heater ISUZU TF SERIES 2004 User Guide

6E–44 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
RELAY A ND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
No .RELAY
(4JA1-TC/4JH1-TC)
X -1 RELAY; TAIL LIGHT
X -2 RELAY; FRT F OG LI GHT
X -3 RELAY; HORN
X -4 RELAY; DIMMER
X -5 RELAY; GLOW
X -6 RELAY; COND, FAN
X -7 RELAY; RR FOG
X -8 RELAY; STARTER
X -9 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-RH (RHD)
X-10 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-LH (RHD)
X -11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
SLOW BLOW FUSE
NO.FUSE
(4JA1-TC/4JH1-TC)
EB-1 10A ECM
EB-2 10A RR FOG
EB-3 15A FRT FOG
EB-4 —
EB-5 10A ILLUMI & TAIL-RH
EB-6 10A TAIL-LH
EB-7 10A H/LIGHT RH-LOW
EB-8 10A H/LIGHT LH-LOW
EB-9 10A TRA ILER
EB-10 10A AC G (S)
EB-11 10A H/LIGHT RH-HIGH
EB-12 10A H/LIGHT LH-HIGH
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD
NO.SLOW BLOW FUSE
4JA1-TC/4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2

6E–114 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONSECM Diagnostic Trouble CodesFlash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)
65 P0100 7 ON Mass Air Flow (MAF) Sensor
Voltage Supply Circuit High
InputMAF sensor power supply
voltage is more than 5.2V.ECM uses mass air flow
1600mg/strk & EGR 10%
conditions as substitute.MAF sensor power supply
voltage is below 5.2V.1. Sensor power supply
circuit short to battery
voltage circuit.
2. MAF sensor malfunction.
3. ECM malfunction.83 —
9 ON Mass Air Flow (MAF) Sensor
Voltage Supply Circuit Low
InputMAF sensor power supply
voltage is below 4.6V.MAF sensor power supply
voltage is more than 4.6V.1. Sensor power supply
circuit short to ground
c i r c u i t .
2. MAF sensor malfunction.
3. ECM malfunction.83 —
B ON Mass Air Flow (MAF) Sensor
Output Circuit Low Input1. Engine speed is between
600rpm and 5000rpm.
2. MAF sensor output is
below -33.7mg/strk.MAF sensor output is more
than -27.4mg/strk.1. Sensor power supply
circuit open circuit.
2. Sensor signal circuit
open or short to ground
c i r c u i t .
3. Sensor heater harness
o p e n c i r c u i t .
4. Poor connector
c o n n e c t i o n .
5. MAF sensor malfunction.
6. ECM malfunction.8 3 /
88P0110(1)
C ON Mass Air Flow (MAF) Sensor
Output Circuit High Input1. Engine speed is between
600rpm and 5000rpm.
2. MAF sensor output is
more than 1378mg/strk
(4JA1-TC) or 1784mg/
strk (4JH1-TC).MAF sensor output is below
1378mg/strk (4JA1-TC) or
1784mg/strk (4JH1-TC).1. Sensor signal circuit
short to voltage circuit.
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. MAF sensor malfunction.
4. ECM malfunction.8 8 /
92P0110(1)
34 P0105 1 ON Vacuum Pressure Sensor
Circuit High InputVacuum sensor output
voltage is more than 4.4V.1. Fuel injection quantity is
r e d u c e d .
2. ECM use 615hpa
conditions for
turbocharger waste gate
control.Vacuum sensor output
voltage is below 4.4V.1. Sensor signal circuit
short to voltage circuit.
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. Vacuum sensor
m a l f u n c t i o n .
4. ECM malfunction.8 5 /
93P0115(1) —
2 ON Vacuum Pressure Sensor
Circuit Low InputVacuum sensor output
voltage is below 0.5V.Vacuum sensor output
voltage is more than 0.5V.1. Sensor power supply
circuit open circuit.
2. Sensor signal circuit
open or short to ground
c i r c u i t .
3. Poor connector
c o n n e c t i o n .
4. Vacuum sensor
m a l f u n c t i o n .
5. ECM malfunction.8 2 /
85——

ENGINE MECHANICAL (6VE1 3.5L) 6A-23
Cylinder Head Cover RH
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
3. Disconnect ventilation hose from cylinder head
cover.
4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.
5. Remove heater pipe fixing bolts from the bracket.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts then the cylinder head
cover.





010RW002
Installation
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.

Apply sealant (TB-1207B or equivalent) of bead
diameter 2‐3 mm at eight place of arched
area of camshaft bracket on front and rea
r
sides.

The cylinder head cover must be installed
within 5 minutes after sealant application to
prevent premature hardening of sealant.

Tighten bolts to the specified torque.
Torque : 9 N




m (0.9 kg




m/7 lb ft)





014RW019
2. Install exhaust gas recirculation pipe and tighten to
specified torque.
Torque :
Exhaust manifold side: 29 N




m (3.0 kg




m/21 lb ft)
Flare nut: 44 N




m (4.5 kg




m/33 lb ft)
Cylinder head side: 20 N




m (2.0 kg




m/14 lb ft)
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injecto
r
harness connector.
Torque : 8 N




m (0.8 kg




m/5.7 lb ft)
4. Install heater pipe bolt to the specified torque.
Torque : 20 N




m (2.0 kg




m/14 lb ft)
5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
Torque : 4 N




m (0.4 kg




m/3 lb ft)
6. Connect ventilation hose to cylinder head.
7. Install air cleaner duct assembly.

