diesel ISUZU TF SERIES 2004 Workshop Manual

5C-60 BRAKES
Inspection and Repair
Vacuum Hose (The built in check valve)
360R300002


1) Inspect the check valve (2), which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in
the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check
valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.

Important Operation-Installation
8. Vacuum Booster Assembly
7. Vacuum Booster Fixing Nut
6. Snap Pin
1) Perform vacuum booster and vacuum booster push rod
adjustment.
Note :
When replacing either the master cylinder or vacuum booster,
be sure to measure push rod, and adjust if required.

RTW35CSH000901

2) Measure the dimension (B) of master cylinder.


3) Apply negative pressure by means of vacuum pump so
that the pressure in the vacuum booster becomes
GASOLINE ENGINE: 66.7 kPa (500 mm Hg) or DIESEL
ENGINE 93.3 kPa (700 mm Hg).
Note :
Be sure to apply NEGATIVE pressure after installing a push
rod gauge on the vacuum booster.

BRAKES 5C-61


















4) Measure dimension (A)

RTW35CSH000801







5) Calculate the gap (B-A) when assembling the master
cylinder and vacuum booster.

GAP mm (in
)
0 
0.4 (0 
0.0157)



6) If dimension (A) is out of the standard range, adjust the
push rod.

Loosen the push rod lock nut (1) on the vacuum
booster.

Set the clevis (2).

Use the adjuster (3) to adjust the length of the
protruding portion of the push rod.

Vacuum (negative) pressure should be GASOLINE
ENGINE: 66.7 kPa (500mm Hg) or DIESEL
ENGINE: 93.3 kPa (700mm Hg) after adjustment.

Tighten the push rod lock nut to the specified torque.







Torque N

m(kgf

m/lb

ft)
18 – 25 (1.8 – 2.5 / 13 – 18)

7) Install the vacuum booster assembly to the dash panel
and pedal mounting bracket.
Torque N

m(kgf

m/lb

ft)
18 – 24 (1.8 – 2.4 / 13 – 17)

ELECTRICAL-BODY AND CHASSIS 8A-317
DIESEL W/SRS MODEL
1. All windows do not operate

Checkpoint Trouble Cause Countermeasure


Reinstall or replace the fuse
SBF-11 (30A)

Poor fuse contact or blown
NG

Replace the circuit breaker
SBF-9 (50A)

SBF-9 (50A, Fuse box)
function

Circuit breaker malfunction


Repair grounding points
C-2
contact


Grounding points
C-2


Poor grounding point contact
NG NG OK
OK OK

Fuse SBF-11 (30A, Fuse box)


Replace the power window
relay

Power window relay
malfunction
NG
Repair an open circuit or a
poor connection of the
connectors between 1
C-108
and 2
B-8
Voltage between the power
window relay harness side
connector terminal 2
B-8
and the ground (Should be
battery voltage present)

Open circuit or poor connector
contact
NG OK

Power window relay function

OK
Repair an open circuit or a
poor connection of the
connectors between 1
B-8
and 1
B-56 and 6 D-5

Open circuit or poor connector
contact
NG Voltage between 6 D-5 and
the ground (Should be battery
voltage present)

OK
Repair an open circuit or a
poor connection of the
connectors between 3
D-5
and
C-2 , or 3 B-8 (12

C-107 )
and C-2

Open circuit or poor connector
contact
NG
Continued on the next page

Voltage between
C-2 and
the ground

6A – 4 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JA1T (L) 4JA1TC
Engine type
Combustion chamber type
Cylinder liner type
Timing gear train system Four-cycle, overhead valve, water cooled
Direct injection
Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 93
92 (3.66
3.62)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement cm3 (in3)
Compression ratio (to 1) 2,499(152.4)
18.5
Compression pressure Mpa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) Approximately 239 (527)
Fuel injection order 1 – 3 – 4 - 2
Fuel injection timing BTDC deg 8 -
Specified fuel type
Idling speed rpm

Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
730  25 (A/C Off)
850  25 (A/C ON)
0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed
type) Electronically controled
Injection nozzle type
Injection nozzle opening pressure Hole with 5 orifices

Mpa(kg/cm2/psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2nd (Reference)
25.527.0
(260275 / 3,7023,920) 2nd (Reference)
34.035.5
(347362 / 4,9365,154)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)

6A – 6 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JH1TC
Engine type Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type
Timing gear train system Dry type, chrome plated
Gear drive
No. of cylinders-bore
stroke mm (in) 4 – 95.4
104.9 (3.76
4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter
Compression ratio (to 1) 2,999
18.3
Compression pressure MPa(kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb) MT : Approximately 249 (549)
AT : Approximately 236 (520)
Fuel injection order 1 – 3 – 4 - 2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm
700
25 (A/C OFF)
800
25 (A/C ON)
Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system
Injection pump type 0.4 (0.016)
0.4 (0.016)
24.5
55.5
54.0
26.0

BOSCH distributor VP44 type
Injection nozzle type
Injection nozzle opening pressure
MPa(kg/cm
2/psi)Hole with 5 orifices

1st 19.5 (199/2,828)
2nd (Reference) 34.335.8 (350365/4,9805,197)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Oil pump type
Oil filter type Gear
Cartridge paper element
Oil capacity lit (US/UK gal)
6.2 (1.64/1.36) (For 4
2)
7.0 (1.85/1.54) (For 4
4)
Oil cooler type Water cooled

6A – 36 ENGINE MECHANICAL
GENERAL DESCRIPTION









RTW46AMF000401

The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.

ENGINE MECHANICAL 6A – 73






Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the
cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and
bore surfaces.

NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.

3. Insert the cylinder liner (1) into the cylinder body (2)
from the top of the cylinder body.










4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).

NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.

6. Use the bench press to apply a seating force of 4,900
N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully
seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder
liner projection.
Refer to "Cylinder Liner Projection Inspection".

012RY00017
012RY00018

6C – 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
DISASSEMBLY




















080L200009


Disassembly Steps
1.
Retaining nut 9.
Collar
2.
Nozzle & pin 10.
Spring seat
3.
Spacer & pin 11.
First spring
4.
Lift Piece 12.
Shim (First nozzle opening
pressure adjustment)
5.
Spring seat 13.
Nozzle holder body
6.
Push rod 14.
Eye bolt
7.
Shim (Second nozzle opening
pressure adjustment) 15.
Gasket
8.
Second spring



Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.

6E–70 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR INJECTION
PUMP
Outline
Instead of the previous face cam type, the radial plunger
distributor type injection pump utilizes a cam ring to
enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
smoke, low noise, high output and clear ex haust
emissions.
Cross-section View
(1) Drive Shaft
(2) Feed Pump
(3) Pump Camshaft Speed Sensor
(4) Pump Control Unit (PSG)
(5) Distributor Head
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve
(8) Constant Pressure Valve (CPV)
(9) Timing Control Valve (TCV)
(10) Timer
(11) Radial Plunger High Pressure Pump
(1) Drive Shaft
(2) Feed Pump
(3) Pump Camshaft Speed Sensor
(4) Pump Control Unit (PSG)
(5) Distributor Head
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve
(8) Constant Pressure Valve (CPV)
(9) Timing Control Valve (TCV)
(10) Timer
(11) Radial Plunger High Pressure Pump

6E–362 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Is the fuel amount enough?
—Go to Step 5Add fuel to the
tank
5 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 6
6 Check the “ECM” fuse (10A) and “Engine” fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 7
7 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 8
8 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 10