lock ISUZU TF SERIES 2004 Workshop Manual

6E–394 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
29 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 30
30 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
Tech 2 data
All electrical connections within a suspected circuit
and/or system
Was a problem found?—Verify repair Go to Step 31
31 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 32
32 Substitute a known good ECM and recheck.
Was the problem solved?
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. —Go to Step 33Go to Step 34
33 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

6E–396 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
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 On Board
Diagnostic
(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 visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 6
6 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 7
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8
8 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 29Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–397
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 29
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 19Go to Step 15
15 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 16
16 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 17
17 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 18Go to Step 30
18 Replace the TPS.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–399
21 Check the ex haust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 22
22 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 23
23 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 24
24 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 25 Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–403
13 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “A/C Information Switch” in the data
display.
Does the Tech 2 indicate correct “A/C Information
Switch” status depending on A/C switch position?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 14
14 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 15
15 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 16
16 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 31Go to Step 17
17 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 22Go to Step 18
18 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 19
19 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 20 Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–407
EXCESSIVE WHITE SMOKE
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(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 visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or ex haust through the
gasket.
Was a problem found?—Verify repair Go to Step 6
6 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 7
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8
8 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 30Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12

6E–410 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
25 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 26
26 Remove the injection nozzles from the engine and
check for the following conditions.
Improper splay condition.
Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
injection nozzle
and verify repair Go to Step 27 Step Action Value(s) Yes No
1st Stage 2nd Sta ge
4JA1-TCApproximatly
19.0 MpaApprox ima tly
33.5 Mpa
4JH1-TCApproximatly
19.5 MpaApprox ima tly
33.8 Mpa

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–413
EXCESSIVE BLACK SMOKE
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(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 visually/physical check performed?
—Go to Step 4Go to Visual /
physical Check
4 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 6
6 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 7
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8
8 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 21Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10

6E–414 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 21
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2 and ignition “On” and engine
“Run”.
2. Monitor the following parameters in the data
display.
“Desired Injection Quantity” & “Injection Quantity”
“Desired Injection Start” & “Actual Injection Start”
Are the large gap or unstable parameter displayed
between “Desired” and “Actual”?
—Go to Step 20Go to Step 15 Step Action Value(s) Yes No
When idling or part-throttle When accelerated


HighD esired
Low
Ti m e Actu al
High
LowD esired
Actual
Tim e

6H – 6 ACCELERATOR CONTROL




RTW46HMH000201

























Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator
control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90
.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if
any abnormality is found.
 The control cable should move smoothly.
 The control cable should not be bent or kinked.
 The control cable should not be damage or
corrosion.

Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of
engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90

until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.


NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.