2004 ISUZU TF SERIES switch

ENGINE MECHANICAL (C24SE) 6A-63
OPERATIONS ON COOLING SYSTEM
Caution!
Before working with the cooling system, be sure to confirm that
the temperature of the engine is cooled down.
Failure to observe this may cause burn.








Cooling System, Check for Leaks
Installation
1. Install commercially available coolant checking
instrument onto compensation tank (Refer to section 6B;
Engine cooling).
2. Check coolant level.

Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.




Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium.
To avoid corrosion, use only anti-freeze with corrosion
protection.


Replace Coolant
1. Confirm the engine is cold enough.
2. Open the radiator cap, pour coolant to the filler neck level
and close the cap.
3. Pour coolant into the reservoir until MAX line is reached.
4. Start the engine, run 2 
3 minutes at idling speed and
switch off the engine.
5. Refill coolant if the coolant level is lowered.

6A-64 ENGINE MECHANICAL (C24SE)
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. When opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at
approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7. Confirm that the temperature gauge reads half or more
of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8. After the engine cools down, check the coolant level and
refill it if necessary. When the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9. Pour coolant into the reservoir to MAX level.







Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92C/197.6F)

Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-
up phase.


Ignition Timing, Check
No Adjustment

ENGINE MECHANICAL (C24SE) 6A-87
Recommended Torque Values
Nm (kgfm)

Bearing cover to cylinder block ....................................................................................... 60
1) 6.1 +40
to 50

Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission ......................................................... 60
2) 6.1
Bracket for engine damping block to engine block ......................................................... 60 6.1
Bracket for pump/compressor to engine block ............................................................... 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft .................................................................................. 50 5.1
Clamping bracket for alternator to intake manifold ......................................................... 25 2.5
Clamping bracket to alternator ........................................................................................ 25 2.5
Con-rod bearing cap to con-rod ...................................................................................... 35
1) 3.5 +45
to 60

Crankshaft pulley bolts .................................................................................................... 20 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90
+90

+90

Engine damping block to engine bracket ........................................................................ 8.5 8.7
Engine damping block to side member ........................................................................... 52
1) 5.3
Exhaust manifold to cylinder head .................................................................................. 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
Nm (kgfm)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30
to 45

Front exhaust pipe to exhaust manifold .......................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket ................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block .......................................................................... 6
2) 0.6
Oil intake pipe to oil pump ............................................................................................... 8 0.8
Oil pan to cylinder block .................................................................................................. 8
2)3) 0.8
Bearing bridge to cylinder block ...................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ....................................................................................... 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................ 30 3.2
Spark plugs in cylinder head ........................................................................................... 20 2.3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side ............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head .............................................................................. 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover .................................................................................................. 4 0.4
Toothed belt rear cover ................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................ 20 2.3
(M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7
(M12) ............................................................................ 60 6.1
Water pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

6C-12 ENGINE FUEL (C24SE)
Fuel Pump Relay
General Description
In order to control the fuel pump and sender assembly
(FPAS) operation, the FPAS relay is provided. When
the starter switch is turned to “ON" position, the FPAS
relay operates the FPAS for 2 seconds.
When it is turned to “START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.

6D3-2 STARTING AND CHARGING SYSTEM


Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion shaft.
When the starter switch is turned on, the contacts of magnetic
switch are closed, and the armature rotates. At the same time,
the plunger is attracted, and the pinion is pushed forward by
the shift lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. When the engine
starts and the starter switch is turned off, the plunger returns,
the pinion is disengaged from the ring gear, and the armature
stops rotation. When the engine speed is higher than the
pinion, the pinion idles, so that the armature is not driven.




Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


Diagnosis
Condition Possible cause Correction
Starter does not run Charging failure Repair charging system
Battery Failure Replace Battery
Terminal connection failure Repair or replace terminal connector
and/or wiring harness
Starter switch failure Repair or replace starter switch
Starter failure Repair or replace starter

6D3-4 STARTING AND CHARGING SYSTEM

Disassembled View
Legend
1 Bolt
2 Magnetic Switch
3 Gear Case
4 Piston
5 Piston Shaft
6 Center Bracket7 Armature
8 Yoke Assembly
9 Brush and Brush Holder
10 Washer
11 Rear Cover
12 Through Bolt

STARTING AND CHARGING SYSTEM 6D3-5



Inspection and Repair
Repair or replace necessary parts if extreme wear or damage
is found during inspection.
Armature
Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).



Check for continuity between commutator and shaft.
Also, check for continuity between commutator and armature
core, armature core and shaft. Replace commutator if there is
continuity (i.e., internally grounded).




Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Brush Holder
Check for continuity between brush holder (+) (4) and base (-).
Replace, if there is continuity (i.e., insulation is broken).




Magnetic Switch
Check for continuity of shunt coil between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).




Continuity of Series Coil
Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).

6D3-6 STARTING AND CHARGING SYSTEM



Continuity of Contacts
With the plunger faced downward, push down the magnetic
switch. In this state, check for continuity between terminals B
and M. Replace, if there is no continuity (i.e., contacts are
faulty).




Pinion
Check if the pinion rotates smoothly in drive direction by hand,
or if it is locked when it is rotated in reverse. If not, replace the
pinion.




Characteristic Test
For easily confirming the characteristics, conduct the noload
test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows and
the starter runs under no load. At this time, measure current,
voltage and speed to check if they satisfy the standard.
Legend
1 Volt Meter
2 Revolution Indicator
3 Battery
4 Ammeter
5 Switch