2004 ISUZU TF SERIES low oil pressure

4B-38 REAR AXLE

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, rust or other problems
are discovered during inspection.

Visual Check
Inspect the following parts for wear, damage or other
abnormal conditions.


Friction disc


Friction plate


Spring plate
1 Sliding surface
2 Protrusion




425RS056

Pressure ring
Check the parts for damage or other abnormal
conditions.
3 Sliding surface for friction disc
If dents or damages are discovered, grind them
with oil stone, and repair them with compound on
surface plate.
4 Sliding surface of pressure ring inner surface and
pinion gear.
5 Slinding surface of pressure ring bore and side
gear.
6 sliding surface of pressure ring and side gear.
7 Sliding surface of pressure ring and pinion shaft.
8 Mating surface to differential cage A.
9 Burrs or dents on sliding surface of pressure ring
and rear differential cage should be repaired,
using oil stone.

425RY00022



Thrust Washer
10 Groove on side gear circumference small burrs of
dens should be repaired, using oil stone.
11 Sliding surface between side gear and thrust
washer.
425RY00024



Differential cage A and B
12 Contact surface to spring plate
13 Differential cage A and B contact surfaces to
thrust washers Small burrs or dents should be
repair, using oil stone.

REAR AXLE 4B-41



425RS066

2. Measuring dimension between thrust washers at
both ends.
Assemble side gear, pinion, pinion shaft pressure
ring and thrust washer.

Eliminate clearance by pushing pressure ring
against the pinion shaft in axial direction.


Eliminate backlash by connecting side gear to
the pinion.


Measure dimension between thrust washers at
both ends. (H)




425RS067

3. After each dimension is measured, perform
adjustment with the following procedure.
Adjust so that ((F-B) + G-H) = 0.05 to 0.2 mm
(0.002 to 0.008 in). Also, select a proper thrust
washer so that the dimension difference from
back face of the pressure ring to thrust washer
(left/right side) does not exceed 0.05 mm (0.002
in).
Thickness : 1.5, 1.6, 1.7 mm (0.059, 0.063,
0.067 in)

Note :
When reassembling, sufficiently apply gear oil on
every part, especially on sliding surface.
1. Install thrust washer in differential cage A and
B.
2. Assemble spring plate, friction plate and
friction disc as following illustration.





Install spring plate with dished side turned
to the differential cage side.
425R300009
Legend

1. Friction Plate
2. Spring Plate
3. Friction Disc

4. Install pressure ring and side gear.


Fit two side gears in two pressure rings, one
from under a ring and the other from above a
ring.


Fit two pairs of a friction disc and a friction
plate under it on and under these two pressure
rings.
5. Set pinion and pinion shaft on differential cage A
assembly.
6. Assemble differential cage A and B.
7. Align the setting marks on differential cage A and
B and tighten screws in diagonal order evenly.

BRAKES 5C-25


Filling Master Cylinder Reservoir
CAUTION :
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used for petroleum based fluids or a container
which is wet with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the hydraulic
brake system. Water mixed with brake fluid lowers the
fluid boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine
is cold.
Never allow the brake fluid to come in contact with the
painted surfaces.
The master cylinder reservoir must be kept properly filled
to ensure adequate reserve and to prevent air and
moisture from entering the hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and the engine, the reservoir must not be
overfilled. Thoroughly clean reservoir cap before removal
to avoid getting dirt into reservoir. Add fluid as required to
bring level to the “MAX” mark on the reservoir tank. Use
“DOT 3” Hydraulic Brake Fluid.

Leakage of Brake Fluid
With engine idling, set shift lever in the neutral position and
continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually, leakage
from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.




BLEEDING OF THE BRAKE HYDRAULIC
CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoir
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
Bleeding operation calls for co-operative action of 2 persons.

Set the parking brake firmly while bleeding.

Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.

Make sure exhaust is suitably ventilated.

Bleed the hydraulic system with the fluid reservoir filled to
the specified level.

Bleed the system starting with the rear wheel cylinde
r
farthest from the master cylinder.

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.



RTW36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0


RTW36ASH000101


4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
130RY00003
6A-6

ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.




Engine coolant Filling up procedure
1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.

Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)
50 %

ENGINE MECHANICAL 6A – 39

18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.

TPS connector

Oil pressure switch connector

Thermo switch connector

Injection pump connector

Engine earth

Thermometer unit connector

TDC sensor
2) Remove the clips fixing engine harness.
P1010009

ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.

Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)

9.5 (2.5/2.1)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.