width ISUZU TF SERIES 2004 Workshop Manual

SHIFT ON THE FLY SYSTEM 4C2-7



RTW440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.










412RW011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.




412RW022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

BRAKES 5C-9
MAIN DATA AND SPECIFICATIONS
FRONT DISC BRAKE mm(in.) 4

2 4

4, 4

2 HIGH RIDE
Caliper type Pin slide
Disc outside diameter 256(10.079) 280 (11.023)
Disc thickness 26(1.024) 27 (1.063)
Piston diameter 42.8 (1.685)

2 45.5 (1.79)
Adjustment method Self-adjusting
REAR DRUM BRAKE mm(in.) 4

2 4

4
Type Leading and Trailing
Drum inside diameter 254(10.008) 295 (11.614)
Brake lining dimension 244

50

5 283

45

5
(Length
Width
Thickness) (9.57
1.97
0.20) (11.14
1.77
0.20)
Adjustment method Self-adjusting
WHEEL CYLINDER mm(in.)
Inside diameter : rear 25.4 (1.000) 23.8 (0.937)
MASTER CYLINDER mm(in.)
Type Split
Bore diameter 25.4 (1.000)
Piston stroke (Primary + Secondary) 21.8 + 12 (0.86 + 0.47)
VACUUM SERVO mm(in.) 6VE1/C24NE 4JA1-T/4JA1-TC/4JH1-TC
Diaphragm diameter 205(8.077) + 230(9.055) 180(7.087) + 205(8.077)
4JA1-T
Power cylinder stroke 35 (1.378)
PEDAL RATIO 3.7
BALANCE EBD (with ABS)
Type Load sensing proportioning valve (without ABS)
Blend valve (without ABS)

ELECTRICAL-BODY AND CHASSIS 8A-9

SPLICING WIRE
Open the Harness
If the harness is taped, remove the tape.
To avoid wire insulation damage, use a sewing "seam ripper"
(available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the
desired wire.
Cut the wire
Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to cut
more wire off to change the location of a splice.
You may have to adjust splice locations to make certain that
each splice is at least 1-1/2" (40 mm) away from other splices,
harness branches, or connectors.
Strip the insulation
When replacing a wire, use a wire of the same size as the
original wire.
Check the stripped wire for nicks or cut strands.
If the wire is damaged, repeat the procedure on a new section
of wire.
The two stripped wire ends should be equal in length.



Crimp the Wires
Select the proper clip to secure the splice.
To determine the proper clip size for the wire being spliced,
follow the directions included with your clips.
Select the correct anvil on the crimper.
(On most crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them between
your thumb and forefinger.
Then, enter the splice clip under the stripped wires and hold it
in place.




Open the crimping tool to its full width and rest one handle
on a firm flat surface.

Center the back of the splice clip on the proper anvil and
close the crimping tool to the point where the back of the
splice clip touches the wings of the clip.

Make sure that the clip and wires are still in the correc
t
position. Then, apply pressure until the crimping tool closes.



Before crimping the ends of the clip, be sure that:

The wires extend beyond the clip in each direction.

No strands of wire are cut loose.

No insulation is caught under the clip.
Crimp the splice again, once on each end.
Do not let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.

ENGINE MECHANICAL 6A – 65
















Valve Contact Width
1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.


Valve Contact Width mm (in)
Standard Limit
Intake 1.7 (0.067) 2.2 (0.087)
Exhaust 2.0 (0.079) 2.5 (0.078)
























Valve Seat Insert Replacement
Valve Seat Insert Removal
1. Arc weld the entire inside circumference (1) of the valve
seat insert (2).
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the valve
seat insert easier.
3. Use a screwdriver (3) to pry the valve seat insert free.
Take care not to damage the cylinder head (4).
4. Carefully remove carbon and other foreign material from
the cylinder head insert bore.


014RY00027
011LX039

6A – 66 ENGINE MECHANICAL


Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller
outside diameter than the valve seat insert) on the valve
seat insert (2).

NOTE:
The smooth side of the attachment must contact the
valve seat insert.

2. Use a bench press (3) to gradually apply pressure to the
attachment and press the valve seat insert into place.

NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.








Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15
, 45
, and 75
blades) to minimize
scratches and other rough areas. This will bring the
contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away unblemished
areas of the valve seat surface.









Valve Seat Angle Degree
45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.











3. Apply abrasive compound to the valve seat insert surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with
the entire circumference of the valve.



