at the
ignition coil fuse, and the ECM fuse.
Was battery voltage presented at the fuses?—Go to Step 6Verify & repair
6 1. Visually/physically inspect for the following
conditions:
Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 7
7 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?—Verify repair Go to Step 8
8 1. Using a Tech 2, display the MAP sensor value.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 9
9 If oscilloscope is available, check the wave form of the
CKP signal.
Was the correct wave form found?—Go to Step 12Go to Step 10
10 Check the CKP sensor wire for open or short circuit.
Was a problem found?—Verify repair Go to Step 11
11 Replace CKP sensor.
Is there still problem?—Replace pulsar
ring. Verify repair

6E–236 ENGINE DRIVEABILITY AND EMISSIONS
HARD START SYMPTOM
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, of may start and then
immediately stall.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 1. Visually/physically inspect for the following
conditions:
Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 5
5 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?—Verify repair Go to Step 6
6 Check engine coolant temperature (ECT) sensor for
shift in value.
1. After 8 hours with hood up and the engine not
running, connect the Tech 2.
2. Ignition On, engine not running.
3. Using Tech 2, compare Engine Coolant
Temperature to Intake Air Temperature.
Are ECT and IAT within the specified value of each
other? 5°CGo to Step 8Go to Step 7

ENGINE DRIVEABILITY AND EMISSIONS 6E–239
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM
DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed
may vary in RPM. Either condition may be severe
enough to stall the engine.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
Was a problem found? —Verify repair Go to Step 5
5 1. Check for incorrect idle speed. Ensure that the
following conditions are present.
Engine fully warm
Accessories are “Off”
2. Using a Tech 2, monitor IAC position.
Is the IAC position within the specified values? 20-30 Steps Go to Step 7Go to Step 6
6 1. Visually/physically inspect for the following
conditions:
Restriction of the air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 7

ENGINE DRIVEABILITY AND EMISSIONS 6E–249
10 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 11
11 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the lean
condition?—Go to Step 12Go to Step 13
12 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 13
13 1. Visually/physically inspect for the following
conditions:
Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 14
14 Check the injector connectors, if any of the injectors
are connected an incorrect cylinder, correct as
necessary.
Was a problem found?—Verify repair Go to Step 15
15 Perform the “Injector Coil/Balance Test” (Refer to 6E-
98 page).
Was a problem found.—Verify repair Go to Step 16
16 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure
regulator assembly.
Was a problem found?—Verify repair Go to Step 17
17 Check for proper ignition voltage output with the spark
tester.
Was a problem found?—Verify repair Go to Step 18
18 1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?—Verify repair Go to Step 19 Step Action Value(s) Yes No

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and
obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be
sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the movement for the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.

0B-4 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid I - - I - - - I - - - I - - - I - - - I Brake sy stem for fluid l eakage I I I I I I I I I I I I I I I I I I I I Brake functi on I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I
PARKING BRAKE Parki ng brake functi on I I I I I I I I I I I I I I I I I I I I Parki ng brake l ever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage
and guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage - I - I - I - I - I - I - I - I - I - I SUSPENSION Leaf / Coil / Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for l ooseness or damage I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - I - I
Spring action for loss of balance
due to weakening - - - I - - - I - - - I - - - I - - - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I WHEELS Wheel nuts T T - T - T - T - T - T - T - T - T - T Wheel disc for damage I I - I - I - I - I - I - I - I - I - I Hub bearing grease - - - - - R - - - - - R - - - - - R - - Front and rear hub bearing for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation (Rotate as required) OTHERS Bolts and nuts on chassis and body I I - I - I - I - I - I - I - I - I - I Lube front free – wheding hubs - - - - - L - - - - - L - - - - - L - -

MAINTENANCE AND LUBRICATION 0B-7




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Brake fluid (4JA1-TC) - - - - - I - - - - - I - - - - - I - - Brake system for fluid leakage
(4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake system for fluid leakage
(4JA1-TC) - - I - - I - - I - - I - - I - - I - - Brake function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Front Disc brake pads and discs wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Front Disc brake pads and discs wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - * Rear brake lining and drum wear (4JH1-TC) - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Brake pedal travel and play (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Brake pedal travel and play (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Pipes and hoses for loose
connections or damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Pipes and hoses for loose
connections or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - PARKING BRAKE Parking brake function (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Parking brake function (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Parking brake lever travel (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Parking brake lever travel (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Cables for looseness or damage and
guide for damage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Ratchet for wear or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Ratchet for wear or damage (4JA1-TC) SUSPENSION Leaf/Coil/Torsion bar springs for
damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Leaf/Coil/Torsion bar springs for
damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Mount for looseness or damage (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Mount for looseness or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shock absorbers for oil leakage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Shock absorbers mount for
looseness (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Rubber bushes of suspension wear
or damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Rubber bushes of suspension wear
or damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Spring action for loss of balance due
to weakening (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Spring action for loss of balance due
to weakening (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Joint ball rubber boot for damage (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage (4JA1-TC) - - I - - I - - I - - I - - I - - I - -

0B-10 MAINTENANCE AND LUBRICATION




I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading or
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60months whichever comes
fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid - - - - - - - I - - - - - - - I - - - - Brake system for fluid leakage - - - I - - - I - - - I - - - I - - - I Brake function - - - I - - - I - - - I - - - I - - - I * Front Disc brake pads and discs wear - - - I - - - I - - - I - - - I - - - I * Rear brake lining and drum wear - - - I - - - I - - - I - - - I - - - I Brake pedal travel and play - - - I - - - I - - - I - - - I - - - I Pipes and hoses for loose
connections or damage - - - I - - - I - - - I - - - I - - - I
PARKING BRAKE Parking brake function - - - I - - - I - - - I - - - I - - - I Parking brake lever travel - - - I - - - I - - - I - - - I - - - I Cables for looseness or damage and
guide for damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
-
Ratchet for wear or damage - - - I - - - I - - - I - - - I - - - I SUSPENSION Leaf/Coil/Torsion bar springs for
damage - - - I - - - I - - - I - - - I - - - I
Mount for looseness or damage - - - I - - - I - - - I - - - I - - - I Shock absorbers for oil leakage - - - I - - - I - - - I - - - I - - - I Shock absorbers mount for
looseness - - - I - - - I - - - I - - - I - - - I
Rubber bushes of suspension wear
or damage - - - I - - - I - - - I - - - I - - - I
Spring action for loss of balance due
to weakening - - - - - - - - - - - I - - - - - - - -
Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I WHEELS Wheel nuts - - - T - - - T - - - T - - - T - - - T Wheel disc for damage - - - I - - - I - - - I - - - I - - - I Hub bearing grease - - - - - - - R - - - - - - - R - - - - Front and rear hub bearings for
looseness - - - I - - - I - - - I - - - I - - - I
Tire pressure and damage I - - I - - - I - - - I - - - I - - - I Tire rotation (Rotate as required) OTHERS Bolts and nuts on chassis and body - - - I - - - I - - - I - - - I - - - I Lube front free - wheeling hubs - - - - - - - L - - - - - - - L - - - -