oil temperature ISUZU TF SERIES 2004 Workshop Manual

8A-430 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
E-54
(6VE1)
Ignition coil E-62
(6VE1)
Cam position sensor
E-54
(4JH1-TC)
Black A/T term ASM E-64
(C24SE)
(6VE1)
Oil pressure switch (P/STRG)
E-55
(6VE1)
Ignition coil E-65
(C24SE)
(6VE1)
Thermo unit
E-56
(6VE1)
Ignition coil E-66
(C24SE)
(6VE1)
Duty solenoid
E-57
(6VE1)
Ignition coil E-67
NOT USED
E-58
(6VE1)
Ignition coil E-68
(C24SE)
Throttle position sensor
E-59
(C24SE)
(6VE1)
(6VE1) Crank position sensor (C24SE) E-68
(6VE1)
Throttle position sensor
E-60
(C24SE)
ECM E-69
(6VE1)
Temperature sensor
E-60
(6VE1)
ECM-A E-70
(C24SE)
IACV
E-61
(6VE1)
ECM-B E-70
(6VE1)
IACV

ELECTRICAL-BODY AND CHASSIS 8A-431


No. Connector face No. Connector face
E-71

NOT USED E-80
(6VE1)
Cylinder revolution
E-72
(C24SE)
(6VE1)
Engine earth-A E-81
(6VE1)
Speed sensor
E-73
(6VE1)
Engine earth-A E-82
(6VE1)
Transmission wire
E-74
(C24SE)
(6VE1)
Engine earth-B E-83
(6VE1)
Oil temperature sensor
E-75
(C24SE)
(6VE1)
Oil pressure switch E-84
(C24SE)
Knock sensor
E-76
(6VE1)
EGR valve E-85
(C24SE)
MAP sensor
E-77
(C24SE)
O2 sensor E-86
(4JA1-L)
SilverThermo switch; QOS
E-77
(6VE1)
O2 sensor RH-Front E-87
(4JA1-L)
WhiteSolenoid CSD
E-78
(6VE1)
O2 sensor LH-Front E-88
(4JA1-L)
SilverThermo switch; EGR
E-79
(6VE1)
Neutral start switch E-89
(4JA1-L)
White

Immobilizer engine control unit

ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.




Engine coolant Filling up procedure
1. 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 rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator 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 rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.

Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)
50 %

ENGINE MECHANICAL 6A – 29


Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature C (F)
82 (180)
Oil Cooler Thermo Valve C (F)
76.5 (170)
EGR Cooler Thermo Valve C (F)
40 (104)

4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature C (F)
95 (203)
Oil Cooler Thermo Valve C (F)
90 (194)
EGR Cooler Thermo Valve C (F)
55 (131)
Valve Lift at Fully Open position mm (in)
9.5 (0.37)
Oil Cooler Thermo Valve mm (in)
4.5 (0.18)
EGR Cooler Thermo Valve mm in)
3.5 (0.14)



Drive Belt Adjustment
Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and
adjust as necessary.
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
4 Oil pump pulley or idler pulley
5 Compressor pulley or idler pulley


030LX014
033RY00002

ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator 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.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.

Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)

9.5 (2.5/2.1)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.

ENGINE COOLING 6B – 3

MAIN DATA AND SPECIFICATIONS
Description Item
M/T A/T
Cooling system
Water pump type
Pump to crankshaft speed ratio (To 1)
Delivery volume lit (US/UK gal)/min
Pump speed at 3000 rpm
Water temperature at 30
C (86
F)
Pump bearing type

Thermostat type
Valve initial opening temperature
C (
F)
(Oil cooler thermo valve)
(EGR cooler thermo valve)
Valve full opening temperature
C (
F)
(Oil cooler thermo valve)
(EGR cooler thermo valve)
Valve lift at fully open position mm (in)
(Oil cooler thermo valve)
(EGR cooler thermo valve) Engine coolant forced circulation
Centrifugal impeller type
1.2
100 (26.3/22.2)


Double row shaft

Wax pellet with jiggle valve
82 (180)
76.5 (170)
40 (104)
95 (203)
90 (194)
55 (131)
9.5 (0.37)
4.5 (0.18)
3.5 (0.14)
Radiator Tube type corrugated
Heat radiation capacity 93.0 kw (79,980 kcal/h)
Heat radiation area
11.63 m
(1.081ft
)
Radiator front area
0.28m
(0.026 ft
)
Radiator dry weight 52 N (5.3 kg/11.7 lb) 53 N (5.4 kg/11.9 lb)
Radiator cap valve opening pressure
93.3
122.7kpa (13.5
17.8psi)
Engine coolant capacity 2.4 lit (5.1 U.S pint) 2.3 lit (4.9 U.S pint)
Engine coolant total capacity 10.1 lit (21.3 U.S pint) 10.0 lit (21.1 U.S pint)

ENGINE COOLING 6B – 7
DIAGNOSIS
Engine Cooling Trouble
Symptom Possible Cause Action
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace

6B – 8 ENGINE COOLING
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolan
t
(EC) level should be between the “MIN" and “MAX" lines o
f
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the “MAX" line.
There should not be any excessive deposit of rust or scales
around the radiator cap or radiator filler hole, and the EC
should also be free from oil.
Replace the EC if excessively dirty.


P1010064
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.

2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do not
remove the cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out unde
r
pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it.
Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.
 Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the radiato
r
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator 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.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–75
When control current flows to the timing control valve
(TCV) coil, the valve needle opens and the fuel annular
chamber flows through the orifice to the feed pump inlet.
Consequently, the pressure of the annular chamber
decreases and the hydraulic stopper is moved to the
retard side.
The timing control valve (TCV) acts as a variable
throttle, using the rapid opening and closing (cycling) of
the valve needle in the timing control valve (TCV).
At normal operation, the TCV controls the pressure
acting on the annular chamber so that the hydraulic
stopper cam move to any position, from the retard
position to the advance position. At this time, the duty
ratio is set by the pump control unit (PSG).
Duty ratio is the ratio of the time that the timing control
valve (TCV) is opened to one complete timing control
valve (TCV) operating cycle. A duty ratio change of
100% to 0% is an advance in injection timing. (The
VP44 displays an ON duty ratio.)The engine control module (ECM) contains
characteristic maps of the start of injection,
corresponding to engine operating conditions (engine
load, engine speed and engine coolant temperature).
The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
injection timing. If there is a difference, the timing
control valve (TCV) is controlled by the duty ratio. (The
actual start of injection timing is determined from the
pump camshaft speed sensor.) (1) Coil
(2) From Annular Chamber
(3) To Feed Pump
(4) Orifice
(5) Valve Needle
Engine Load
Engine Speed
Engine Coolant
TemperatureEngine
Control
Module
(ECM)Pump
Control
Unit
(PSG)
Pump Camshaft
Speed Sensor
Timing
Control
Valve
(TCV)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–217
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 4)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 8)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The voltage on the coil of the relay glow plug is supplied
by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
66 P0380 4 ON Glo w Re la y Circuit Volta ge
Lo wGlow relay circuit open or
sho rt to ground circuit.No fa il-sa fe fun ctio n.
8 ON Glo w Re la y Circuit Volta ge
HighGlo w re la y circuit short to vo lt-
age circuit.