ENGINE MECHANICAL (6VE1 3.5L) 6A-49
Engine Assembly
Removal

P1010068
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.

Disconnect the two connectors from the ECM.

. Remove fixing bolts on the common chamber.

Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (lef
t
front side of engine compartment), disconnect shift
on the fly harness connector from front side o
f
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the lef
t
bank.

17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
23. Move drive belt tensioner to loose side using
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side o
f
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic transmission. Otherweise, the
transmission may be damaged.

6A-50 ENGINE MECHANICAL (6VE1 3.5L)





012RS009
1. Install engine assembly. Tighten engine mount
fixing bolts to frame to the specified torque.
Torque: 41 N




m (4.2 kg




m/30 lb ft)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaus
t
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb ft)






LTW36FSH000101
7. Reconnect O2 sensor connector.
8. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque : 10 N




m (1.0 kg




m/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
Torque : 43 N




m (4.4 kg




m/32 lb ft)
10. Install power steering pump, tighten fixing bolt to
the specified torque.
Torque :
M8 bolts : 25 N




m (2.5 kg




m/18 lb ft)
M10 bolts : 43 N




m (4.4 kg




m/32 lb ft)
11. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.



850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Drive Belt

12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back o
f
right dash panel.

6B-2 ENGINE COOLING (6VE1 3.5L)
General Description



030RW001
Legend (7)Cylinder Head
(1) Water Pump (8) Right Bank
(2) Thermostat (9) Throttle Body
(3) Radiator (10) Cylinder Block
(4) Reserve Tank (11) Cylinder Head
(5) Cooling Fan (12) Left Bank
(6) Cylinder Block (13) Heater


The engine cooling system consists of the radiator, the
water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature fo
r
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolan
t
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.

6B-6 ENGINE COOLING (6VE1 3.5L)
Draining and Refilling Cooling
System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“ MIN" and “MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
“ MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.




P1010064
2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiato
r
are still hot. Scalding fluid and steam can be blown
out under pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a
solution that is 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
 Make sure that the engine is cool.
 Open radiator cap pour coolant up to filler neck.
 Pour coolant into reservoir tank up to “MAX" line.

 Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
not vapor or boiling water. To open the radiato
r
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.

After tightening radiator cap, warm up the engine at
about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolan
t
circulate also into heater water system.
 Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5 –minute idling again and stop the engine.
 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
cooling system and reservoir tank hose for leakage.
 Pour coolant into the reservoir tank up to “MAX"
line.

6B-14 ENGINE COOLING (6VE1 3.5L)
6. After directly filling the radiator, fill the reservoir to
the maximum level.
7. Install and 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.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
hot vapor or boiling water. To open the radiato
r
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.
8.
After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into
heater water system.
9. Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5-minute idling again and stop the engine.
10. 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.
11. Fill the coolant into the reservoir tank up to “MAX"
line.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-31

RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX

RELAY
NO. Relay name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; FOG LIGHT
X-6 RELAY; STARTER
X-7 RELAY; COND, FAN
X-8 RELAY;

X-9 RELAY; HAZARD-RH
X-10 RELAY; HAZARD-LH
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO


FUSE





 
 
 
 


  
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3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-55
Vehicle Speed Sensor (VSS)



The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
Heated Oxygen (O2) Sensor




1
(1) Bank 1 Heated Oxygen Sensor (RH)






1
(1) Bank 2 Heated Oxygen Sensor (LH)

Each oxygen sensor consists of a 4-wire low
temperature activated zirconia oxygen analyzer elemen
t
with heater for operating temperature of 315C, and
there is one mounted on each exhaust pipe.
A constant 450millivolt is supplied by the ECM between
the two supply terminals, and oxygen concentration in
the exhaust gas is reported to the ECM as returned
signal voltage.
The oxygen present in the exhaust gas reacts with the
sensor to produce a voltage output. This voltage should
constantly fluctuate from approximately 100mV to
1000mV and the ECM calculates the pulse width
commanded for the injectors to produce the prope
r
combustion chamber mixture.
Low oxygen sensor output voltage is a lean mixture
which will result in a rich commanded to compensate.
High oxygen sensor output voltage is a rich mixture
which result in a lean commanded to compensate.
When the engine is first started the system is in "Open
Loop" operation. In "Open Loop", the ECM ignores the
signal from the oxygen sensors. When various
conditions (ECT, time from start, engine speed &
oxygen sensor output) are met, the system enters
"Closed Loop" operation. In "Closed Loop", the ECM
calculates the air fuel ratio based on the signal from the
oxygen sensors.

Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control to
begin operation and allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors to
become active.
Oxygen sensor heaters are required by catalyst monito
r
and sensors to maintain a sufficiently high temperature
which allows accurate exhaust oxygen content readings
further away from the engine.