2004 ISUZU TF SERIES oil capacity

REAR AXLE 4B-3

MAIN DATA AND SPECIFICATIONS
REAR AXLE
Ring gear size mm(in)220 (8.66)
Rear axle type Banjo, semi-floating
Rear axle capacity N (kg/lb)16475 (1680/3700)
Rear axle case 16965 (1730/3815) (EC)
Axle tube section
Outside diameter mm(in)80 (3.15)
Thickness mm(in)4.5 (0.118)
Final drive type Single speed
Final gear type Hypoid
Drive pinion bearing preload kg-cm(lb.in)
Starting torque (At drive pinion flange nut) 7-13 (6.1-11.3)
Preload adjusting method Collapsible
Final gear backlash mm(in)0.15-0.20 (0.006-0.008)
Differential carrier assembly
Weight (Dry) kg/lb29.0/63.9
Lubrication
Specified gear oil (APL grade) GL5 (STD), GL5LSD (LSD)
Oil capacity lit (US/UK gal)2.4 (0.63/0.53)

4B-8 REAR AXLE

SERVICING
Rear Axle Oil Replacement
Oil Capacity liters (US/UK gal.)
2.4 (0.63/0.53)

Specified gear oil GL5 (API grade)(STD)
GL5LSD (LSD)

Filler Plug and Drain Plug Torque N
m (kgf
m/lb
ft)
78 (8.0/58)

Axle Shaft Roller Bearing Endplay
Inspection
1.
Raise and suitably support vehicle.
2.
Remove the wheel and brake drum.
3.
Inspect the axle shaft roller bearing endplay using
dial gauge.
Endplay mm (in
)
Standard 0

0.2 (0

0.008)
If the endplay exceeds 0.2mm (0.008 in), replace the
axle shaft roller bearings.
Refer to Rear Axle Reassembly.

RTW34BSH000101

FRONT WHEEL DRIVE 4C1-3
MAIN DATA AND SPECIFICATIONS
FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in) 194 (7.6)
Axle tube
Type It consists of the duce, a cast iron housing and the Axle tube.
Gear type Hypoid
Gear ratio (to 1) 4.100, 4.300, 4.555, 4.777, 5125
Differential type Two pinion
Specified gear oil (APL grade) GL-5
Oil capacity liter 1.4
(US/UK gal.) (0.4/0.33)
Axle shaft type Constant velocity joint (Birfield joint type and double offset joint).


FRONT PROPELLER SHAFT mm(in)
4

4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE 6VE1
Transmission Type 5M/T (MUA) 5M/T
(MUA) 4A/T 5M/T
(MUA) 5M/T
(MUA) 4A/T
Front Axle 194 mm










Outside Diameter mm 40 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 586 607
(in) (23.90) (23.90) (26.61) (23.07) (23.07) (23.90)
Fix Bolt Size T/F M10 M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10 M10

SHIFT ON THE FLY SYSTEM 4C2-11






5. Actuator


Clean the actuator contact surface with the housing.


Apply liquid gasket to the contact surface on the
actuator side.


Align shift arm with the groove of sleeve and install the
actuator.

4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque N m (kg m/lb ft)
9 (0.95/78)














3. Front Axle Drive Shaft (LH side)
2. Bolt


Install front axle drive shaft and mounting bracket.


Tighten fitting bolts to specified tightening torque.
Bolt Torque N m (kg m/lb ft)
116 (11.8/85)
1. Filler Plug


Pour specified amount of differential gear oil.
Front Differential Oil Capacity liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity liter (US/UK gal)
0.12 (0.03/0.03)


Install filler plug through packing and tighten to
specified torque.
Filler Plug Torque Nm (kgm/lbft)
78 (8.0/58)

6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn
ON ? Go to section
6E “On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —

TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? — Repair or
replace the
brush holder
assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? — Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity
generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—
Go to Step 2 Go to
visual/physical
check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? — Repair or
replace the
brush and/or
the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? — Repair or
replace the
rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? — Repair or
replace the
stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —
Repair the
loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? — Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

ENGINE MECHANICAL 6A – 5
Engine model
Item 4JA1T (L) 4JA1TC
Oil pump type
Oil filter type
Oil capacity lit (US/UK gal)
Oil cooler type Gear
Cartridge paper element
6.2 (1.64/1.36)
Water cooled
Cooling system
Water pump type Centrifugal
Thermostat type Wax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage
No. of units 80D26L
1

95D31L
1 (OPT)
Generator capacity V-A 12 – 60
12 – 80
Starter motor output V-Kw 12 – 2.3
Turbocharger model
Turbine type
Compressor type *IHI RHF 4H
Mixed flow type
Backward & rake

*IHI : Ishikawajima-Harima Heavy Industries., Ltd.

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