2004 ISUZU TF SERIES warning

8B-10 CRUISE CONTROL SYSTEM
Diagnosis
The cruise control unit uses the cruise main indicator light and diagnosis the failure, when the control unit detects
abnormality on the table below.

PART POSSIBLE CAUSE DETECTION PERIOD DTC
Actuator Motor system short circuit Energizing motor 1-1
Clutch system short circuit Energizing clutch 1-2
Clutch system open circuit Energizing clutch 1-2
Mechanical defect Cruise controlling 1-3
Close side of motor system open circuit Cruise controlling 1-1
Cruise control unit Close side of motor system open circuit While starter sw on 1-4
Clutch output abnormality While starter sw on 1-4
Vehicle speed sensor Signal of vehicle speed disconnection Cruise controlling 2-1
Signal of vehicle speed abnormality Cruise controlling 2-1
Switch Turning on switch at all times While starter sw on 3-1
Turning on switch at the same time While starter sw on 3-1
DTC : Diagnostic Trouble Code

DTC Display Condition
1. With the vehicle stationary and the ignition ON, activate the ‘Cruise Cancel’ switch three times within 2 seconds.
2. If there are no DTC’s stored in the Cruise control unit, the LED on the Cruise Main switch will blink rapidly (2Hz).
3. Any DTC’s stored in the Cruise control unit will be displayed by the CRUISE SET warning lamp in the meter
cluster.
4. Read the set DTC’s by referring to then charts on this page.

NOTE:

The DTC display mode will be aborted if either the vehicle speed rises above 10km/h or the RESUME switch is
operated.

The control module stores the DTC in a ‘volatile’ memory – that is the memory is only active while the ignition is
ON.
Turning the ignition to the OFF position will clesr any stored DTC’s.

TROUBLESHOOTING 6 – 11
9. Oil Pressure Does Not Rise
Step Action Value(s) Yes No
1 Was the oil pressure warning lamp working OK? —
Go to Step 2 Replace the oil
pressure
warning lamp
2 Does the oil filter element clog? — Replace the oil
filter element Go to Step 3
3 Does the relief valve open? — Repair or
replace the
relief valve Go to Step 4
4 Does the oil strainer clog? — Clean or
replace the oil
strainer Go to Step 5
5 Was the oil pump working OK? (The pump related
parts worn etc.) —
Go to Step 6 Repair or
replace the oil
pump.
6 Was the rocker arm and/or relation parts worn? — Replace the
rocker arm
and/or relation
parts Go to Step 7
7 Was the camshaft and/or relation parts worn? — Replace the
camshaft
and/or relation
parts Go to Step 8
8 Was the crankshaft and/or relation parts worn? — Replace the
crankshaft
and/or relation
parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved

Table of pressure unit
Pressure kPa (kg/cm
2) 100
(1.0) 980
(10.0)
Resistance ohm 81 30
Electric current A 63.5 106.7

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 – 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 – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold

6A – 46 ENGINE MECHANICAL
13. Injection Pump
Rrefer to secton 6C-19 (Injection Iump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


027R100007
037RY00001

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler Water Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

6A – 122 ENGINE MECHANICAL

















RTW46ASH001601































9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque N·m(kg·m/Ib ft)
39 (4.0/29)

10) Install the water feed pipe with the gaskets and tighten
to the specified torque.
Water Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)

11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)

13) Install the hoses for the water feed and return.






















9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)

Do not install the catalytic converter, if drop down it.
10. Heat Protector
Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque N·m(kg·m/Ib ft)
9 (0.9/6.5 Ib in)

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11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified
torque.
Pulley Nut Torque N·m(kg·m/Ib ft)
8 (0.8/6)

12. Oil Cooler Water Pipe
13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch
027R100007