oil change ISUZU TF SERIES 2004 Repair Manual

0B-10 MAINTENANCE AND LUBRICATION




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
SERVICE BRAKES Brake fluid - - - - - - - I - - - - - - - I - - - - Brake system for fluid leakage - - - I - - - I - - - I - - - I - - - I Brake function - - - I - - - I - - - I - - - I - - - I * Front Disc brake pads and discs wear - - - I - - - I - - - I - - - I - - - I * Rear brake lining and drum wear - - - I - - - I - - - I - - - I - - - I Brake pedal travel and play - - - I - - - I - - - I - - - I - - - I Pipes and hoses for loose
connections or damage - - - I - - - I - - - I - - - I - - - I
PARKING BRAKE Parking brake function - - - I - - - I - - - I - - - I - - - I Parking brake lever travel - - - I - - - I - - - I - - - I - - - I Cables for looseness or damage and
guide for damage
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
I
-
-
-
-
Ratchet for wear or damage - - - I - - - I - - - I - - - I - - - I SUSPENSION Leaf/Coil/Torsion bar springs for
damage - - - I - - - I - - - I - - - I - - - I
Mount for looseness or damage - - - I - - - I - - - I - - - I - - - I Shock absorbers for oil leakage - - - I - - - I - - - I - - - I - - - I Shock absorbers mount for
looseness - - - I - - - I - - - I - - - I - - - I
Rubber bushes of suspension wear
or damage - - - I - - - I - - - I - - - I - - - I
Spring action for loss of balance due
to weakening - - - - - - - - - - - I - - - - - - - -
Joi nt ball rubber boot for damage - - - I - - - I - - - I - - - I - - - I WHEELS Wheel nuts - - - T - - - T - - - T - - - T - - - T Wheel disc for damage - - - I - - - I - - - I - - - I - - - I Hub bearing grease - - - - - - - R - - - - - - - R - - - - Front and rear hub bearings for
looseness - - - I - - - I - - - I - - - I - - - I
Tire pressure and damage I - - I - - - I - - - I - - - I - - - I Tire rotation (Rotate as required) OTHERS Bolts and nuts on chassis and body - - - I - - - I - - - I - - - I - - - I Lube front free - wheeling hubs - - - - - - - L - - - - - - - L - - - -

MAINTENANCE AND LUBRICATION 0B-11
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
G : Gasoline engine
B : Driving on rough roads
4JA1-T : 4JA1-T Diesel engine
C : Driving on dusty roads
4JA1-TC : 4JA1-TC Diesel engine
D : Driving in extremely cold weather and/or on salted roads
4JH : 4JH1-TC Diesel engine
E : Towing trailer or climbing mountain frequently
D
: Diesel engine
MT : Manual transmission

AT : Automatic transmission

4WD
Four wheel drive


Condition
A B C D E A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month4JA1-T : Change every 2,500 km (1,500 miles) 4JA1-TC : Change every 5,000 km (3,000 miles) 4JH : Change every 7,500 km (4,500 miles)



G Replace every 5,000 km (3,000 miles) or 3 month



Engine oil filter
D Replace every 5,000 km (3,000 miles)




Exhaust system Inspect every 5,000 km (3,000 miles)







Air cleaner element Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)



Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000
miles)



Transmission or transfer case
oil MT Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


AT Transmission:
Change every 20,000 km (12,000 miles)






4WD Transfer:
Change every 20,000 km (12,000 miles)


Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)






Interval Item

0B-12 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)


Severe driving conditions
4JA1-TC : 4JA1-TC Diesel engine
A: Repeated short trips
4JH : 4JH1-TC Diesel engine
B: Driving on rough roads
D : Diesel engine
C: Driving on dusty roads
MT : Manual transmission
D: Driving in extremely cold weather and/or on salted roads
AT : Automatic transmission
E: Towing trailer or climbing mountein frequently
4WD : Four wheel drive


Condition
Item Interval
A B C D A+D
Engine oil 4JH : Change every 5,000 km (3,000 miles) 4JA1-TC : Change every 7,500 km (4,500 miles)



