automatic transmission ISUZU TF SERIES 2004 Workshop Manual

CRUISE CONTROL SYSTEM 8B-9


RTW3A0SH001001
Removal
1. Disconnect the battery cable.
2. Remove the cruise actuator Assembly (4).

Disconnect the connector (3).

Remove the cable end (1) from the throttle link (cruise
control side).

Loosen a fixing nut of the cruise control cable (2).

Remove fixing screws of the actuator (5).


Installation
To install, follow the removal steps in the reverse order, noting
the following point.
1. Take care not to bend the cable excessively.





RTW3A0SH001501
Adjustment
After installing the cruise actuator, the following steps must be
carried out for cruise control cable adjustment.
1. Install the cruise control cable end (3) to the throttle link (4).
2. Put the screw portion of the cable in the bracket (5).
3. Put the nut (1) to the bracket and then tighten the nut (2).
CAUTION: Don't move a position of the nut (1) from
supplied condition.
4. If the distance between the throttle link (4) and the throttle
link lever (6) is out of the specified range, loosen the nut (2)
to adjust it.

Mode Switch


Removal and Installation
Refer to the Mode Switch removal and installation steps in
Automatic Transmission section.

6B – 16 ENGINE COOLING

P1010064
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





PTW46BSH000101
5. Remove fan guide(1), clips(2) on both sides and the bottom
lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.





RTW36BMH000101
7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking
care not to damage the radiator core with a fan blade.

6B – 18 ENGINE COOLING




110RS005

 Check the rubber hoses for swelling.

Installation
1. Install radiator assembly (9) with hose, taking care not to
damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and
secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the
engine.





RTW36BMH000101

6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–9
ABBREVIATION CHARTS
A bbreviations A ppellation
A/C Air conditioner
A/T Automatic transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CAN Controller Area Network
CEL Check engine lamp
CKP Crankshaft position sensor
DLC Data link connector
DTC Diagnosis trouble code
DVM Digital voltage meter
ECM Engine control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Ex haust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VCC Voltage constunt control
VIO Violet
VSS Vehicle speed sensor
WHT Whi te
YEL Yellow

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–67
Engine Coolant Temperature (ECT) Sensor
The ECT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other
words it measures a temperature value. It is installed on
the coolant stream. Low coolant temperature produces
a high resistance.
The ECM supplies 5 volts signal to the ECT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.
Vehicle Speed Sensor (VSS)
M/T & A /T 4WD
A/T 2WD
The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
The 2WD model fitted with automatic transmission,
vehicle speed sensor signal is transmitted to from the
TCM to the ECM via vehicle speed meter. (1) Engine Coolant Temperature (ECT) Sensor
(2) Thermo Unit for Water Temperature Gauge
12
Characteristic of ECT Sensor -Reference-
10 100 1000 10000 100000
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Engine Coolant Temp (deg. C) (Tech2 Reading)
Resistance (ohm) (Solid Line)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–85
DIAGNOSIS WITH Tech 2
If no codes are set:
Refer to F1: Data Display and identify the electrical
faults that are not indicated by trouble code.
Refer to “SYMPTOM DIAGNOSIS”.
If codes are set:
1. Record all trouble codes displayed by Tech 2 and
check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty
status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is
intermittent. In this case, refer to “DIAGNOSIS
AIDS”.
6. If a code is present, refer to DTC Chart for
diagnosis.
7. Check trouble codes again using the Tech 2.
Tech 2 CONNECTION
Tech 2 scan tool is used to electrically diagnose the
automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Te c h 2 .
1. Configuration of Tech 2
Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
Check the key switch is turn OFF.
Insert the PCMCIA card (1) into the Tech 2 (5).Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
Connect the DLC cable (4) to the Tech 2 (5).
Connect the SAE 16/19 adapter (3) to the data
link connector of the vehicle.
Turn the key switch of the vehicle ON and press
the “PWR” key of the Tech 2.
Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.

6A-48 ENGINE MECHANICAL (6VE1 3.5L)
Rear Oil Seal
Removal
1. Remove transmission assembly.

See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal
using 5884022860.




015RS017
2. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on the crankshaft and flywheel
mounting surface.

Tighten fixing bolts to the specified torque.
NOTE: Do not reuse the bolts and do not apply oil o
r
thread lock to the bolts.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018
3. Install transmission.

See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic transmission. Otherwise, the
transmission may be damaged.






012RS009

ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal

P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.

Disconnect the two connectors from the ECM.

. Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.

17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.

ENGINE COOLING (6VE1 3.5L) 6B-11
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





P1010064
5. Remove fan guide(1), clips(2) on both sides and
the bottom lock, then remove lower fan guide(3)
with fan shroud(4).







RTW46BSH000101
6. Disconnect the reserve tank hose(6) from radiator.
7. Remove bracket(5).





110RW004
8. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 93.3






122.7
(13.5






17.8)
Cap tester: 5 –8840 –0277 –0
Adapter: 5 –8840 –2603 –0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.

ENGINE COOLING (6VE1 3.5L) 6B-13
6. Connect oil cooler hose to automatic transmission.




RTW36BSH000101
7. Connect battery ground cable.
8. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.




RTW36BSH000101
Important operation (in case of 100% engine
coolant change) procedure for filling with engine
coolant.

Engine coolant change
1. To change engine coolant, make sure that the
engine is cool.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiato
r
cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure when
the coolant has become cooler.
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best result it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flash the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even mino
r
cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylen-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
CAUTION: A failure to correctly fill the engine
cooling system in changing or topping up coolant
may sometimes cause the coolant to overflow from
the filler neck even before the engine and radiato
r
are completely full.
If the engine runs under this condition, shortage o
f
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling ove
r
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
5.
After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.