fuel ISUZU TF SERIES 2004 Workshop Manual

MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SCHEDULE (For EUROPE)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

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
DIESEL ENGINE * Engine oil (4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * Engine oil filter(4JH1-TC) - R - R - R- R- R- R- R - R - R- R* Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - I I I I I I I I I I I I I I I I I I I
Valve clearance (4JH1-TC) - - - A - - - A - - - A - - - A - - - A Valve clearance (4JA1-TC) - - A - - A - - A - - A - - A - - A - - * Air cleaner element (4JH1-TC) I I I I I I I R I I I I I I I R I I I I * Air clearance element (4JA1-TC) - - I I I I I I R I I I I I I I I R I I Fuel filter (4JH1-TC) - - R - - R - - R - - R - - R - - R - - Fuel filter (4JA1-TC) - - - - - - - - R - - - - - - - - R - - Engine coolant concentration (4JH1-TC) - I - I - I - I - I - I - I - I - I - I Engine coolant concentration
(4JA1-TC) - - I - - I - - I - - I - - I - - I - - Cooling system for water leakage
(4JH1-TC) - I - I - I - I - I - I - I - I - I - I Cooing system for water leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - CLUTCH Clutch fluid (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch fluid (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Clutch pedal travel and play (4JH1-TC) I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play (4JA1-TC) - - I - - I - - I - - I - - I - - I - - TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * Manual transmission with fluid
(4JA1-TC) - - R - - I - - R - - I - - R - - I - - * Transfer case oil (4JH1-TC) - - - I - - - I - - - I - - - I - - - I * Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - - Oil leakage (4JH1-TC) I I I I I I I I I I I I I I I I I I I I Oil leakage (4JA1-TC) - - I - - I - - I - - I - - I - - I - - Gear control mechanism for
looseness (4JH1-TC) - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Automatic transmission fluid
(4JH1-TC) - - - I - - - I - - - I - - - I - - - I * AT Automatic transmission fluid (4JA1-TC) - - - - - - - - I - - - - - - - - I - I * AT Transfer case oil (4JH1-TC) - R - I - - - R - - - I - - - R - - - I * AT Transfer case oil (4JA1-TC) - - R - - I - - R - - I - - R - - I - -

MAINTENANCE AND LUBRICATION 0B-9


Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
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
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R* Engine oil filter - - - R - - - R - - - R - - - R - - - ROil leakage and contamination - - - I - - - I - - - I - - - I - - - I Idling speed and acceleration - - - I - - - I - - - I - - - I - - - I Fan belt tension and damage - - - I - - - I - - - I - - - I - - - I Exhaust system - - - I - - - I - - - I - - - I - - - I All hoses and pipes in engine
compartment for clog of damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
Valve clearance - - - A - - - A - - - A - - - A - - - A * Air cleaner element - - - I - - - I - - - R - - - I - - - I Fuel filter - - - - - - - - - - - R - - - - - - - - Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid - - - I - - - I - - - I - - - I - - - I Clutch pedal travel and play - - - I - - - I - - - I - - - I - - - I TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* AT Automatic transmissi on fl ui d - - - - - - - - - - - I - - - - - - - - * AT Transfer case oil - - - R - - - I - - - R - - - I - - - R PROPELLER SHAFT Loose connections - - - I - - - I - - - I - - - I - - - I * Universal joints and splines for wear - - - I - - - I - - - I - - - I - - - I 4WD Universal joints and sliding
sleeve - - - L - - - L - - - L - - - L - - - L
FRONT AND REAR AXLE * Differential gear oil (Front and rear) - - - R - - - I - - - R - - - I - - - ROil leakage - - - I - - - I - - - I - - - I - - - I Shift on the fly system Gear oi l - - - - - - - - - - - I - - - - - - - - Front axle shaft rubber boot for
damage - - - - - - - - - - - I - - - - - - - I
Axle case for distortion or damage - - - - - - - - - - - I - - - - - - - I Axle shafts for distortion or damage - - - - - - - - - - - I - - - - - - - I STEERING Power steering fluid - - - I - - - R - - - I - - - R - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I * Steering system for looseness or
damage - - - I - - - I - - - I - - - I - - - I
Power steering hose - - - I - - - I - - - I - - - R - - - I Steering wheel play - - - I - - - I - - - I - - - I - - - I Steeri ng function - - - I - - - I - - - I - - - I - - - I Right and left turning radius - - - - - - - - - - - I - - - - - - - - Wheel al i gnment - - - - - - - - - - - I - - - - - - - - Joi nt ball for oil l eakage or damage - - - I - - - I - - - I - - - I - - - I Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I

MAINTENANCE AND LUBRICATION 0B-13
Recommended Fluids and Lubricants (For GENERAL EXPORT)
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
The lubrication intervals in the maintenance schedule and coverage and period of new vehicle warranty are based
on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart which will serve as a guide
for selecting lubricants of proper brand name.