011LX063 014RY00026
011LX037
011LX038

ENGINE MECHANICAL 6A – 81

Connecting Rod Bearing Inside Diameter
1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening
method.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60

3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.



Crankpin and Bearing Clearance
If the clearance between the measured bearing inside diameter
and the crankpin exceeds the specified limit, the bearing
and/or the crankshaft must be replaced.


Crankpin and Bearing Clearance mm (in)
Standard Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100(0.0039)
4JH1TC 0.029-0.083
(0.0011-0.033) 0.100 (0.0039)






Clearance Measurements (With Plastigage)
Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting surface,
the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30
to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal
across the full width of the bearing.
6. Install the bearing caps with the bearing.








7. Tighten the bearing caps to the specified torque.


Crankshaft Bearing Cap Bolt Torque mm (in)
167 (17/123)
Do not allow the crankshaft to turn during bearing cap
installation and tightening.
8. Remove the bearing cap.



015RY00012
015RY00013 015RY00011

6A – 82 ENGINE MECHANICAL




































9. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1. Use a micrometer to measure the crankshaft outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the bearing
must be replaced.


Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.032 - 0.077
(0.0013 - 0.0030) 0.110 (0.0043)
































Crankpin and Bearing Clearance
1. Clean the crankshaft, the connecting rod, the bearing cap,
and the bearings.
2. Install the bearing to the connecting rod and the bearing
cap.
Do not allow the crankshaft to move when installing the
bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from falling.
5. Install the bearing cap and tighten it to the two step of
anglar tihtening method.
Do not allow the connecting rod to move when installing
and tightening the bearing cap.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60

015LX129
015LX060

ENGINE MECHANICAL 6A – 83































6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the specified limit, perform
the following additional steps.
1. Use a micrometer to measure the crankpin outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing must
be replaced.


Crankpin and Bearing Clearance mm (in)
Standard Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100 (0.0039)
4JH1TC 0.029-0.083
(0.0011-0.0033) 0.100 (0.0039)

CRANKSHAFT BEARING SELECTION
Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing inserts.
Match the crankshaft bearing housing grade marks and the
crankshaft journal grade marks in the table below to determine
the correct crankshaft bearing size.

Crankshaft Bearing Housing Grade Mark
Position
Crankshaft bearing housing grade marks 1, 2 or 3 are stamped
on the rear right hand side of the cylinder body.




Crankshaft Journal Grade Mark Position
The crankshaft journal grade marks (1 or -, 2 or --, 3 or ---) are
stamped on each crankshaft journal web.
The crankshaft journal and bearing clearance must be the
same for each position after installation of the crankshaft and
the crankshaft bearings.

NOTE:
The crankshaft journal mark No. 4 is stamped on
crankshaft No. 4 journal web front side or rear side.
015LX060
015RY00016

6E–118 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
64 P0243 8 ON Turbocharger Wastegate
Solenoid "A" HighWastegate control EVRV
circuit short to voltage circuit.1. Fuel injection quantity is
r e d u c e d .
2. EGR EVRV becomes
1 0 % c o n d i t i o n .
3. Wastegate control EVRV
becomes 32% condition.Wastegate control EVRV
circuit is correct condition.1. Wastegate control EVRV
circuit short to voltage
c i r c u i t .
2. Wastegate control EVRV
m a l f u n c t i o n .
3. ECM malfunction.96 — —
53 P0251 6 ON Injection Pump Malfunction 1. No pump camshaft
s p e e d s e n s o r e r r o r .
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection
quantity. 1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
becomes 0mg/strk.No recovery until condition
match in the next ignition key
cycle.1. PSG (pump control unit)
m a l f u n c t i o n .
2. Pump camshaft speed
sensor malfunction.——
7 ON Injection Pump Malfunction 1. No pump camshaft
s p e e d s e n s o r e r r o r .
2 . N o C K P s e n s o r e r r o r .
3. Difference of engine
speed and doubled pump
camshaft speed is more
than 720rpm (4JA1-TC)
or 690rpm (4JH1-TC). 1. No pump camshaft
s p e e d s e n s o r e r r o r .
2 . N o C K P s e n s o r e r r o r .
3. Difference of engine
speed and doubled pump
camshaft speed is below
800rpm (4JA1-TC) or
6 9 0 r p m ( 4 J H 1 - T C ) .
No recovery until in the
next ignition key cycle. 1. Missing CKP sensor
p u l s e s .
2. Electrical interference.
3. Magnetic interference.
4. PSG (pump control unit)
malfunction.91 —
9 ON Injection Pump Malfunction No pump map programmed
in the PSG (pump control
unit) or PSG malfunction.No recovery until condition
match in the next ignition key
cycle.PSG (pump control unit)
malfunction. — —
A ON Injection Pump Malfunction EEPROM or A/D converter
malfunction in the PSG
(pump control unit).Fuel injection quantity is
reduced.EEPROM or A/D converter
no malfunction in the PSG
( p u m p c o n t r o l u n i t ) .
No recovery until in the next
ignition key cycle.PSG (pump control unit)
malfunction.
——
B ON Injection Pump Malfunction PSG (pump control unit)
recognized high pressure
solenoid valve drive circuit
error.No fail-safe function. No recovery until condition
match in the next ignition key
cycle.PSG (pump control unit)
malfunction.
——
D ON Injection Pump Malfunction PSG (pump control unit)
could not measure the high
pressure solenoid valve drive
voltage.PSG (pump control unit)
malfunction.
——
E ON Injection Pump Malfunction ECM could not accept PSG
(pump control unit) message.1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
becomes 0mg/strk.ECM accepts PSG (pump
control unit) message.1. CAN high circuit open,
short to ground or short
t o v o l t a g e c i r c u i t .
2. CAN low circuit open,
short to ground or short
t o v o l t a g e c i r c u i t .
3 . E C M m a l f u n c t i o n .
4. PSG (pump control unit)
malfunction.9 9 /
100P1650(A)/











