air condition ISUZU TF SERIES 2004 Manual PDF

6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element.
2 Was the intake air leakage found from intake
system? — Repair or
replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —
Go to Step 4 Clean or
replace the fuel
filter element.
4 Check the fuel injection pipes.
Does the injection pipes have obstruction or any
damage? — Repair or
replace the fuel
injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Readjust the
injection nozzle
pressure or
replace the
nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 8 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? — Repair or
replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? — Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger
assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger
assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved

6 – 10 TROUBLESHOOTING
8. Dark Exhaust Smoke
Step Action Value(s) Yes No
1 Was the air cleaner element normal condition? —
Go to Step 2 Clean or
replace the air
cleaner
element
2 Was the EGR valve sticking? — Replace the
EGR valve Go to Step 3
3 Was the injection nozzle pressure or the injection
spray pattern OK? —
Go to Step 4 Replace the
injection nozzle
4 Was the oil leakage found from the turbocharger oil
seal? — Replace the oil
seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted?— Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the
turbocharger center housing restricted? — Clean the
center housing Go to Step 7
7 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 8
8 Does PCV (Positive Crankcase Ventilation) Valve
has problem? — Repair or
replace the
relation parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the
turbocharger? —
Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? — Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged?— Replace the
damaged
gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? — Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? — Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? — Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? — Repair or
replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? — Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/
10W–30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil
feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved

6 – 16 TROUBLESHOOTING
14. Battery Charging and Noise Problem
Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? — Repair or
replace the
brush and/or
the slip ring. Go to Step 3
3 Inspect the stator coil on the generator.
Was there an open circuit or the scorching on the
stator coil? —
Replace the
stator coil. Go to Step 4
4 Inspect the rotor coil on the generator.
Was there an open circuit or the scorching on the
rotor coil? —
Replace the
rotor coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? — Replace the
rectifier Go to Step 6
6 Inspect the IC regulator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

14-2 Battery Overcharging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the terminal circuit.
Were the B and F terminals shorted? — Repair the
short circuit. Go to Step 3
3 Check the regulating voltage.
Was the IC regulator voltage excessive? — Replace the IC
regulator. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? — Repair or
replace the
brush holder
assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? — Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity
generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? — Repair or
replace the
brush and/or
the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —
Repair the
loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

TROUBLESHOOTING 6 – 19
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? — Replace the
brush or repair
the
commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty?
—
Clean contact
face Go to Step 4
4 Was the pinion clutch slipped? — Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil.
Was there an open circuit or a short circuit in the
armature field coil? — Repair or
replace the
armature field
coil. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

15-2 Incorrect pinion and ring gear engagement
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken? —
Replace the
wron parts. Go to Step 3
3 Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect? — Adjust or
replace the
movement
parts. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

6 – 20 TROUBLESHOOTING
15-3 Starter motor continues to run after the starter switch is turned off
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the magnetic switch contact point.
Was the contact point seized? — Repair or
replace the
magnetic
switch. Go to Step 3
3 Inspect the starter switch.
Was the starter switch defective? — Replace the
starter switch. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

15-4 Excessive commutator sparking
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? — Replace the
brush or repair
the
commutator. Go to Step 3
3 Was there the slag accumulation on the contact
face? — Clean the
contact face or
replace the
brush. Go to Step 4
4 Was the brush holder loose? — Repair the
brush holder Go to Step 5
5 Inspect the commutator.
Was there excessive wear or pitting? — Repair or
replace the
commutator. Go to Step 6
6 Was there loose the solder on the commutator? — Clean and
repair Go to Step 7
7 Inspect the armature shaft.
Was the run-out of armature shaft outside the
standard value due to worn bearing ? —
Replace the
bearing Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.



RTW36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0


RTW36ASH000101


4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
130RY00003
6A-6

ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
With oil filter
replacement Without oil
filter
replacement
4
2
4
4
(4JA1L/TC)6.2 (1.64/1.36) 5.2  4.2
(1.37  1.11
/ 1.14  0.92) 4.5  3.5
(1.19  0.93
/ 0.99  0.77)
4
2
(4JH1TC)
6.2 (1.64/1.36) 5.2  4.2
(1.37  1.11
/ 1.14  0.92) 4.5  3.5
(1.19  0.93
/ 0.99  0.77)
4
4
(4JH1TC) 7.0 (1.85/1.54) 6.2  5.2
(1.64  1.37
/ 1.36  1.14) 5.3  4.3
(1.72  1.14
/ 1.17  0.95)

9. Start the engine and check for oil leakage from the
main oil filter.
6A-7




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.






RTW46ASH000501








2. Clean the fuel filter cartridge fitting faces.
This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench : 5-8840-0253-0 (J-22700)





6. Operate the priming pump until the air discharged
completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.
041RY00009

ENGINE MECHANICAL 6A – 39

18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.

TPS connector

Oil pressure switch connector

Thermo switch connector

Injection pump connector

Engine earth

Thermometer unit connector

TDC sensor
2) Remove the clips fixing engine harness.
P1010009