Engine oil filter 4JH : Replace every 5,000 km (3,000 miles) 4JA1-TC : Replace every 7,5000 km (4,500 miles)




Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element Replace every 20,000 km (12,000 miles)



Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)




Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)



Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)



AT
Transmission:
Inspection every 20,000 km (12,000 miles)





4WD Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)



Differential oil Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and discs Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)

1-48 HEATER AND AIR CONDITIONING

Checking and Adjusting for Compressor
Replacement
180 cm3 (5.0 lmp fl oz) of oil is charged in compressor (service
parts). So it is necessary to drain the proper amount of oil from
the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the compressor.
3) Drain the compressor oil and measure the extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.

Amount of oil drained
From used compressor Draining amount of oil
From new compressor
less than
90 cm
3 (2.5 lmp fl oz) Some as drained
amount
more than
90 cm
3 (2.5 lmp fl oz) 90 cm
3 (2.5 lmp fl oz)

6) Evacuate, charge and perform oil return operation.
7) Check system operation.


CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even is the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
 The capacity of the oil has increased.
 The oil has changed color to red.

Foreign substances, metal powder, etc., are present in the
oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.

7B1-56 MANUAL TRANSMISSION

2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OKNG NG NG NG
OK OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxWorn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG NG
OKShift block sleeve movement

MANUAL TRANSMISSION 7B1-113

2. HARD SHIFTING

Checkpoint Trouble Cause Countermeasure

Change lever play
Clutch pedal free play
Repair or replace the
applicable parts and regrease
Readjust the clutch pedal free
play
Worn change lever sliding
portions
Improper clutch pedal free
play
Change lever operationRepair or regrease the change
lever assembly
Replenish or replace the
engine oil
Hard operating change lever
caused insufficient grease
Insufficient or improper gear
oil
OK
OKNG NG NG NG
OK OKGear oil
Continued on the next page
Shift rod and quadrant box
sliding faces, and other partsReplace the shidt rod and/or
the quadrant boxWorn shift rod and/or sliding
faces
Repair or replace the sleeveSleeve movement failure
NG NG
OKShift block sleeve movement

7D1-34 TRANSFER CONTROL SYSTEM

Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shft on the fly)
If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz and, at the
same time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes
out.
Cause of excessive synchronous shifting load

Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization)
 High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.

1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.

1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and axle, connecting the front wheel
and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed

, the indicator flashes
at a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.

2.
When shifting from 4H to 2H
2-1 When 4WD indicator continues flashing at 2Hz
When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed
. When torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle
is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.


: Shift on the fly only.

7A2-10 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Control and Functions
Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the
gear ratio is controlled by the ON/ OFF signal using the
shift solenoid S1 and the shift solenoid S2.
Band Apply Control
The band apply is controlled when in the 3 –2 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow
of the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch (TCC) solenoid using the ON/OFF
signal.
Line Pressure Control
The throttle signal allows the current signal to be sent
to the force motor. After receiving the current signal,
the force motor activates the pressure regulator valve
to regulate the line pressure.
On –Board Diagnostic System
Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and read
out of it afterward.
The serial data lines, which are required for the testing
of the final assembly and the coupling to othe
r
electronic modules, can be regulated by this function.
Fail –Safe Mechanism
If there is a problem in the transmission system, the
TCM will go into a “backup" mode.
The vehicle can still be driven, but the driver must use
the select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change o
f
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning,
TCC, and the 3rd start mode.
Reverse Lock Out Control
With the selector lever in reverse position, the TCM will
not close the PWM solenoid until the vehicle is below
15 km/h (9.3 mph), thus preventing reverse
engagement above this speed.