P1651(B) Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–119
43 P0335 B ON Crankshaft Position Sensor
Circuit Malfunction1. Engine speed is more
t h a n 6 6 5 r p m .
2. CKP sensor pulse width
error.When pump camshaft speed
sensor is OK:
ECM uses doubled pump
camshaft speed as substitute
engine speed.
When pump camshaft speed
s e n s o r i s n o t O K :
1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
becomes 0mg/strk. ECM detects correct CKP
pulse width.1 . D u r i n g e n g i n e r u n :
1. CKP sensor harness
open circuit, short to
ground or short to
voltage circuit.
2. Poor connector
c o n n e c t i o n .
3. CKP sensor malfunction.
4. Pulse sensing gap
i n c o r r e c t .
5 . P u l s e r m a l f u n c t i o n .
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.9 0 /
9 8 /
101P1335 (A)
D ON Crankshaft Position Sensor
Circuit Malfunction1. No pump camshaft
s p e e d s e n s o r e r r o r .
2. "Crankshaft Position
Sensor Circuit
Malfunction (Symptom
Code B)" is not stored.
3 . E n g i n e s p e e d i s 0 r p m .
4. Doubled pump camshaft
speed is more than
50rpm.When pump camshaft speed
s e n s o r i s O K :
ECM uses doubled pump
camshaft speed as substitute
engine speed.
Other than pump camshaft
s p e e d s e n s o r i s O K :
Fuel injection quantity is
reduced.1. Engine speed is more
than 0rpm.
2. Doubled pump camshaft
speed is below 100rpm.During engine crank:
1. CKP sensor harness
open circuit, short to
ground or short to
voltage circuit.
2. Poor connector
c o n n e c t i o n .
3. CKP sensor malfunction.
4. Pulse sensing gap
i n c o r r e c t .
5 . P u l s e r m a l f u n c t i o n .
6. Electrical interference.
7. Magnetic interference.
8. ECM malfunction.9 0 /
9 8 /
101P1135 (A)
E ON Engine Speed Input Circuit
Range/PerformanceEngine speed is more than
5700rpm.When intermittent
malfunction:
1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
b e c o m e s 0 m g / s t r k .
When preliminary
malfunction:
ECM uses doubled pump
camshaft speed as substitute
engine speed.Engine speed is below
5700rpm.1. Engine over-running.
2. CKP sensor malfunction.























3 . P u l s e r m a l f u n c t i o n .
4. ECM malfunction.
9 0 /
9 8 /
101—
66 P0380 4 ON Glow Relay Circuit Voltage
LowGlow relay circuit open or
short to ground circuit.No fail-safe function. Glow relay circuit is correct
condition.1. Glow relay circuit open or
short to ground circuit.
2. Glow relay malfunction.
3. ECM malfunction.94 —
8 ON Glow Relay Circuit Voltage
HighGlow relay circuit short to
voltage circuit.ECM malfunction.
—— Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)