ESP ISUZU TF SERIES 2004 Workshop Manual

ENGINE DRIVEABILITY AND EMISSIONS 6E–245
HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Check the fuel quality.
Is the customer using improper fuel or degraded fuel?—Replace fuel Go to Step 5
5 1. Using a Tech 2, display the MAP sensor value in
comparison with atmosphere temperature.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 6
6 Observe the throttle position display on the Tech 2
while slowly increasing throttle pedal.
Does the throttle position increase steady with
increasing smoothly?
—Go to Step 7Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis
7 Check the knock sensor wire, shield wire, or
installation condition.
Was a problem found?—Verify repair Go to Step 8
8 Run Engine.
Check the fuel control Heated Ox ygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn’t check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may
have a white powdery coating. Silicon contamination
sends a rich ex haust signal which causes the ECM to
command and excessively lean air/fuel mix ture.
Was a problem found?—Verify repair Go to Step 9
9 Check the fuel pressure. Refer to 6E-108
Fuel
System Diagnosis
.
Was a problem found?—Verify repair Go to Step 10

ENGINE DRIVEABILITY AND EMISSIONS 6E–251
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM
DEFINITIONS: Engine delivers less than ex pected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?—Verify repair Go to Step 3
3 Was a visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 1. Remove and check the air filter element for dirt or
restrictions.
2. Replace the air filter element if necessary.
Was a repair required?—Verify repair Go to Step 5
5 Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 6
6 1. Using a Tech 2, display the MAP sensor value in
comparison with atmosphere temperature.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 7
7 1. Using a Tech 2, display the ECT sensor and IAT
sensor value and warm up condition compared
with the typical data.
2. Check the specified value or wire.
Was the problem found?—Verify repair Go to Step 8
8 Observe the throttle position display on the Tech 2
while slowly increasing throttle pedal.
Does the throttle position increase steady with
increasing smoothly?
—Go to Step 9Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis
9 Check the knock sensor wire, shield wire, or
installation condition.
Was a problem found?—Verify repair Go to Step 10
10 Run Engine.
Check the fuel control Heated Ox ygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn’t check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may
have a white powdery coating. Silicon contamination
sends a rich ex haust signal which causes the ECM to
command and excessively lean air/fuel mix ture.
Was a problem found?—Verify repair Go to Step 11
11 Check the fuel pressure. Refer to
Fuel System
Diagnosis
6E-108.
Was a problem found?—Verify repair Go to Step 12

ENGINE DRIVEABILITY AND EMISSIONS 6E–259
16 1. Remove ex cessive carbon buildup with a top
engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the ex haust emission test.
Does the vehicle pass the test? —System OK Go to Step 18
17 Perform the ex haust emission test.
Does the vehicle pass the test?—System OK Go to Step 18
18 Run Engine.
Check the fuel control Heated Ox ygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn’t check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may
have a white powdery coating. Silicon contamination
sends a rich ex haust signal which causes the ECM to
command and excessively lean air/fuel mix ture.
Was a problem found?—Verify repair Go to Step 19
19 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Go to Step 20Go to Step 21
20 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P1167 “Fuel
Supply System Rich During Deceleration Fuel Cut
Off”. Make any necessary repairs.
2. Perform the ex haust emission test.
Does the vehicle pass the test? —System OK Go to Step 22
21 1. Check items that can cause the engine to run
lean. Refer to Diagnostic Aids in DTC P1171 “Fuel
Supply System Lean During Power Enrichment”.
Make any necessary repairs.
2. Perform the ex haust emission test.
Does the vehicle pass the test?—System OK Go to Step 22
22 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
Was a problem found?—Verify repair Go to Step 23
23 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 24 Step Action Value(s) Yes No

