oil temperature ISUZU TF SERIES 2004 Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 2853 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–277
SPARK PLUG CABLES
The cable contains a synthetic conductor which is easily
damaged. Never stretch or kink the cable. Disconnect
the cable from spark plug and the ignition coil.
The original equipment cables and the ignition coil are
marked to show correct location of the cables. If spark
plug cables or the ignition coil are replaced previously,
before cables are removed from the ignition coil, mark
the cables and the coil so they can be reconnected in
the same position.
Inspection
NOTE: Never puncture the spark plug cable’s insulation
with a needle or the pointed end of a probe into the
cable. An increase in resistance would be created which
would cause the cable to become defective.
1. If the cable has broken or cracked insulation, it must
be replaced.
2. If the terminals are corroded or loose, the cable
must be replaced.
3. Check that the cable resistance does not ex ceed
specified value.
#1 cylinder: 3.50k - 5.24k
#2 cylinder: 2.89k - 4.33k
#3 cylinder: 2.49k - 3.73k
#4 cylinder: 2.22k - 3.32k
EMISSION CONTROL ;
CO ADJUSTER (W/
O CATALYSTIC CONVERTER)
CO : Carbon monox ide
Location
Under the leht-hand side of the front sheet.
Removal Procedure
1. Remove the left-hand side of the front sheet. Refer
to Sec.10 CAB “Front Sheet”.
2. Disconnect the CO adjuster connector.
3. Remove the CO adjuster.
Installation Procedure
1. Connect the CO adjuster connector.
2. Install the left-hand side of the front sheet. Refer to
Sec.10 CAB “Front Sheet”.
3. Check and adjust CO concentration.
Checking procedure
1. Operate the engine at normal temperature.
2. Turn all accessories switch OFF.
3. Place the select lever in the “N” range.
4. Start the engine at idle.
Page 3004 of 4264
0B-16 MAINTENANCE AND LUBRICATION
OIL VISCOSITY CHART
Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of
lubricants according to the ambient temperature by referring to the following table.
OIL VISCOSITY CHART FOR DIESEL ENGINE
APPLY DIESEL ENGINE OIL
(Single grade)VISCOSITY GRADE - AMBIENT TEMPERATURE
-25 C -15 C -10 C
32 F 5 F -13 F 77 F
0 C 30 C
86 F
*Not recomended for sustained high speed driving.
SAE 30
SAE 10W-30
SAE 15W-40, 20W-40, 20W-50
SAE 5W-30
SAE 20, 20W
SAE 10W
SAE 40, 50
25 C
15 C
(Multi grade)
*
60 F 14 F
ED-03
OIL VISCOSITY CHART FOR GASOLINE ENGINE
APPLY GASOLINE ENGINE OIL
(Malti grade)
Page 3093 of 4264
HEATER AND AIR CONDITIONING 1-83
AIR CONDITIONING CYCLE TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE CORRECTION
No cooling or
insufficient
cooling
1. Magnetic clutch does not run
Refer to “MAGNETIC CLUTCH”
troubleshooting in this section
2. Compressor is not rotating properly
Drive belt loosened or broken
Adjust the drive belt to the specified
tension or replace the drive belt
Magnetic clutch face is not clean and
slips Clean the magnetic clutch face or replace
Incorrect clearance between magnetic
drive plate and pulley
Adjust the clearance (Refer to
“COMPRESSOR OVERHAUL”
Compressor oil leaks from shaft seal or
shell
Replace the compressor
Compressor seized
Replace the compressor
3. Insufficient or excessive charge of
refrigerant
Discharge and recover refrigerant.
Recharge to specified amount.
4. Leaks in the refrigerant system
Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient radiation
Clean the condenser or replace as
necessary
Check radiator or condenser fan function
6. Temperature control link unit of the heater
unit defective
Repair the link unit
7. Unsteady operation due to foreign
substance in expansion valve
Replace the expansion valve
8. Poor operation of electronic thermostat
Check electronic thermostat and replace
as necessary
Insufficient
velocity
of cooling air
1. Evaporator clogged or frosted
Check evaporator core and replace or
clean the core
2. Air leaking from cooling unit or air duct
Check evaporator and duct connection,
then repair as necessary
3. Blower motor does not rotate prop-erly
Refer to “FAN CONTROL KNOB (FAN
SWITCH)” troubleshooting in this section
* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,
RECYCLING, EVACUATING AND CHARGING” in this section.
