length ISUZU TF SERIES 2004 Owner's Guide
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 2504 of 4264
6A-84 ENGINE MECHANICAL (C24SE)
Piston Pins
Dimensions
Length mm
Diameter mm
61.5
21
Type Shank-fit in con-rod
Clearance
In piston mm
In con-rod mm 2.4L
0.010 to 0.015
0
Installation See operation “Con-rod, Replace”
Page 2539 of 4264
ENGINE FUEL (C24SE) 6C-15
Filler Neck
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck
assembly is restored.
Each joint area of the hose (to restore axial
direction and insertion length of the hose)
Each fasten area of the clamp (to restore axial
direction and position of the clamp)
Each bolt in the clamp (to restore fasten length
of bolt in the clamp)
The band clip (to restore position and fasten
length of the band clip)
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Installation
1. Align each marking and restore the following point.
Each joint area of the hose (Restore axial
direction and insertion length of the hose)
Each fasten area of the clamp (Restore axial
direction and position of the clamp)
Each bolt in the clamp (Restore fasten length o
f
bolt in the clamp)
Torque: 2.5 N
m (0.25 kg
m / 2 lb ft) … filler neck
side except flat deck model.
The band clip (Restore position and fasten
length of the band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
Fuel Gauge Unit
Removal and Installation
As for removal and installation of the Fuel Gauge Unit,
refer to “Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sende
r
assembly.
Page 2559 of 4264
STARTING AND CHARGING SYSTEM 6D3-5
Inspection and Repair
Repair or replace necessary parts if extreme wear or damage
is found during inspection.
Armature
Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).
Check for continuity between commutator and shaft.
Also, check for continuity between commutator and armature
core, armature core and shaft. Replace commutator if there is
continuity (i.e., internally grounded).
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Brush Holder
Check for continuity between brush holder (+) (4) and base (-).
Replace, if there is continuity (i.e., insulation is broken).
Magnetic Switch
Check for continuity of shunt coil between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).
Continuity of Series Coil
Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).
Page 2571 of 4264
STARTING AND CHARGING SYSTEM 6D3-17
fan.
4. Replacing the brushes (inbuilt regulator)
Check the brushes for length, this is measured from the brush
holder to the end of the brush along it's centre line. Also
inspect for any sideways wear. If worn replace both brushes.
The minimum length is 3.8mm. Inspect the brush springs for
signs of corrosion or loss of tension or uneven tension.
Replacing the brushes, using a soldering iron apply heat to the
soldered joints on the rear of the brush holder of the regulator,
using a small lever prise up the retaining tabs to release the
brush lead and spring. Thread the new brush lead up the
brush holder along with the spring, pull the lead through the
tabs until the brush is protruding 12mm from the holder.
Bend down the tabs and solder the brush lead taking care not
to allow the solder to run up the lead which will reduce
flexibility. Use 60/40 resin cored solder.
5. Ball bearing
Please note the bearings used in this KCA generator are a
high
tolerance type, only fully sealed bearings of the same
specification are to be used as replacements. It is
recommended that the bearings be replaced during the
reconditioning process to restore the unit to original
specification.
6. Regulator
The regulator can only be tested when fitted into an altenator.
Warning: do not reverse"S" and "L" connections or put 12
volt supply to "L" terminal, this connection must not be
used as a supply source other than to supply the
requirements of the warning lamp 2(watts).
Such action will destroy the regulator warning lamp
circuit.
For test voltages refer to Generator output testing section.
See also additional information on regulator function earlier in
this instruction.
Page 2575 of 4264
STARTING AND CHARGING SYSTEM 6D3-21
Technical Data
(mm)
Brush wear - Minimum Length 3.8
Sliprings - Minimum Diameter 26.7
Sliprings - Trueness <0.06
Pole claws - Trueness <0.05(93.25
0.05)
Torque
N.m(kgf
m)
Pulley retaining nut 54-68(5.5-6.9)
Capacitor retaining screw 2.7-3.8(0.3-0.4)
Capacitor whiz nut 1.5-2.2(0.1-0.2)
B+ terminal nut M8 7.5-8.5(0.8-0.9)
B+ terminal rectifier nut 6.0-7.5(0.6-0.8)
Regulator retaining screw 1.6-2.3(0.1-0.2)
Rectifier retaining screw 1.6-2.3(0.1-0.2)
Bearing retaining plate screw 2.1-3.0(0.2-0.3)
Through bolt 3.8-5.5(0.4-0.6)
Winding resistance(between phases)
(
)
Stator Rotor
70 Amp generator 0.086+10% 2.6
0.13
85 Amp generator 0.058+10% 2.6
0.13
90 Amp generator 0.056+10% 2.6
0.13
Warning lamp fault indication
Fault running Generator not
running Ignition ONGenerator
Iginiton ON
Generator out cable
O/CON ON
Battery "S" cable O/C ON ON
Battery overcharged ON ON
Positive diode short OFF ON
Negative diode short ON ON
Positive diode open ON OFF
Negative diode open ON OFF
Phase voltage sensing ON ON
cable open circuit
Power transistor
shortedON ON
Warnign lamp driver
O/COFF OFF
Page 2687 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–111
10 Locate and repair the loss of vacuum to the fuel
pressure regulator.