GRADE LUBRICATION MAKE BRAND / TYPE
API ACEA

Petrol engine crankcase ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL
CALTEX / TEXACO SHELL
ELF
TOTAL
CASTROL BESCO RACING - ACE SJ (5W-30)
BESCO MULTI - Z SUV (5W-30)
BESCO MULTI - ACE (7.5W-30)
ESOO SUPERFLO (15W-40, 15W-50, 20W-50)
ESOO UNIFLO (15W-40, 15W-50, 20W-50)
MOBIL SUPER XHP (15W-40, 15W-50, 20W-50)
HAVOLINE FORMULA-3 (15W-40, 20W-50)
HELIX SUPER (10W-30)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
GTX-2 (15W-40) SJ
SH/CF
SG
SJ
SJ
SJ
SJ
SJ
SG
SJ
SG/SH



A2
A2
A3


A2

Diesel engine crankcase ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL CALTEX/CHEVRON SHELL
ELF
TOTAL
CASTROL BESCO MULTI - Z TYPE CE (10W-30)
BESCO MULTI - Z (10W-30)
BESCO MULTI - Z SUV (5W-30)
BESCO S-3 (10W, 20W, 30, 40)
ESSOLUBE XD-3+ (15W-40)
ESSOLUBE XT 331 (15W-40)
DELVAC HP (15W-40, 30, 40)
DELO CXJ (15W-40, 30, 40)
RIMULA D (15W-40, 30, 40)
PERFORMANCE TROPHY (15W-40)
RUBIA XT (15W-40)
RX SUPER PLUS (15W-40)
CE
CD
SH/CF
CD
CG-4/CF
CG-4/CF
CF/CE
CF
CD/CF
CE
CF-4
CC/CD
CG-4/CH-4



E2/B2
E2/B2



E3
E2
E3/B3

Manual transmission Transfer
case ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL CALTEX / TEXACO SHELL
ELF
TOTAL
CASTROL BESCO GEAR OIL TRANSAXLE (5W-30)
ESSOLUBE XD-3+ (15W-40)
ESSOLUBE XT 331 (15W-40)
MOBIL SUPER (10W-30)
HAVOLINE FORMULA-3 (15W-40, 20W-50)
RIMULA D (15W-40)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
RX SUPER PLUS (15W-40)
SG
CG-4/CF
CG-4/CF
SH
SH
CD/CF
SG/CD
SJ/CF
CC/CD
CG-4/CH-4
E2/B2
E2/B2




A2/B2
E3/B3

Differential
Shift on the fly system
(GL-5 only) ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL BESCO GEAR OIL SH (80W-90, 90, 140)
BESCO SHIFT ON THE FLY (75W-90)
GEAR OIL GX (85W-90)
MOBILUBE HD (80W-90, 85W-140)
THURBAN GL-5 EP (80W-90, 85W-140)
SPIRAX HD (90, 140)
TRANSELF TYPE B (80W-90, 85W-140)
TRANSMISSION TM (80W-90, 85W-140)
EPX 90 (90)
DYNA DRIVE (80W-90) GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5









Differential
(Limited Slip Differential) ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
ELF
TOTAL
CASTROL BESCO GEAR OIL LSD (140)
GEAR OIL LSA (90)
MOBILUBE HD LS (80W-90)
GEAR OIL LSD (90)
TRANSELF TYPE BLS (90)
TRANSMISSION DA (85W-90)
HYPOY LS (90) GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5

0B-14 MAINTENANCE AND LUBRICATION


GRADE LUBRICATION MAKE BRAND / TYPE
API ACEA
Automatic transmission
Power steering ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL BESCO ATF III, ATF II
ESSO ATF D (DEXRON

II-D)
MOBIL ATF (DEXRON
III)
ATF HD (DEXRON
II)
SHELL DONAX TA (DEXRON
II-D)
ELFMATIC G3 (DEXRON
III)
TOTAL FLUID IID (DEXRON
II-D)
TQ-D (DEXRON
II)
TQ DEXRON III (DEXRON
III)
















Grease fitting
(Multi purpose grease) ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX / TEXACO
SHELL
TOTAL
CASTROL BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)
RONEX MP (No.2)
MOBILGREASE HP 222 (No.2)
STARPLEX-2 (No.2)
RETINAX A (No.2)
MULTIS EP2, EP3 (No.2, No.3)
LM GREASE (No.2, No.3)












Propeller shaft sliding yoke
Universal joint
Multi purpose grease
containing molybdenum
disulfide ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
CALTEX
TOTAL ONE LUBER MO GREASE
BEACON Q2 (No.2)
MULTIPURPOSE GREASE (Moly) (No.2)
MOLYTEX GREASE EP2 (No.2)
TOTAL MULTIS MS2 (No.2)








Engine cooling system ISUZU GENUINE
TEXACO


CALTEX

GM GENUINE BESCO LLC SUPER TYPE E
HAVOLINE EXTENDED LIFE ANTIFREEZE
COOLANT
HAVOLIN XLC
EXTENDED LIFE COOLANT 6280
XLC
GOODWRENCH DEX-COOL
(TM) ANTIFREEZE
EXTENDED LIFE COOLANT















FLUID TYPE
Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade


DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD) Based on K2204 GAS OIL
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590 : 1997
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE J-313C
BS (BRITISH STANDARD) Based on BS EN590 : 1997


NOTE:
Use the applicable standard or equivalent for diesel fuels.

