2004 ISUZU TF SERIES section table

ENGINE DRIVEABILITY AND EMISSIONS 6E–263
10 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Camshaft drive belt slipped or stripped
Was a problem found?—Verify repair Go to Step 11
11 Check leakage at exhaust system.
Check the intake and ex haust manifold for casting
flash. Refer to Engine Mechanical.
Was a problem found?—Verify repair Go to Step 12
12 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 13
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step Action Value(s) Yes No

FRAME AND BUMPER 2A-1

SECTION 2A
FRAME AND BUMPER
TABLE OF CONTENTS
PAGE
Front Bumper ..................................................................................................................... 2A- 2
Rear Step Bumper ............................................................................................................. 2A- 4
Rear Bumper And Rear Guard ASM ................................................................................. 2A- 7
Frame Dimensions............................................................................................................. 2A- 9

SHEET METAL 2B-1

SECTION 2B
SHEET METAL

This section includes items of front end sheet metal that are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance.
When servicing these panes, areas on which this material has been disturbed, should be properly recoated with
service-type anticorrosion material.
TABLE OF CONTENTS
PAGE
Engine Hood Assembly ..................................................................................................... 2B- 2
Engine Hood Lock ............................................................................................................. 2B- 5
Front Fender Panel ............................................................................................................ 2B- 7
Radiator Grille .................................................................................................................... 2B- 10
Rear Body ........................................................................................................................... 2B- 11
Body Mounting ................................................................................................................... 2B- 13
Body Dimension.................................................................................................................2B- 19

GENERAL INFORMATION 0A-1

SECTION 0A
GENERAL INFORMATION
TABLE OF CONTENTS
PAGE
General Repair Instructions ............................................................................................ 0A- 2
Notes on The Format of this Manual .............................................................................. 0A- 3
Identification .................................................................................................................... 0A- 6
Lifting Instructions .......................................................................................................... 0A- 7
Conversion Table............................................................................................................. 0A- 9

MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
TABLE OF CONTENTS
PAGE
Maintenance Schedule (For GENERAL EXPORT) ......................................................... 0B- 2
Maintenance Schedule (For EUROPE) ........................................................................... 0B- 5
Severe Conditions Maintenance Schedule (For GENERAL EXPORT) ........................ 0B-11
Severe Conditions Maintenance Schedule (For EUROPE) .......................................... 0B-12
Recommended Fluids and Lubricants (For GENERAL EXPORT)................................ 0B-13
Recommended Fluids and Lubricants (For EUROPE).................................................. 0B-15
Oil Viscosity Chart ........................................................................................................... 0B-16

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service .......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor ...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier ................................................................................................................... 1- 39
Removal and Installation ............................................................................................ 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE) ...................................................................... 1- 40
Removal and Installation (6VE1) ................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Removal and Installation ............................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Removal and Installation ............................................................................................ 1- 57
Disassembly and Reassembly ................................................................................... 1- 59
Evaporator (With A/C)...................................................................................................... 1- 60
Removal and Installation ............................................................................................ 1- 60
Disassembly and Reassembly ................................................................................... 1- 61

HEATER AND AIR CONDITIONING 1-83

AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE CORRECTION
No cooling or
insufficient
cooling
1. Magnetic clutch does not run


Refer to “MAGNETIC CLUTCH”
troubleshooting in this section
2. Compressor is not rotating properly

Drive belt loosened or broken

Adjust the drive belt to the specified
tension or replace the drive belt


Magnetic clutch face is not clean and
slips
Clean the magnetic clutch face or replace




Incorrect clearance between magnetic
drive plate and pulley

Adjust the clearance (Refer to
“COMPRESSOR OVERHAUL”



Compressor oil leaks from shaft seal or
shell

Replace the compressor




Compressor seized

Replace the compressor

3. Insufficient or excessive charge of
refrigerant

Discharge and recover refrigerant.
Recharge to specified amount.
4. Leaks in the refrigerant system




Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient radiation


Clean the condenser or replace as
necessary


Check radiator or condenser fan function

6. Temperature control link unit of the heater
unit defective

Repair the link unit

7. Unsteady operation due to foreign
substance in expansion valve

Replace the expansion valve

8. Poor operation of electronic thermostat


Check electronic thermostat and replace
as necessary
Insufficient
velocity
of cooling air

1. Evaporator clogged or frosted


Check evaporator core and replace or
clean the core
2. Air leaking from cooling unit or air duct

Check evaporator and duct connection,
then repair as necessary

3. Blower motor does not rotate prop-erly


Refer to “FAN CONTROL KNOB (FAN
SWITCH)” troubleshooting in this section

* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,
RECYCLING, EVACUATING AND CHARGING” in this section.

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.