Is the action complete?—Veri fy repai r—
11 Replace the fuel pressure regulator.
Is the action complete?—Veri fy repai r—
12 1. Run the fuel pump with the Scan Tool.
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?—Go to Step 13Go to Step 15
13 Visually inspect the fuel supply line and repair any
leaks.
Was a problem found?—Verify repair Go to Step 14
14 Remove the fuel tank and inspect for leaky hose or in-
tank fuel line.
Was a problem found?—Verify repair Go to Step 8
15 1. If the pliers are still clamped to the fuel supply
hose, remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
3. Run the fuel pump with the Scan Tool.
4. After pressure has built up, remove power to the
pump.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?—Go to Step 11Go to Step 16
16 Locate and replace any leaking fuel injector(s).
Is the action complete?—Veri fy repai r—
17 Is the fuel pressure indicated by the fuel pressure
gauge above the specified limit?376 kPa
(55 psi) Go to Step 18Go to Step 21
18 1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flex ible hose to the fuel rail
return outlet passage.
4. Place the open end of the flex ible hose into an
approved gasoline container.
5. Run the fuel pump with the Scan Tool.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?290-376 kPa
(42-55 psi) Go to Step 19Go to Step 20
19 Locate and correct the restriction in the fuel return
line.
Is the action complete?—Veri fy repai r—
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found?—Verify repair Go to Step 11
21 Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22Go to Step 23 Step Action Value(s) Yes No
Page 2804 of 4264
6E–228 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P1693
TACHOMETER OUTPUT LOW VOLTAGE
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
Based on the information from the Crank Position
Sensor (CKP), X58 reference signal is generated at
each rotation of the crankshaft.
Engine Control Module (ECM) converts X58 reference
signal into the square wave signal which is used to drive
the pulse generator of the tachometer.
When the wave length of the output signal is long, the
tacho meter indicates the engine speed is low, and vise
versa.
This malfunction detects a low impedance short toground or open contact on the Tacho output, the
Diagnostic Trouble Code P1693 will be set.
Diagnostic Aids
Poor connections or a damaged harness - Inspect
the harness connections for: backed out terminals,
imprope, mating or damaged terminals. Also check
for open circuit, short to ground, and short to voltage.
This malfunction detects a low impedance short to
ground or open contact on the ECM out put circuit.
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P1693 B Tacho mete r Output Lo w Vo lta ge Tacho o utput circuit sho rt to gro und circuit. No fail-safe functio n.
Page 2981 of 4264
GENERAL INFORMATION 0A-9
CONVERSION TABLE
TABLE OF CONTENTS
PAGE
Length ............................................................................................................................... 0A- 9
Area ................................................................................................................................... 0A-11
Volume .............................................................................................................................. 0A-11
Mass.................................................................................................................................. 0A-13
Pressure ........................................................................................................................... 0A-14