MAINTENANCE AND LUBRICATION 0B-15
RECOMMENDED FLUIDS AND LUBRICANTS (For EUROPE)






In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.

LUBRICATION/FLUID GRADE
API ACEA OTHER
Diesel engine crankcase B2/B3
E2/E3
Manual transmission
Transfer case B2/B3
E2/E3
Differential
Shift on the fly system
(GL-5 only)
GL-5 BESCO GEAR OIL SH (80W-90, 90, 140) (ISUZU GENUINE)
BESCO SHIFT ON THE FLY (75W-90) (ISUZU GENUINE)
GEAR OIL GX (85W-90) (EXXON / ESSO)
MOBILUBE HD (80W-90, 85W-140) (MOBIL)
THURBAN GL-5 EP (80W-90, 85W-140) (CALTEX)
SPIRAX HD (90, 140) (SHELL)
TRANSELF TYPE B (80W-90, 85W-140) (ELF)
TRANSMISSION TM (80W-90, 85W-140) (TOTAL)
Differential
(Limited Slip Differential)
GL-5 * Limited
Slip
Differential
Gear
Lubricant
BESCO GEAR OIL LSD (140) (ISUZU GENUINE)
GEAR OIL LSA (90) (EXXON/ESSO)
MOBILUBE HD LS (80W-90) (MOBIL)
GEAR OIL LSD (90) (CALTEX)
TRANSELF TYPE BLS (90) (SHELL)
TRANSMISSION DA (85W-90) (ELF)
HYPOY LS (90) (TOTAL)
Automatic transmission
Power steering
DEXRON II, III
Propeller shaft sliding yoke
Universal joint
(General purpose grease in
Molybdenum) NLGI #2 or #3
multi purpose type grease
containing molybdenum disulfide
Engine cooling system Good quality ethylene glycol antifreeze or GM spec.
6033-M or equivalent
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant together with Limited Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or
equivalent.



FLUID TYPE

Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade


DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
BS (BRITISH STANDARD) Based on K2204 GAS OIL
Based on EN590: 1997L
Based on SAE J-313C
Based on BS EN590: 1997
NOTE:
Use the applicable standard or equivalent for diesel fuels.

MANUAL TRANSMISSION 7B1-7

Transmission (4





2)
Disassembled View


RTW47BLF000701
Legend

(1) Gear Control Lever Knob (10) Slave Cylinder
(2) Rear Floor Console (bucket seat) (11) Nut : rear mount to Crossmember
(3) Front Floor Console (12) Transmission Crossmember
(4) Grommet Assembly (13) Nut : rear mount to transmission
(5) Gear Control Lever (14) Rear Mount Rubber
(6) Rear Propeller Shaft (15) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe (6VE1 only) (17) Transmission Assembly
(9) Fuel Pipe Bracket

MANUAL TRANSMISSION 7B1-9

6. Remove gear control lever (5).
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.

401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)
150R300003

10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the
transmission.

Neutral Switch


Back up Switch

Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly

7B1-16 MANUAL TRANSMISSION

6. Install starter(15). (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
Remove the transmission jack from transmission
side.
10. Apply grease to top hole portion of the shift fork.
Install slave cylinder (10) and tighten the bolts to the
specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N




m (7.7 kg




m/56 lb




ft)
Nut 37 N





m (3.8 kg





m/28 lb





ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly




6VE1, C24NE
Scan-1
12. Connect transmission harness connectors and clip.
Connector: neutral switch, car speed sensor, and
backup switch.
13. Tighten exhaust pipe fixing nuts (7) to the specified
torque. (Diesel engine only)
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
150R300003

7B1-64 MANUAL TRANSMISSION

Transmission (4





4)
Disassembled View

RTW47BLF001001
Legend

(1) Gear Control Lever Knob (10) Transmission-Transfer Fixing Bolt
(2) Rear Floor Console (bucket) (11) Transfer Assembly
(3) Front Floor Console (12) Fuel Pipe Bracket
(4) Grommet Assembly (13) Slave Cylinder
(5) Gear Control Lever (14) Rear Mount Nut
(6) Rear Propeller Shaft (15) Transmission Crossmember
(7) Front Propeller Shaft (16) Starter (Diesel engine only)
(8) Exhaust Pipe Nut (Diesel engine) (17) Transmission Retaining Nut and Bolt
(9) Exhaust Pipe Assembly (6VE1) (18) Transmission Assembly

MANUAL TRANSMISSION 7B1-67

13. Remove transmission-transfer fixing bolts (10), and
remove the transfer assembly (11) from the
transmission.
14. Disconnect harness connectors and clips on the
transmission.


Neutral switch; Transmission

Back up Switch

2W-4W Switch


Neutral Switch; Transfer
15. Remove the fuel pipe brackets (12) with pipes from
the transmission (18).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly



6VE1, C24NE
Scan-2
16. Remove slave cylinder (13) and put aside it.
220LV019
17. Support transmission with a transmission jack.
220RS0001
18. Remove engine rear mount nuts (14) from
transmission crossmember (15).