piston ISUZU TF SERIES 2004 Owner's Guide

7C-38 CLUTCH
SLAVE CYLINDER (6VE1)
DISASSEMBLY
206RW004-X

Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body

CLUTCH 7C-39
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.


206RS003
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
206RS004
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
2. Replace the inner parts with new parts shown in the
illustration.
206RS005

3. Measure the clearance between slave cylinder wall and
piston.
4. If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
mm(in)

Standard Limit
0.07 (0.0028) 0.15 (0.006)

7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:


206RS006
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the fron
t
of cylinder. Use care so as not to scratch the cylinder.

CLUTCH 7C-49

4. CLUTCH NOISE

1) Clutch Pedal Depressed (Clutch Disengaged)

Checkpoint
Trouble Cause
Countermeasure

Replace the pedal shaft with
the sleeveWorn pedal shaft and/or
sleeve
Clean and grease the pedal
shaft and sleeveInsufficient grease at the
pedal shaft and sleeve
NG NGPedal shaft and sleeve
Master cylinder piston and
push rod contact facesClean and grease the master
cylinder piston and push rod
contact facesInsufficient grease at the
maser cylinder piston and
push rod contact faces NG OK
Driven plateReplace the driven plate
assemblyLoose or broken damper
spring NG OK
Crankshaft pilot bearingReplace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn) NG OK



2) Clutch Pedal Not Depressed (Clutch Engaged)

Replace the driven plateWeak or broken damper
spring NGDriven plate damper spring
Replace the crankshaft pilot
bearingInsufficient grease at the
crankshaft pilot bearing (pilot
bearing worn) OK
NG
Crankshaft pilot bearing

7C-50 CLUTCH

5. OIL LEAKAGE

Checkpoint
Trouble Cause
Countermeasure


Replace the body sub
assembly
Weak or damaged piston cup
NG

Tighten the oil pipe


Tighten the oil pipe connection


Tighten the fluid pipe and/or
hose connections


Fluid reservoir

Loosely connected oil pipe


Loosely connected oil pipe


Master cylinder fluid pipe and
hose

Loosely connected fluid pipe
and/or hose


Slave cylinder oil pipe


Replace the piston cup

Slave cylinder

Weak or damaged piston cup

NG NG NG NG
OK OK
OK
OK

Master cylinder

TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? — Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust
valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at
200rpm
Go to Step 11 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element.
2 Was the intake air leakage found from intake
system? — Repair or
replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —
Go to Step 4 Clean or
replace the fuel
filter element.
4 Check the fuel injection pipes.
Does the injection pipes have obstruction or any
damage? — Repair or
replace the fuel
injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Readjust the
injection nozzle
pressure or
replace the
nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 8 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? — Repair or
replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? — Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger
assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger
assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 7
4. Excessive Fuel Consumption
Step Action Value(s) Yes No
1 Was the air cleaner element clogged? — Clean or
replace the air
cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of
the turbocharger? — Repair or
replace the air
intake side of
the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger
4 Was there the fuel leakage? — Repair or
replace the fuel
leakage part. Go to Step 5
5 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 6 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Replace the
injection nozzle
7 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction
found? (Include radiator cap) — Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the
fan clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump
assembly.
8 Was the restriction by the foreign materials in the
cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. — Clean or
replace the
clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? — Replace the
sealing cap or
replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 2 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
2 Was the PCV (Positive Crankcase Ventilation) valve
working completely? —
Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved

6 – 12 TROUBLESHOOTING
10. Abnormal Engine Noise
10–1 Engine knocking
Step Action Value(s) Yes No
1 Was the injection nozzle pressure or injection spray
pattern OK? —
Go to Step 2 Replace the
injection nozzle
2 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm Go to Step 3 Replace the
cylinder head
gasket or
piston ring
3 Are any DTC stored? — Go to indicated
DTC Solved

10–2 Gas leakage noise
Step Action Value(s) Yes No
1 Was the exhaust pipe loose or broken? — Retighten or
replace the
exhaust pipe Go to Step 2
2 Was the exhaust manifold loose? — Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket Go to Step 3
3 Was the injection nozzle loose? — Retighten or
replace the
injection nozzle
fixing bolt Go to Step 4
4 Was the cylinder head gasket broken? — Replace the
cylinder head
gasket Go to Step 5
5 Are any DTC stored? — Go to indicated
DTC Solved