11A-6 IMMOBILIZER SYSTEM

What happens without proper transponder
operation?
One of the function of transponder is to deactivate or
activate starter function. lf the proper transponder is not
used, starter cannot be operated. Because starter rela
y
stays off, cranking engine is not possible.
After the starter relay is activated, transponder signal
triggers to let lCU calculate by transponder address
signal and immobilizer algorithm.
When the result matches with necessary condition, it
makes injector power source be activated.
If transponder does not send correct signal, lCU and
ECM do not activate injector system on.
Therefore the vehicle cannot be operated.
No proper transponder is available, what
should be done for the system?
When any proper transponder is not available, a new
transponder should be programmed. Up to 5
transponders can be provided with a scan tool (Tech-2)
and by proper procedure.
In addition to the absence of proper transponder, it ma
y
happen particular secret code to the particular vehicle is
missing. ln this case, the secret code must be provided
by your organization.
Otherwise transponder cannot be programmed in an
y
way.
lf the essential for a scan tool (Tech-2) for programming
and proper software for Tech-2 are not available, there
is no permanent way to fix system. Temporary replace
with new ECM, new ICU and new transponder without
any secret code can make the system be deactivated,
but it does not last long. Such a replacement does not
solve any condition. Even after replacement, the system
is activated automatically in short time and then no
operation of the vehicle can be made in any way.
Tech-2 should be provided in your organization.
Caution to the operation
lf an attempt is made to start the engine while the
immobilizer system is activated, the check engine lamp
flashes and the engine will not start.
Summary of operation
Switch on: Set the ignition and starter switch to OFF.
(Activate)
Switch off: Set the ignition and starter switch to ON b
y
using the transponder key. (Deactivate)

What your organization should provide for
your customer





Car Pass

For a new owner, your dealership must hand Car Pass
card, which has identification numbers of new owner's
vehicle immobilizer system. This information is ver
y
important in case of repair or lost of transponder.
The followings are necessary items provided by you
r
responsibility.
1)
Car pass with identification for a new owner
2)
Blank car pass card when it is for reissue
3)
Instruction to dealers how to use car pass card






Security code management

Your organization must keep security codes for all
vehicles as confidential data. Once the security codes
are lost, anybody who have the security code can
access immobilizer system. Your organization has
responsibility of any missing vehicles caused by stolen
security code.






Essential tool (Scan tool : Tech-2)

Your dealership must have Tech-2, and Tech-2 updated
software for immobilizer system.

IMMOBILIZER SYSTEM 11A-17

Important Instructions
Only data corresponding to the delivery status of the
vehicle can be issued. Car pass data requests will onl
y
be processed if the first column is filled out completely.
Signed and sent to your organization along with proof of
ownership.
Information via telephone is only possible in exceptional
circumstances via your service organization.
As for the delivery of new vehicles, the customer must
be informed about all features of the car pass that are
relevant to vehicle security, for example, that the ca
r
pass should be kept in a safe place(not in the vehicle)
and should be presented when an authorized you
r
organization name workshop is visited, The exact
phrasing can be found in the relevant Owner's Manual.

11A-32 IMMOBILIZER SYSTEM

Diagnostic Trouble Code (DTC) list with ECM





Immobilizer Control Unit (ICU)
DTC
Description Note
B0001
REPLACE ELECTRONIC CONTROL UNIT
(ECU) (IMMOBILIZER FAULT) This error code appears if a RAM /ROM Error was
detected or the EEPROM is defect.
B0002 IMMOBILIZER NOT PROGRAMMED Immobilizer control unit is not programmed.
B0003 TRANSPONDER KEY PROBLEM

Reading of Transponder information failed with ignition
on transponder has a fault.


Hardware fault in reading circuit.
B0004
IMMOBILIZER COIL CIRCUIT (ANTENNA
COIL FAULT) Immobilizer coil has a fault.
B0005 COMMUNICATION LINE W VOLTAGE LOW Short circuit to ground or open circuit.
B0006 COMMUNICATION LINE W VOLTAGE HIGH Short circuit to 12V.
B0007 NO ENGINE REQUEST RECEIVED No ECM Challenge.
B0008 WRONG TRANSPONDER KEY Incorrect security code response received.
B0009 NO TRANSPONDER KEY PROGRAMMED Transponder security code table empty
B0010 UNKNOWN TRANSPONDER KEY Transponder security code not valid.