Torque............................................................................................................................... 0A-15
Temperature ..................................................................................................................... 0A-16
LENGTH
MILLIMETERS TO INCHES
mm in. mm in. mm in. mm in. 1 0.0394 26 1.0236 51 2.0079 76 2.9921 2 0.0787 27 1.0630 52 2.0472 77 3.0315 3 0.1181 28 1.1024 53 2.0866 78 3.0709 4 0.1575 29 1.1417 54 2.1260 79 3.1102 5 0.1969 30 1.1811 55 2.1654 80 3.1496 6 0.2362 31 1.2205 56 2.2047 81 3.1890 7 0.2756 32 1.2598 57 2.2441 82 3.2283 8 0.3150 33 1.2992 58 2.2835 83 3.2677 9 0.3543 34 1.3386 59 2.3228 84 3.307110 0.3937 35 1.3780 60 2.3622 85 3.346511 0.4331 36 1.4173 61 2.4016 86 3.385812 0.4724 37 1.4567 62 2.4409 87 3.425213 0.5118 38 1.4961 63 2.4803 88 3.464614 0.5512 39 1.5354 64 2.5197 89 3.503915 0.5906 40 1.5748 65 2.5591 90 3.543316 0.6299 41 1.6142 66 2.5984 91 3.582717 0.6693 42 1.6535 67 2.6378 92 3.622018 0.7087 43 1.6929 68 2.6772 93 3.661419 0.7480 44 1.7323 69 2.7165 94 3.700820 0.7874 45 1.7717 70 2.7559 95 3.740221 0.8268 46 1.8110 71 2.7953 96 3.779522 0.8661 47 1.8504 72 2.8346 97 3.818923 0.9055 48 1.8898 73 2.8740 98 3.858324 0.9449 49 1.9291 74 2.9134 99 3.897625 0.9843 50 1.9685 75 2.9528 100 3.9370 101 3.9764 111 4.3701 121 4.7638 131 5.1575102 4.0157 112 4.4094 122 4.8031 132 5.1968103 4.0551 113 4.4488 123 4.8425 133 5.2362104 4.0945 114 4.4882 124 4.8819 134 5.2756105 4.1339 115 4.5276 125 4.9213 135 5.3150106 4.1732 116 4.5669 126 4.9606 136 5.3543107 4.2126 117 4.6063 127 5.0000 137 5.3937108 4.2520 118 4.6457 128 5.0394 138 5.4331109 4.2913 119 4.6850 129 5.0787 139 5.4724
INCHES TO MILLIMETERS
in. mm in. mm 1/64 0.3969 33/64 13.0969 1/32 0.7938 17/32 13.4938 3/64 1.1906 35/64 13.89061/16 1.5875 9/16 14.2875 5/64 1.9844 37/64 14.6844 3/32 2.3813 19/32 15.0813 7/64 2.7781 39/64 15.47811/8 3.1750 5/8 15.8750 9/64 3.5719 41/64 16.2719 5/32 3.9688 21/32 16.6688 11/64 4.3656 43/64 17.06563/16 4.7625 11/16 17.4625 13/64 5.1594 45/64 17.8594 7/32 5.5563 23/32 18.2563 15/64 5.9531 47/64 18.65311/4 6.3500 3/4 19.0500 17/64 6.7469 49/64 19.4469 9/32 7.1438 25/32 19.8438 19/64 7.5406 51/64 20.24065/16 7.9375 13/16 20.6375 21/64 8.3344 53/64 21.0344 11/32 8.7313 27/32 21.4313 23/64 9.1281 55/64 21.82813/8 9.5250 7/8 22.2250 25/64 9.9219 57/64 22.6219 13/32 10.3188 29/32 23.0188 27/64 10.7156 59/64 23.41567/16 11.1125 15/16 23.8125 29/64 11.5094 61/64 24.2094 15/32 11.9063 31/32 24.6063 31/64 12.3031 63/64 25.00311/2 12.7000 1 25.4000
Page 2982 of 4264
0A-10 GENERAL INFORMATION
LENGTH
FEET TO METERS
ft. 0 1 2 3 4 5 6 7 8 9 ft. m m m m m m m m m m - 0.305 0.610 0.914 1.219 1.524 1.829 2.134 2.438 2.743 - 10 3.048 3.353 3.658 3.962 4.267 4.572 4.877 5.182 5.486 5.791 10 20 6.096 6.401 6.706 7.010 7.315 7.620 7.925 8.230 8.534 8.839 20 30 9.144 9.449 9.754 10.058 10.363 10.668 10.973 11.278 11.582 11.887 30 40 12.192 12.497 12.802 13.106 13.411 13.716 14.021 14.326 14.630 14.935 40 50 15.240 15.545 15.850 16.154 16.459 16.764 17.069 17.374 17.678 17.983 50 60 18.288 18.593 18.898 19.202 19.507 19.812 20.117 20.422 20.726 21.031 60 70 21.336 21.641 21.946 22.250 22.555 22.860 23.165 23.470 23.774 24.079 70 80 24.384 24.689 24.994 25.298 25.603 25.908 26.213 26.518 26.822 27.127 80 90 27.432 27.737 28.042 28.346 28.651 28.956 29.261 29.566 29.870 30.175 90100 30.480 30.785 31.090 31.394 31.699 32.004 32.309 32.614 32.918 33.223 100
METERS TO FEET
