clutch ISUZU TF SERIES 2004 Repair Manual

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

CLUTCH 7C-51

SPECIAL SERVICE TOOL
ITEM NO. ILLUSTRATION PART NO. PART NAME





5-85253-001-0

Clutch pilot aligner

7C-52 CLUTCH
MEMO

8A-424 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
C-68
~
C-76 NOT USED C-106
NOT USED
C-77

Clutch switch C-107
WhiteJ/B E2
C-78
~
C-93 NOT USED C-108
White
J/B E1
C-94
(6VE1)
Gray TCM-(A) C-109
SilverBody-LH ; ground
C-94
(4JH1-TC)
White TCM C-110
~
C-114NOT USED
C-95
(6VE1)
White TCM-(B) C-115
(4JH1-TC)
BrownEVRV
C-95
(4JH1-TC)
White TCM C-116


C-96
~
C103 NOT USED C-117
(6VE1)
(4JH1-TC)
Anti theft horn
C-104
Brown
Resister C-118
(4JH1-TC)
A/C Resister & Neutral switch
C-105
White
Blower motor C-119
(6VE1)
Auto cruise actuator

8A-428 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
E-1
(4JH1-TC)
White Oil pressure switch E-10
SilverEngine ground
E-2
(C24SE)
(6VE1)


Magnetic clutch E-11
(6VE1)

Neutral switch
E-3
(4JH1-TC)
Black
Magnetic clutch AC COMP E-11
(4JH1-TC)
Natural
green
Neutral switch
E-4
~
E-5 NOT USED E-12
(6VE1)

Neutral switch
E-6
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-12
(4JH1-TC)
Natural
green
Neutral switch
E-6
(4JH1-TC)

Injector pump E-13
~
E-17 NOT USED
E-7
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-18
(C24SE)

Ignition coil
E-8
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-19
(4JH1-TC)
Blue Thermo meter unit
E-9
(C24SE)
(6VE1)


(6VE1) Fuel injector (C24SE) E-20
~
E-21 NOT USED
E-9
(4JH1-TC)
Gray T.D.C sensor E-22
(4JH1-TC)
BrownTPS 1 main

CRUISE CONTROL SYSTEM 8B-1
SECTION 8B
CRUISE CONTROL SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution .........................................................................................................................8B- 3
General Description .......................................................................................................................8B- 3
Brake Switch ...................................................................................................................................8B- 5
Removal .......................................................................................................................................8B- 5
Installation ..................................................................................................................................8B- 5
Adjustment ..................................................................................................................................8B- 6
Clutch switch ...................................................................................................................................8B- 6
Removal and Installation ........................................................................................................8B- 6
Adjustment ..................................................................................................................................8B- 6
Starter Switch ..................................................................................................................................8B- 6
Removal .......................................................................................................................................8B- 6
Installation ..................................................................................................................................8B- 6
Cruise Control Main Switch .........................................................................................................8B- 7
Removal .......................................................................................................................................8B- 7
Installation ..................................................................................................................................8B- 7
Cruise Control Switch (Combination Switch) ........................................................................8B- 7
Removal and Installation ........................................................................................................8B- 7
Cruise Control Unit ........................................................................................................................8B- 8
Removal .......................................................................................................................................8B- 8
Installation ..................................................................................................................................8B- 8
Cruise Actuator ...............................................................................................................................8B- 8
Actuator Cable Diagram ..........................................................................................................8B- 9
Removal .......................................................................................................................................8B- 9
Installation ..................................................................................................................................8B- 9
Adjustment ..................................................................................................................................8B- 9
Mode Switch ....................................................................................................................................8B- 9
Removal and Installation ........................................................................................................8B- 9

8B-2 CRUISE CONTROL SYSTEM
Diagnosis ..........................................................................................................................................8B- 10
DTC Display Condition ............................................................................................................8B- 10
DTC Display Format .................................................................................................................8B- 11
Circuit Diagram ..........................................................................................................................8B- 11
DTC 1-1 Motor System Short Circuit ....................................................................................8B- 13
DTC 1-2 Clutch Open or Short Circuit .................................................................................8B- 14
DTC 1-3 Mechanical Defect ....................................................................................................8B- 15
DTC 1-4 Close Side of Motor System ..................................................................................8B- 16
DTC 2-1 Signal of Vehicle Speed Malfunction ..................................................................8B- 17
DTC 3-1 Turning On Switch at All time or at the same time ..........................................8B- 18

8B-4 CRUISE CONTROL SYSTEM
2. RESUME/ACCEL Switch Function
1. Resume Function: When the RESUME/ACCEL switch is turned on/off after the system is temporarily
deactivated by pressing the brake or clutch pedal while the vehicle is running, the vehicle resumes the speed
stored before the system was released, and the vehicle automatically runs at the stored speed.
2. Accelerate Function: When the RESUME/ACCEL switch is kept on the vehicle accelerates its speed during
that time. The vehicle speed at which the vehicle was running when the switch was turned off is stored in the
memory, and the vehicle automatically returns to this speed.
3. Tap-up Function: When the RESUME/ACCEL switch is turned on and off instantaneously while the vehicle
is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the vehicle
was running when the switch was turned off last is stored in the memory, and the vehicle automatically
returns to this stored speed.

3. CANCEL Function
1. Temporary Cancellation:

Brake pedal is pressed.

Clutch pedal is pressed. (M/T)

Select lever is shifted to any position other than “D”, “3”, “2” or “L”. (A/T)

Cancel switch is operated.

Vehicle speed exceeds about 12.5mph over the vehicle speed stored in the memory.
Turning the RESUME/ACCEL switch will return the vehicle to the speed stored in the cruise control memory.
2. Complete Cancellation:

Starter switch or the main switch is turned off.

Fail-safe function is activated.

Vehicle speed is about 38 km/h mph.

Speed becomes 20 (12.5) km/h (mph) or less form the speed memorized by Control unit.

8B-6 CRUISE CONTROL SYSTEM
Adjustment
1. Check to be sure that the brake pedal has been completely
returned by the return spring.
2. Disconnect the switch connector.



RTW3A0SH001201

3. Release the lock (2) by turning the switch (1) counter-clock-
wise.
4. After doing so, pull the pedal arm (3) to you a little so tha
t
the pedal arm is not pushed in.
5. Making the pedal arm not movable with one hand, push in
the whole switch with the other hand until the plunger of the
switch is pushed in and the switch itself hits the rubber o
f
the pedal arm.
In the condition, turn the switch clock-wise until "click"
sound is made and lock it.
By doing this, the switch is adjusted at 0.2 to 1.2mm (0.01-
0.06 in.) clearance.

Clutch Switch


Removal and Installation
Refer to the Clutch Control removal and installation steps in
Clutch section.

Adjustment
1. Turn the clutch switch or stopper bolt 1 until the switch bolt
or stopper bolt just touches the clutch pedal arm.
2. Adjust clutch switch or stopper bolt by backing it out half a
turn, and measure the clearance (L) between the clutch
pedal arm and the clutch switch bolt end or stopper bolt.
3. Lock the lock nut
2.
4. Connect the clutch switch connector.

Clutch switch and clutch and clutch pedal clearance
mm (in)

Limit 0.5-1.5 (0.020-0.059)


Starter Switch

431R300001
Removal
1. Steering Lock Assembly

Refer to the Steering Lock assembly removal steps o
f
"Steering Column" in Power-Assisted Steering System
section.
2. Starter Switch

Installation
Follow the removal procedure in the reverse order to install the
starter switch.