2004 ISUZU TF SERIES oil

6 – 16 TROUBLESHOOTING
14. Battery Charging and Noise Problem
Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? — Repair or
replace the
brush and/or
the slip ring. Go to Step 3
3 Inspect the stator coil on the generator.
Was there an open circuit or the scorching on the
stator coil? —
Replace the
stator coil. Go to Step 4
4 Inspect the rotor coil on the generator.
Was there an open circuit or the scorching on the
rotor coil? —
Replace the
rotor coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? — Replace the
rectifier Go to Step 6
6 Inspect the IC regulator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

14-2 Battery Overcharging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the terminal circuit.
Were the B and F terminals shorted? — Repair the
short circuit. Go to Step 3
3 Check the regulating voltage.
Was the IC regulator voltage excessive? — Replace the IC
regulator. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? — Repair or
replace the
brush holder
assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? — Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity
generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? — Repair or
replace the
brush and/or
the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —
Repair the
loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

6 – 18 TROUBLESHOOTING
14-5 Charging System Noise
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and
decreasing engine speed? —
Replace the
bearing. Go to Step 3
3 Was there a growling sound and does this sound
stop when the connector was disconnected? — Replace the
stator coil. Go to Step 4
4 Was intermittent sound heard when the generator
was running? — Replace the
brush and/or
slip ring. Go to Step 5
5 Was frictional sound heard when generator was
running? — Clean the slip
ring or replace
the brush. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

TROUBLESHOOTING 6 – 19
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? — Replace the
brush or repair
the
commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty?
—
Clean contact
face Go to Step 4
4 Was the pinion clutch slipped? — Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil.
Was there an open circuit or a short circuit in the
armature field coil? — Repair or
replace the
armature field
coil. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

15-2 Incorrect pinion and ring gear engagement
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken? —
Replace the
wron parts. Go to Step 3
3 Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect? — Adjust or
replace the
movement
parts. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved

ENGINE MECHANICAL 6A – 3
Lubricating Flow ........................................................................................................ 6A- 126
Oil Pump and Oil Filter .............................................................................................. 6A- 127
Oil Pump ..................................................................................................................... 6A- 128
Disassembly............................................................................................................ 6A- 128
Inspection and Repair ............................................................................................ 6A- 129
Reassembly............................................................................................................. 6A- 130
Oil Filter and Oil Cooler ............................................................................................. 6A- 131
Disassembly............................................................................................................ 6A- 131
Inspection and Repair ............................................................................................ 6A- 132
Reassembly............................................................................................................. 6A- 133
Inter Cooler .................................................................................................................... 6A- 135
Removal .................................................................................................................. 6A- 136
Installation .............................................................................................................. 6A- 136
Special Tools.................................................................................................................. 6A- 137

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)

ENGINE MECHANICAL 6A – 5
Engine model
Item 4JA1T (L) 4JA1TC
Oil pump type
Oil filter type
Oil capacity lit (US/UK gal)
Oil cooler type Gear
Cartridge paper element
6.2 (1.64/1.36)
Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage
No. of units 80D26L
1

95D31L
1 (OPT)
Generator capacity V-A 12 – 60
12 – 80
Starter motor output V-Kw 12 – 2.3
Turbocharger model
Turbine type
Compressor type *IHI RHF 4H
Mixed flow type
Backward & rake

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

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