2004 ISUZU TF SERIES sensor

INDUCTION 6J-3


Installation
1. Install air cleaner element.
2.
Attach the air cleaner duct cover to the body completely,
then clamp it with the clip.
3. Install mass air flow sensor.
4. Install mass air temperature sensor.
5. Install positive crankcase ventilation hose connector.

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:

1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I
(DIESEL) I I I I I I I R I I I I I I I R I I I I * P Engine oil (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil (C24SE) Replace every 12,000km * D Engine oil (4JH1-TC) - R - R - R - R - R - R - R - R - R - R * D Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * D Engine oil (4JA1-T) RR R R RR RRRRRRRR R R R RRR * P Engine oil filter (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil filter (C24SE) Replace every 12,000km * D Engine oil filter (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R * D Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination
(GASOLINE) - I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage I I - I - I - I - I - I - I - I - I - I Fuel tank - - - | - - - | - - - | - - - | - - - | P O2 Sensor Replace every 160,000km P Valve clearances (6VE1) Check and adjust if noisy D Valve clearances A - - A - - - A - - - A - - - A - - - A P Spark plugs (C24SE) (for leaded
fuel use) - R - R - R - R - R - R - R - R - R - R
P Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
P Spark plugs (6VE1) Replace every 160,000km Spark plug wire | | - | - | - | - | - | - | - | - | - | Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R Fuel filter (DIESEL) - - R - - R - - R - - R - - R - - R - - Engi ne / Accessory dri ve belt
(GASOLINE) - - - - - - - - - R - - - - - - - - - R
Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (6VE1) - - - - - - - - - R - - - - - - - - - R (C24SE) - | - | - | - | - R - | - | - | - | - R Engine coolant level concentration
(DESEL) I I I I I I I I I R I I I I I I I I I R
Cooli ng sy stem for water l eakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
P Timing belt (C24SE) - - - - - - - - - - - - - - - I - - - - (Replace every 120,000km) P Timing belt (6VE1) Replace every 160,000km CLUTCH Cl utch fl ui d I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I

1-50 HEATER AND AIR CONDITIONING
DISASSEMBLY


This illustration is based on the 4J engine model
871R300002

Disassembly Steps

1. Drive plate bolt
2. Plain washer

3. Drive plate
4. Snap ring

5. Pulley assembly

6. Snap ring
7. Thermo sensor and lead wire connector
8. Field coil
9. Compressor

Important Operations - Dissassembly


1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from rotating, then remove the bolt.
Drive Plate Holder: 5-8840-4056-0 (J-37872)

1-52 HEATER AND AIR CONDITIONING
REASSEMBLY


This illustration is based on the 4J engine model
871R30003

Reassembly Steps
1. Compressor

2. Field coil
3. Thermo sensor and lead wire connector
4. Snap ring

5. Pulley assembly
6. Snap ring
7. Drive plate
8. Plain washer

9. Drive prate bolt

1-62 HEATER AND AIR CONDITIONING

This illustration is based on RHD model
Important Operation -Reassembly
6. Electronic Thermostat
1) Install the electronic thermostat to the evaporator core
specified position with the clip.
2) Sensor part must not interfere with the evaporator core.

HEATER AND AIR CONDITIONING 1-85

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Discharge
(High)
pressure
gauge
abnormally
high Reduced or no air flow through
the condenser


Condenser clogged or dirty


Radiator (condenser) fan
does not operate properly

Clean


Check cooling fan
operation
No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)




Excessive refrigerant in
system





Check sight glass.
(See “Reading Sight
Glass”)


Discharge and
recover refrigerant.
Recharge to specified
amount
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28 PSI) quickly

Air in system


Evacuate and charge
refrigerant system
Discharge
(High)
pressure
gauge
abnormally
low Insufficient cooling and excessive
bubbles in the sight glass







Insufficient refrigerant in
system







Check sight glass.
(See “Reading Sight
Glass”)

Check for leaks


Discharge and
recover refrigerant.
Recharge to specified
amount
Low pressure gauge indicates
vacuum

Clogged or defective
expansion valve

Replace the
expansion valve
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum
Restriction caused by debris
or moisture in receiver/drier


Check system for
restriction and
replace receiver/drier

After turning off air conditioning,
high and low pressure gauge
balanced quickly


Compressor seal defective


Poor compression due to
defective compressor
gasket

Replace or repair
compressor
Suction
(Low)
pressure
gauge
abnormally
high Low pressure gauge is lowered
after condenser is cooled by
water


Excessive refrigerant in
system



Discharge and
recover refrigerant
Recharge to specified
amount
Low pressure hose temperature
around the compressor refrigerant
line connector is lower than
around evaporator



Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve


Expansion valve opens too
long

Replace the
expansion valve




After turning off air conditioning,
high and low pressure gauge is
balanced quickly

Compressor gasket is
defective


Replace


Air conditioning turns off before
passenger compartment is
sufficiently
cool
Electronic thermostat
defective

Check the electronic
thermostat and
replace as necessary


* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.

1-86 HEATER AND AIR CONDITIONING

RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Suction
(Low)
pres-sure
abnormally
low
Condenser is not hot and
excessive bubble in sight glass







Insufficient refrigerant








Check sight
glass.(See “Reading
Sight Glass”)


Check for leaks


Discharge and
recover refrigerant.
Recharge to specified
amount
Frost on the expansion valve inlet
line

Expansion valve clogged


Replace the
expansion valve

A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier

Receiver/drier clogged




Replace the receiver/
drier


Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum



The temperature sensor of
the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant

Replace the
expansion valve



Discharge temperature is low and
air flow from vents is restricted

Frozen evaporator core fins


Check electronic
thermostat and
replace as necessary
Low-pressure gauge reading is
low, or a vacuum reading may be
shown

Clogged or blocked
refrigerant line


Replace refrigerant
line
Suction
(Low) and
Discharge
(High)
pressure
abnor-
mally
high
No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)





Excessive refrigerant in
system






Check sight
glass.(See “Reading
Sight Glass”)


Discharge and
recover refrigerant.
Recharge to specified
amount
Reduce air flow through con-
denser


Condenser clogged

Radiator (condenser) fan
does not rotate properly

Clean

Check cooling fan
operation
Suction (Low) pressure hose is
not cold

Air in system

Evacuate and charge
refrigerant
Suction
(Low) and
Discharge
(High)
pres-sure
abnor-
mally
low
Insufficient cooling and excessive
bubbles in the sight glass

Insufficient refrigerant in
system


Check sight glass.
(See “Reading Sight
Glass”)


Check for leaks

Discharge and
recover refrigerant.
Recharge to specified
amount

7B-8 MSG MODEL


Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.





Rear Propeller Shaft (Single Shaft Type)
1. Remove the propeller shaft flange yoke at the drive pinion
side

1.
2. Remove the propeller shaft from the transmission main
shaft spline

2.





Rear Propeller Shaft (Dual Shaft Type)
1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation
procedure.
2. Remove the 2nd propeller shaft flange yoke bolts at the
drive pinion side

1.
3. Remove the center bearing retainer bolts

2 .
4. Remove the 1st propeller shaft with the center bearing and
the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle
until the spline yoke is free of the transmission main shaft.



Harness Connector
Disconnect the back up light switch connector and the
speedometer sensor connector.




Slave Cylinder
Remove the slave cylinder from the transmission case.