service ISUZU TF SERIES 2004 Workshop Manual

ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE
General Description........................................................................................................ 6B- 2
Service Precaution......................................................................................................... 6B- 3
Diagnosis......................................................................................................................... 6B- 5
Draining and Refilling Cooling System ......................................................................... 6B- 6
Water Pump ..................................................................................................................... 6B- 7
Water Pump and Associated Parts ........................................................................... 6B- 7
Removal ...................................................................................................................... 6B- 7
Inspection ................................................................................................................... 6B- 7
Installation .................................................................................................................. 6B- 8
Thermostat ...................................................................................................................... 6B- 9
Removal ...................................................................................................................... 6B- 9
Inspection ................................................................................................................... 6B- 9
Installation .................................................................................................................. 6B- 9
Fan clutch with Cooling Fan .......................................................................................... 6B- 9
Inspection and Repair................................................................................................ 6B- 9
Radiator ........................................................................................................................... 6B-11
Radiator and Associated Parts ................................................................................. 6B-11
Removal ...................................................................................................................... 6B-11
Inspection ................................................................................................................... 6B-12
Installation .................................................................................................................. 6B-13
Main Data and Specifications ........................................................................................ 6B-13
Special Service Tool ....................................................................................................... 6B-14

ENGINE COOLING 6B-3


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 other
corrosion inhibitors) on threaded fasteners or fastener
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.


Water pump
The water pump is centrifugal type and is driven by timing belt.


Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.





110RS001
Radiator
The radiator is a flow type with corrugated fins.

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.

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

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.

ENGINE ELECTRICAL 6D1-1
SECTION 6D1
ENGINE ELECTRICAL
CONTENTS
PAGE
Battery ............................................................................................................................. 6D1- 2
General Description ................................................................................................... 6D1- 2
Service Precaution ..................................................................................................... 6D1- 2
Diagnosis .................................................................................................................... 6D1- 3
Battery Charging ........................................................................................................ 6D1- 4
Jump Starting ............................................................................................................. 6D1- 4
Removal ...................................................................................................................... 6D1- 6
Installation .................................................................................................................. 6D1- 6
Main Data and Specifications ................................................................................... 6D1- 6

6D1-2 ENGINE ELECTRICAL

Battery
General Description
There are six battery fluid caps on top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small vent
holes on the side. These vent holes permit the escape of small
amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire service life
of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive charge,
resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge than a
conventional type battery.



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 other
corrosion inhibitors) on threaded fasteners or fastener
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.

IGNITION SYSTEM 6D2-1
SECTION 6D2
IGNITION SYSTEM
CONTENTS
PAGE
General Description........................................................................................................ 6D2- 2
Service Precaution ......................................................................................................... 6D2- 2
Diagnosis......................................................................................................................... 6D2- 2
Ignition Coil ..................................................................................................................... 6D2- 2
Removal ...................................................................................................................... 6D2- 2
Installation .................................................................................................................. 6D2- 2
Spark Plug ....................................................................................................................... 6D2- 3
Removal ...................................................................................................................... 6D2- 3
Inspection and Repair................................................................................................ 6D2- 3
Installation .................................................................................................................. 6D2- 4
Crankshaft Angle Sensor ............................................................................................... 6D2- 4
Removal ...................................................................................................................... 6D2- 4
Installation .................................................................................................................. 6D2- 4
Main Data and Specifications ........................................................................................ 6D2- 5

6D2-2 IGNITION SYSTEM



General Description
Ignition is done by the Ignition Module that fires.
Since the cylinder on exhaust stroke requires less energy to
fire its spark plug, energy from the ignition coils can be utilized
to fire the mating cylinder on compression stroke.
A notch in the timing disc on the crankshaft activates the crank
angle sensor which then sends information such as firing order
and starting timing of ignition coil to the ECM.
By receiving signals such as crank position, engine speed,
water temperature and Manifold Absolute Pressure (MAP), the
ECM controls the ignition timing.




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 other
corrosion inhibitors) on threaded fasteners or fastener
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.




Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to
electronic ignition system (El system).





Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Disconnect the Ignition coil connector.
3. Remove the ignition coil.



Installation
1. Install the ignition coil.
Connect ignition coil connector and ignition coil, then tighten
bolt to the specified torque.
Torque: 20 N




m (2.0 kgf




m)
2. Connect battery ground cable.