Engine Control Module (ECM: Gasoline Engine {6VE1, C24SE})

DTC Description
Note
P1626 No Response From Immobilizer Refer to Engine Control system section
P1631 Received Response Was Not Correct Refer to Engine Control system section
P1648 Received Incorrect Security Code Refer to Engine Control system section
P1649 Security Code & Security Key Not
Programmed Refer to Engine Control system section






Engine Control Module (ECM: Diesel Engine {4JH1-TC, 4JA1-TC})

DTC Description Note
P1610 Seeds and Key File Destroyed Refer to Engine Control system section
P1611 Wrong Security Code Entered Refer to Engine Control system section
P1612/
P1613 Immobilizer No or Wrong Signal Refer to Engine Control system section
P1649 Wrong Transponder Key Refer to Engine Control system section

IMMOBILIZER SYSTEM 11A-33

Diagnostic Trouble Code (DTC) list with Engine Immobilizer Unit (4JA1-T Diesel Engine)





Engine Immobilizer Unit
Code
(DTC) Description Detecting Condition
B0011 TRANSPONDER KEY PROBLEM Transponder code unsuccessfully read 5 consecutive
time. (No completely read in 500ms transponder code)
B0012 WRONG TRANSPONDER KEY Immobilizer program no executed.
B0013 IMMOBILIZER NOT PROGRAMMED Processing program no executed.
B0014 NO TRANSPONDER KEY PROGRAMMED Processing to save the transponder key in the control unit
not Executed.
B0015 FREQUENCY SIGNAL Lo Lo level (less than 2.5) input during the Hi level was being
output to the communication line.
B0016 FREQUENCY SIGNAL Hi (Diesel) Hi level (more than 2.5v) input during the Lo level was
being output to the communication line.
B0023 ANTENNA COIL OPEN Antenna coil not connected.
B0024 WRONG TRANSPONDER RESPONSE Transponder response signal with challenge is wrong.
B0055 EEPROM ERROR Write and read cannot be correctly made to and from the
EEPROM in the control unit.

FRONT SUSPENSION 3C-35

3. Apply the setting marks(2) to the height control
arm and torsion bar, then remove height control
arm.
NOTE: “Besco chassis grease” shall be applied on
contact area of height control arm with frame.
(RH & LH Both side)





410RS005
4. Apply the setting marks (3) to the torsion bar and
lower control arm, then remove torsion bar.


RTW340SH000301
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts:

Torsion bar


Height control arm


Adjust bolt
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks (3).






410RS007



RTW340SH000301

7D1-42 TRANSFER CONTROL SYSTEM
Cannot shift from 2WD to 4H or 4L.

When shifting from 2H to other position, the indicator (4WD, 4Lo, Check4WD, neutral)
does not respond.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Failed operation switch. Only 2H
is stuck at ON condition and 4H-
4L position is internally
disconnected. Or,
Failed controller Indicator lamp burnt out.
Disconnected harness wire .
After repairing, trace this chart
from the beginning.


Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10
seconds.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 3. Indicator lamp burnt out.
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 After 2 seconds, check that the
Check4WD lamp is ON or OFF.
Is the Check4WD lamp OFF? Go to step 4. Failed actuator position detection
switch (LS1, LS2, LS3, LS4,
GND).
Short or disconnection of harness
of this detection switch.
After repairing, trace this chart
from the beginning.
4 Press the 4H button.
Is sound of relay heard from the
transfer control? Go to step 5. Failed controller.
Replace the controller and trace
this chart from the beginning.
5 Is the sound of running motor
heard? Failed control system of the
transfer mechanism. Check and
repair and trace this chart from
the beginning. Failed actuator motor.
Disconnected controller motor
drive output circuit, GND short
circuit. +B fuse blown out.
Disconnection of that harness.
After repairing, trace this chart
from the beginning.
*Before determining a trouble (Non-trouble mode)

TRANSFER CONTROL SYSTEM 7D1-45
Transfer cannot shift to a position other than 4H.
When shifting from 4H to other position, indicator (4WD, 4Lo, Check4WD, neutral) does
not respond (Only 4WD keeps lighting).
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Failed 4WD indicator and
harness.
After repairing, trace this chart
from the beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON?
Then, only 4H lights up. Go to step 3. Indicator lamps other than the
4WD indicator are burnt out.
(Check for GND short circuit
between the 4WD indicator and
transfer controller.)
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 Press the 2H button.
Is the sound of relay heard from
under the seat, and the sound of
running motor heard? Failed controller.
After replacing the controller,
trace this chart from the
beginning. *Failed operation switch. Or
disconnected or shorted of the
harness for the operation switch.
* The operation switch is an analog type switch which reads the internal composite resistance value at the time of
operation. If an abnormal value is detected, it is judged to be an instruction to 4H.