m 0 1 2 3 4 5 6 7 8 9 m ft. ft. ft. ft. ft. ft. ft. ft. ft. ft. - 3.2808 6.5617 9.8425 13.1234 16.4042 19.6850 22.9659 26.2467 29.5276 - 10 32.8084 36.0892 39.3701 42.6509 45.9318 49.2126 52.4934 55.7743 59.0551 62.3360 10 20 65.6168 68.8976 72.1785 75.4593 78.7402 82.0210 85.3018 88.5827 91.8635 95.1444 20 30 98.4252 101.7060 104.9869 108.2677 111.5486 114.8294 118.1102 121.3911 124.6719 127.9528 30 40 131.2336 134.5144 137.7953 141.0761 144.3570 147.6378 150.9186 154.1995 175.4803 160.7612 40 50 164.0420 167.3228 170.6037 173.8845 177.1654 180.4462 183.7270 187.0079 190.2887 193.5696 50 60 196.8504 200.1312 203.4121 206.6929 209.9738 213.2546 216.5354 219.8163 223.0971 226.3780 60 70 229.6588 232.9396 236.2205 239.5013 242.7822 246.0630 249.3438 252.6247 255.9055 259.1864 70 80 262.4672 265.7480 269.0289 272.3097 275.5906 278.8714 282.1522 285.4331 288.7139 291.9948 80 90 295.2756 298.5564 301.8373 305.1181 308.3990 311.6798 314.9606 318.2415 321.5223 324.8032 90 100 328.0840 331.3648 334.6457 337.9265 341.2074 344.4882 347.7690 351.0499 354.3307 357.6116 100
MILES TO KILOMETERS
miles 0 1 2 3 4 5 6 7 8 9 miles km km km km km km km km km km - 1.609 3.219 4.828 6.437 8.047 9.656 11.265 12.875 14.484 - 10 16.093 17.703 19.312 20.921 22.531 24.140 25.750 27.359 28.968 30.578 10 20 32.187 33.796 35.406 37.015 38.624 40.234 41.843 43.452 45.062 46.671 20 30 48.280 49.890 51.499 53.108 54.718 56.327 57.936 59.546 61.155 62.764 30 40 64.374 65.983 67.592 69.202 70.811 72.420 74.030 75.639 77.249 78.858 40 50 80.467 82.077 83.686 85.295 86.905 88.514 90.123 91.733 93.342 94.951 50 60 96.561 98.170 99.779 101.389 103.000 104.607 106.217 107.826 109.435 111.045 60 70 112.654 114.263 115.873 117.482 119.091 120.700 122.310 123.919 125.529 127.138 70 80 128.748 130.357 131.966 133.576 135.185 136.794 138.404 140.013 141.622 143.232 80 90 144.841 146.450 148.060 149.669 151.278 152.888 154.497 156.106 157.716 159.325 90 100 160.934 162.544 164.153 165.762 167.372 168.981 170.590 172.200 173.809 175.418 100
KILOMETERS TO MILES
km 0 1 2 3 4 5 6 7 8 9 km miles miles miles miles miles miles miles miles miles miles - 0.621 1.243 1.864 2.485 3.107 3.728 4.350 4.971 5.592 - 10 6.214 6.835 7.456 8.078 8.699 9.321 9.942 10.563 11.185 11.806 10 20 12.427 13.049 13.670 14.292 14.913 15.534 16.156 16.777 17.398 18.020 20 30 18.641 19.262 19.884 20.505 21.127 21.748 22.370 22.990 23.612 24.233 30 40 24.855 25.476 26.098 26.719 27.340 27.962 28.583 29.204 29.826 30.447 40 50 31.065 31.690 32.311 32.933 33.554 34.175 34.797 35.418 36.039 36.661 50 60 37.282 37.904 38.525 39.146 39.768 40.389 41.010 41.632 42.253 42.875 60 70 43.496 44.117 44.739 45.360 45.981 46.603 47.224 47.845 48.467 49.088 70 80 49.711 50.331 50.952 51.574 52.195 52.816 53.438 54.059 54.681 55.302 80 90 55.923 56.545 57.166 57.187 58.409 59.030 59.652 60.273 60.894 61.516 90 100 62.137 62.758 63.390 64.001 64.622 65.244 65.865 66.487 67.108 67.729 100
Page 3143 of 4264
MSG MODEL 7B-25
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness mm(in)
Standard Limit
1st-2nd 9.6-9.8 (0.378-0.386) 9.0 (0.354)
3rd-4th 6.95-7.2 (0.273-0.283) 6.5 (0.256)
Rev.-5th 6.8-6.9 (0.268-0.272) 6.3 (0.248)
DETENT SPRING FREE LENGTH
Use a venier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the
detent spring must be replaced.
Detent Spring Free Length mm(in)
Standard Limit
25.6 (1.01) 23.6 (0.93)
DETENT SPRING TENSION
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.
Valve Spring Tension N(kg/lb)
Compressed
Height mm(in)Standard Limit
22.1 (0.870)61.8-65.7
(6.3-6.7/13.9-14.8)55.9
(5.7/12.6)
BLOCK RING AND DOG TEETH
CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance mm(in)
Standard Limit
1st,2nd 2.0 (0.078) 1.3 (0.051)
3rd, 4th, 5th 1.5 (0.059) 0.8 (0.032)