2004 ISUZU TF SERIES fuel

6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element.
2 Was the intake air leakage found from intake
system? — Repair or
replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —
Go to Step 4 Clean or
replace the fuel
filter element.
4 Check the fuel injection pipes.
Does the injection pipes have obstruction or any
damage? — Repair or
replace the fuel
injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Readjust the
injection nozzle
pressure or
replace the
nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 8 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? — Repair or
replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? — Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger
assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger
assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 7
4. Excessive Fuel Consumption
Step Action Value(s) Yes No
1 Was the air cleaner element clogged? — Clean or
replace the air
cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of
the turbocharger? — Repair or
replace the air
intake side of
the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger
4 Was there the fuel leakage? — Repair or
replace the fuel
leakage part. Go to Step 5
5 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 6 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Replace the
injection nozzle
7 Are any DTC stored? — Go to indicated
DTC Solved

ENGINE MECHANICAL 6A – 1


SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit ........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43

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)

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

6A – 18 ENGINE MECHANICAL
Fuel Injection System (4JA1L)

N·m (kg·m/lb·ft)




RTW46AXF001101

ENGINE MECHANICAL 6A – 19
Fuel Injection System (4JA1TC)
N·m (kg·m/lb·ft)





RTW46AXF001201

6A – 20 ENGINE MECHANICAL
Fuel Injection System (4JH1TC)
N·m (kg·m/lb·ft)





RTW46AXF001301