radiator ISUZU TF SERIES 2004 Workshop Manual

8A-128 ELECTRICAL-BODY AND CHASSIS
LIGHTING SYSTEM
REMOVAL AND INSTALLATION


HEADLIGHT
Removal
1. Remove the radiator grille center bolt.
2. Use a screwdriver to raise the clip and release the lock.
Place a clean rag beneath the screwdriver tip to protect the
body painted surfaces.
3. Remove the radiator grille.
4. Remove the front bumper.
5. Disconnect the headlight connector.
6. Remove the headlight assembly.
7. Remove the headlight cover.
 Remove the gaid.
8. Remove the headlight.


HALOGEN HEADLIGHT
Removal
1. Remove the head light socket.
2. Remove the headlight cover.



3. Out side the lock spring.



4. Remove the bulb.

8A-142 ELECTRICAL-BODY AND CHASSIS

FRONT FOG LIGHT
Removal
1. Remove the radiator grille.
2. Remove the front bumper
3. Disconnect the fog light connector.
4. Remove the fog light.



5. Remove the bulb from the socket.
 Remove the socket by turning it counterclockwise.


Installation
Follow the removal procedure in the reverse order to install the
fog light.
Pay close attention to the important points mentioned in the
following paragraphs.



Bulb
Be absolutely sure that the fog light bulb is correctly installed.
This will prevent a poor contact and open circuit.


FRONT FOG LIGHT ADJUSTMENT
Vertical Adjustment
Turn the adjusting screw (1) with a screwdriver to adjust the
aim of the fog light vertically.



RTU4Z0SH000601
FRONT FOG & REAR FOG SWITCH

8A-178 ELECTRICAL-BODY AND CHASSIS
BACK UP LIGHT SWITCH
Removal
1. Disconnect the battery ground cable.
2. Disconnect the connector
1.
3. Remove the back up light switch from the transmission
2.



Installation
Follow the removal procedure in the reverse order to install the
back up light switch.
Pay close attention to the important points mentioned in the
following paragraphs.



Back up Light Switch Threads
Apply liquid gasket to the threaded portion and install the back
up light switch.



Connector
Be absolutely sure that the back up light connector is securely
connected.
This will prevent a poor contact and an open circuit.

HORN
Removal
1. Remove the radiator grille.
Refer to the “HEADLIGHT” removal procedure.
2. Loosen the horn bolt.
3. Disconnect the horn connector.


Installation
Follow the removal procedure in the reverse order to install the
horn.
Pay close attention to the important point mentioned in the
following paragraphs.



Connector
Be absolutely sure the horn connector is securely connected.
This will prevent a poor contact and open circuit.

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction
found? (Include radiator cap) — Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan
belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the
fan clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the
fan clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump
assembly.
8 Was the restriction by the foreign materials in the
cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. — Clean or
replace the
clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? — Replace the
sealing cap or
replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 2 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
2 Was the PCV (Positive Crankcase Ventilation) valve
working completely? —
Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved

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 %

6A – 28 ENGINE MECHANICAL


Cooling System Inspection
Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage. The testing pressure must not exceed the
specified pressure.

Testing Pressure kPa(kg/cm
2 /psi)
150 (1.5/21)



Radiator Cap Inspection
The radiator filler cap is designed to maintain coolant
pressure in the cooling system at 103 kPa(1.05 kg/cm2,
15psi).
Check the radiator filler cap with a radiator filler cap tester.
The radiator filler cap must be replaced if it fails to hold the
specified pressure during the test procedure.
Radiator Cap Valve Opening Pressure
kPa(kg/cm
2 /psi)
90 – 120 (0.9 – 1.2/13 – 17)

Negative Valve (Reference) kPa(kg/cm2 /psi)
1.9 – 4.9 (0.02 – 0.05/0.28 – 0.71)
030LX003
030LX002

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

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 MECHANICAL 6A – 135


INTER COOLER
REMOVAL AND INSTALLATION





RTW46ALF001001

Removal Steps
1. Radiator grille
2. Front bumper fascia
3. Front bumper inpact support assembly
4. Inter cooler

Installation Steps
4. Inter cooler
3. Front bumper inpact support assembly
2. Front bumper fascia
1. Radiator grille

6A – 136 ENGINE MECHANICAL





RTW36ASH000601
Removal
1. Radiator Grille

Refer to removal procedure in Sheet Metal section.







RTW36ASH000501
2. Front Bumper Fascia

Remove the nine clips and four screws.

Disconnect the fog light harness connectors.
















RTW46ASH002101
3. Front Bumper Impact Support Assembly

Remove the nut and two bolts.



4. Inter Cooler

Remove the nut and two bolts.

Disconnect the air hose.




Installation
4. Inter Cooler

Tighten the nut and two bolts.


3. Front Bumper Impact Support Assembly

Tighten the nut and two bolts.



2. Front Bumper Fascia

Install the nine clips and four screws.

Connect the fog light harness connectors.


1. Radiator grille

Refer to installation procedure in Sheet Metal section.