Downhill Control
This mode is automatically activated from NORMAL
mode only when downhill conditions are recognized.
The shift pattern is identical to NORMAL mode except
3-4 and 4-3 shift lines at low throttle modified to get
engine braking on a larger speed range.
Uphill Control
When uphill condition are recognized the 2-3 and 3-4
shift and TCC apply are down only when the engine
torque is sufficient in order to avoid shift hunting.
Gear Shift Control 3rd start


SELECT LEVER RANGE SHIFT PATTERN
D(Drive) 1


2TCC

3TCC

4TCC
3(Third) 1

2TCC

3TCC
2(Second) 1

2(
3)
L(First) 1(
2)
TCC: Torque Converter Clutch
(Notice1): “( )" means over-revving prevention control.
Mode Type


Mode Type Select lever position
Normal drive mode
(NOR) Entire range (excluding “R")
Power drive mode
(PWR) Entire range (excluding “R")

Mode Selection



SWITCH(SW) LAMP
Mode Type PWR/N
OR.S 3RD
START SW POWER
DRIVE LAMP 3RD
START LAMP
Normal
drive mode
(NOR) OFF OFF OFF OFF
Power
drive mod
(PWR) ON OFF ON OFF
3rd Start
mode OFF ON OFF ON
However, the 3rd start switch prevails over the
PWR/NOR switch.
The mode become normal drive mode when the 3rd
start switch is operated from ON to OFF.

TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-43

DTC P0712 (FLASHING CODE 15) Transmission Oil Temperature Sensor
Circuit Low Input

RTW37AMF000201
Circuit Description
The oil temperature sensor is a thermistor sensor that
is installed in the transmission case and converts
temperature changes into continuous electric signals,
then outputs them to the Transmission Control Module
(TCM). When the ATF temperature is low, the
resistance of the sensor (thermistor) goes up, so that
the voltage of the TCM signal becomes high.
As the ATF is gradually warmed, the resistance of the
sensor goes down and the voltage becomes low. At the
normal operating ATF temperature (80

C/176

F) of the
transmission, the voltage of the TCM is about 3.7V.
Condition for setting the DTC

The TCM detects following "Condition" for 5 min
continuously.
Condition ("Short"):

Oil temperature is more than 220

C (428

F).

Action Taken When The DTC Sets

The TCM judges oil temperature is 100

C (212

F).
 Check Trans ON.

DTC stored.
Conditions For Clearing The DTC

The DTC can be cleared from the TCM history by
using a scan tool.
 The DTC will be cleared from history when the
vehicle has achieved 40 warm-up cycles without a
failure reported.

After more than 1 second has elapsed after the
ignition key has been turned “ON", short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.

7A2-44 TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)

Diagnostic Aids

Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring. Inspect
for a broken wire inside the insulation.

When diagnosing for a possible intermittent short o
r
open condition, move the wiring harness while
observing test equipment for a change.
 Check oil temperature sensor for proper mounting
and adjustment.



DTC P0712 (FLASHING CODE 15) Transmission Oil Temperature Sensor
Circuit Low Input


Step Action Value(s) YES NO
1
Was the powertrain On-Board Diagnostic (OBD)
System Check performed? — Go to Step 2 Go to OBD
System Check
2 Perform the transmission fluid checking procedure.
Refer to checking Transmission Fluid level and
Condition in Automatic Transmission 7A section.
Was the fluid checking procedure performed ? — Go to Step 3 Refer to
Checking
Transmission
Fluid level and
Condition in
Automatic
Transmission
(AW30-40LE)
section
3

1. Install the scan tool.

2. Key “ON"
3. Review and record scan tool data.

4. Operate the vehicle with in scan tool data.
Does the scan tool indicate DTC P0712 ? — Go to Step 4 Refer to
Diagnostic Aids
4 Measure the voltage of the transmission fluid
temperature sensor by the J39200 DMM.

1. Key “OFF".
2. Disconnect the oil temperature sensor connector.

3. Key “ON".

4. Connect the J39200 DMM to the each terminal of
the oil temperature sensor connector E83-2 and
E83-1.
Does the scan tool indicate less than specified
value ? 5V Go to Step 5 Go to Step 6
5 Replace the transmission fluid temperature sensor.
Is the action complete ? — Verify repair —