Page 3437 of 4264
POWER-ASSISTED STEERING SYSTEM 3B-7
Power Steering System Test
Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
(3) Power Steering Unit
(4) Power Steering Pump
Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, i
f
necessary, must be made.
Inspect pump reservoir for proper fluid level.
Inspect pump belt for proper tension.
Inspect pump driver pulley condition.
1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2.
With the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
3. Check the fluid level. Fill the reservoir with powe
r
steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Powe
r
Steering System in this section.
5. Start the engine and check the fluid level. Add
power steering fluid if required. When the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.
Page 3438 of 4264
3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
If the pressure recorded is within 9300-9800 kPa
(95-100 kg/cm
2/1350-1420 psi), the pump is
functioning within its specifications.
If the pressure recorded is higher than 9800 kPa
(100 kg/cm
2/1420 psi), the valve in the pump is
defective.
If the pressure recorded is lower than 9300 kPa (95
kg/cm
2/1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the powe
r
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and fron
t
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
Inspect belt for tightness.
Inspect pulley for looseness or damage. The pulle
y
should not wobble with the engine running.
Inspect hoses so they are not touching any othe
r
parts of the vehicle.
Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130
F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.
Flushing The Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.
Page 3505 of 4264
FRONT SUSPENSION 3C-13
Disassembly
1. Install the support fixture (5-8840-0595-0) to the base (5-
8840-003-0).
2. Install the upper adapter (5-8840-0597-0) and the lower
adapter (5-8840-0596-0) to the base and support fixture
assembly.
3. Install the shock absorber assembly to the support fixture.
4. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.
CAUTION :
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.
INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.
Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
Shock absorber
Rubber bushing
Coil spring
Page 3660 of 4264
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.
Page 3681 of 4264
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)
CONTENTS
Service Precaution .................................................
7A2-2
General Description ...............................................
7A2-2
Electronic Control Diagram ...............................
7A2-3
Transmission Control Module (TCM) (1/2) ......
7A2-4
Transmission Control Module (TCM) (2/2) ......
7A2-5
TCM Point Table .................................................
7A2-6
TCM Voltage & Resistance Check Sheet .......
7A2-7
Control System Diagram ....................................
7A2-9
Control and Functions ........................................
7A2-10
Gear Shift Control 3rd start ...............................
7A2-10
Mode Type ...........................................................
7A2-10
Mode Selection ....................................................
7A2-10
Comparison of mode ..........................................
7A2-11
3rd start Mode .....................................................
7A2-11
Backup Mode .......................................................
7A2-11
Functions of Input / Output Components ........
7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................
7A2-13
High speed CAN bus ..........................................
7A2-13
Diagnosis .................................................................
7A2-13
Electronic Diagnosis ...........................................
7A2-13
Check Trans Indicator ........................................
7A2-13
On Board Diagnostic Check ..............................
7A2-13
"Check Trans" Check .........................................
7A2-14
Tech 2 OBD Connection ....................................
7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............
7A2-30
16 - Terminal Data Link Connector (DLC) ......
7A2-31
Clear DTC ............................................................
7A2-32
DTC Check ..........................................................
7A2-32
TCM Precaution ..................................................
7A2-32
Information On TCM ...........................................
7A2-32
TCM Diagnostic Trouble Codes ........................
7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ...........................................
7A2-34
DTC P0602 (FLASHING CODE 63)
Transmission Control Module (TCM)
Programming Error ................................................
7A2-36
DTC P0705 (FLASHING CODE 17)
Transmission Range Sensor Circuit
Malfunction .............................................................
7A2-38
DTC P0712 (FLASHING CODE 15)
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................
7A2-42
DTC P0713 (FLASHING CODE 16)
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................
7A2-45
DTC P0717 (FLASHING CODE 14)
Input Speed Sensor Signal Error .........................
7A2-48
DTC P0722 (FLASHING CODE 11)
Output Speed Sensor Signal Error .....................
7A2-51
DTC P0743 (FLASHING CODE 33)
Torque Converter Clutch Electrical .....................
7A2-54
DTC P0748 (FLASHING CODE 35)
Pressure Control Solenoid Electrical ..................
7A2-57
DTC P0753 (FLASHING CODE 31)
Shift Solenoid S1 Electrical ..................................
