timing belt ISUZU TF SERIES 2004 Service Manual

ENGINE COOLING 6B-7
Water Pump
Water Pump and Associated Parts








Legend
1 Water Pump Assembly 2 O-Ring
3 Bolt

2 3 1

















Removal
1. Disconnect battery ground cable.
2. Drain coolant.
3. Disconnect radiator hose (on inlet pipe side).
4. Remove timing belt, refer to "Timing Belt" in this manual.
5. Remove water pump assembly.
Inspection
Make necessary repair and parts replacement if extreme wear
or damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced:

6B-8 ENGINE COOLING











Crack in the water pump body

EC leakage from the seal unit

Play or abnormal noise in the bearing

Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with
silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 N




m (2.5 kgf




m)
3. Timing belt

Install timing belt, refer to timing belt installation step in
"Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
5. Connect battery ground cable.

ENGINE DRIVEABILITY AND EMISSIONS 6E–241
17 Perform the procedure in Fuel System Pressure Test
(Refer to 6E-108
Fuel System Diagnosis) to
determine if there is a problem with fuel delivery.
Was a problem found?—Verify repair Go to Step 18
18 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Camshaft drive belt slipped or stripped
Was a problem found?—Verify repair Go to Step 19
19 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 20
20 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 21
21 Replace the ECM.
Is the action complete?
IMPORTANT: 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.—Verify Repair— Step Action Value(s) Yes No

6E–250 ENGINE DRIVEABILITY AND EMISSIONS
19 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Camshaft drive belt slipped or stripped
Was a problem found?—Verify repair Go to Step 20
20 1. Check for faulty engine mounts.
2. If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 21
21 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 22
22 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 23
23 Replace the ECM.
Is the action complete?
IMPORTANT: 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.—Verify Repair— Step Action Value(s) Yes No

6E–252 ENGINE DRIVEABILITY AND EMISSIONS
12 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 13
13 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 14
14 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 15
15 Check for proper ignition voltage output with a spark
tester.
Was the problem found?—Verify repair Go to Step 16
16 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 17
17 Drain sample fuel, visual inspection.
Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspencion of alcohol contamination,
completely drain the fuel, replace by fuel from known
vehicle source.—Verify repair Go to Step 18
18 Check the ex haust system for a possible restriction:
Damaged or collapsed pipes
Internal muffler failure
Was a problem found?—Verify repair Go to Step 19
19 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Loose timing belt
Was a problem found?—Verify repair Go to Step 20
20 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 21 Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–263
10 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Camshaft drive belt slipped or stripped
Was a problem found?—Verify repair Go to Step 11
11 Check leakage at exhaust system.
Check the intake and ex haust manifold for casting
flash. Refer to Engine Mechanical.
Was a problem found?—Verify repair Go to Step 12
12 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 13
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: 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.—Veri fy repai r— Step Action Value(s) Yes No

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

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
ENGINE Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I
(DIESEL) I I I I I I I R I I I I I I I R I I I I * P Engine oil (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil (C24SE) Replace every 12,000km * D Engine oil (4JH1-TC) - R - R - R - R - R - R - R - R - R - R * D Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * D Engine oil (4JA1-T) RR R R RR RRRRRRRR R R R RRR * P Engine oil filter (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil filter (C24SE) Replace every 12,000km * D Engine oil filter (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R * D Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination
(GASOLINE) - I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage I I - I - I - I - I - I - I - I - I - I Fuel tank - - - | - - - | - - - | - - - | - - - | P O2 Sensor Replace every 160,000km P Valve clearances (6VE1) Check and adjust if noisy D Valve clearances A - - A - - - A - - - A - - - A - - - A P Spark plugs (C24SE) (for leaded
fuel use) - R - R - R - R - R - R - R - R - R - R
P Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
P Spark plugs (6VE1) Replace every 160,000km Spark plug wire | | - | - | - | - | - | - | - | - | - | Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R Fuel filter (DIESEL) - - R - - R - - R - - R - - R - - R - - Engi ne / Accessory dri ve belt
(GASOLINE) - - - - - - - - - R - - - - - - - - - R
Fan belt tension and damage
(DIESEL) 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 Engine coolant concentration (6VE1) - - - - - - - - - R - - - - - - - - - R (C24SE) - | - | - | - | - R - | - | - | - | - R Engine coolant level concentration
(DESEL) I I I I I I I I I R I I I I I I I I I R
Cooli ng sy stem for water l eakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
P Timing belt (C24SE) - - - - - - - - - - - - - - - I - - - - (Replace every 120,000km) P Timing belt (6VE1) Replace every 160,000km CLUTCH Cl utch fl ui d I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I