7A2-60
DTC P0758 (FLASHING CODE 32)
Shift Solenoid S2 Electrical ..................................
7A2-63
DTC P1767 (FLASHING CODE 67)
ECM CAN Invalid ...................................................
7A2-66
DTC P1790 (FLASHING CODE 61)
Transmission Control Module ROM
Checksum Error .....................................................
7A2-69
DTC P1791 (FLASHING CODE 62)
Transmission Control Module RAM
Error .........................................................................
7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................
7A2-73
Page 3686 of 4264
7A2-6 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)
TCM Point Table
RTW37ASF000101-1
PIN No. SIGNAL NAME
A1 GND
A2 PRESSURE CONTROL SOLENOID GND
A3 —
A4 PRESSURE CONTROL SOLENOID
A5 L-up SOLENOID
A6 STARTER SW(IG1)
A7 CAN COMMUNICATION (-)
A8 —
A9 —
A10 —
A11 T/M OIL TEMPERATURE SENSOR
A12 T/M OIL TEMPERATURE SENSOR GND
A13 —
A14 —
A15 SHIFT SOLENOID (S2)
A16 SHIFT SOLENOID (S1)
A17 CAN COMMUNICATION (+)
A18 —
A19 —
A20 —
A21 —
A22 —
A23 GND
A24 BATTERY
PIN No. SIGNAL NAME
B1 NEUTRAL START SW (R)
B2 POWER LAMP
B3 CHECK TRANS LAMP
B4 PATTERN SELECT SW (3rd START)
B5 SPEED SENSOR (+)
B6 INPUT REVOLUTION SENSOR (+)
B7 NEUTRAL START SW (D)
B8 NEUTRAL START SW (N)
B9 NEUTRAL START SW (3)
B10 3rd START LAMP
B11 OIL TEMPERATURE WARNING LAMP
B12 DIAGNOSIS TERMINAL
B13 PATTERN SELECT SW (POWER)
B14 SPEED SENSOR (-)
B15 —
B16 INPUT REVOLUTION SENSOR (+)
B17 —
B18 NEUTRAL START SW (L)
B19 NEUTRAL START SW (2)
B20 NEUTRAL START SW (P)
B21 TRANSMISFER LOW 4 SW
B22 BRAKE LAMP SW
B23 DIAGNOSIS OUT PUT
B24 —
B25 —
B26 CRUISE CONTROL UNIT
Page 3687 of 4264
TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L) 7A2-7
TCM Voltage & Resistance Check Sheet
CHECK ITEM PIN No. VALUE NOTE
VIGN A6 –A1 VIGN
Key “ON ”
A6 –A23 VIGN
Key “ON ”
Backup Power Supply A24 –A1 +B (Always)
Key “ON ”
Inhibitor (Select) SW P B20 –A1 “P ” Range VIGN Key “ON ”
Except “P ” 0V
Inhibitor (Select) SW R B1
–A1 “R ” Range VIGN Key “ON ”
Except “R ” 0V
Inhibitor (Select) SW N B8
–A1 “N ” Range VIGN Key “ON ”
Except “N ” 0V
Inhibitor (Select) SW D B7
–A1 “D ” Range VIGN Key “ON ”
Except “D ” 0V
Inhibitor (Select) SW 2 B19
–A1 “2 ” Range VIGN Key “ON ”
Except “2 ” 0V
Inhibitor (Select)SW 1 B18
–A1 “1 ” Range VIGN Key “ON ”
Except “1 ” 0V
Inhibitor (Select) SW 3 B9
–A1 “3 ” Range VIGN Key “ON ”
Except “3 ” 0V
Power SW B13
–A1 ON 0V Key “ON ”
OFF VIGN
3rd Start SW B4
–A1 ON 0V Key “ON ”
OFF VIGN
Brake SW B22
–A1 ON VIGN Key “ON ”
OFF 0V
AT Oil Temperature
Sensor A11
–A12 20 C 4.6V Engine run.
155
C 1.1V
4L Signal B21
–A1 4L 0V Key “ON ”
2H/4H VIGN
Diag SW B12
–A1 ON VIGN Key “ON ”
OFF 0V
Shift Solenoid A (S1) A16
–A1 P VIGN Engine run.
R VIGN
N VIGN
D –1 VIGN
D –2 VIGN
D –3 0V
D –4 0V