fuse box ISUZU TF SERIES 2004 Repair Manual

6E-30 3.5L ENGINE DRIVEABILITY AND EMISSIONS
RELAY AND FUSE
RELAY AND FUSE BOX LOCATION (LHD & RHD)



LHD
RHD

RTW48ALF000201 & 825R300008

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


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6E-32 3.5L ENGINE DRIVEABILITY AND EMISSIONS

FUSE & RELAY LOCATION (LHD & RHD)



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RELAY
Connector No. B-7 B-8 B-40
6VE1 REAR DEFOGGER POWER WINDOW ACC SOCKET

FUSE BOX

6E-64 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:

Improves your understanding and definition of the
customer complaint

Saves time by avoiding testing and/or replacing
good parts


Allows you to look at the problem from different
perspectives

Guides you to determine what level o
f
understanding about system operation is needed:
 Owner’s manual level
 Service manual level
 In-depth (engineering) level
1. Verify the Complaint
What you should do
To verify the customer complaint, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure o
f
the system.
The following information will help you verify the
complaint:

WHAT the vehicle model/options are

WHAT aftermarket and dealer-installed
accessories exist

WHAT related system(s) operate properly

WHEN the problem occurs

WHERE the problem occurs

HOW the problem occurs

HOW LONG the condition has existed (and if the
system ever worked correctly)

HOW OFTEN the problem occurs

Whether the severity of the problem has
increased, decreased or stayed the same
What resources you should use
Whenever possible, you should use the following
resources to assist you in verifying the complaint:
Service manual Theory or Circuit Description
sections

Service manual “System Performance Check”

Owner manual operational description

Technician experience

Identical vehicle for comparison


Circuit testing tools

Vehicle road tests

Complaint check sheet

Contact with the customer
2. Perform Preliminary Checks
NOTE: An estimated 10 percent of successful
vehicle repairs are diagnosed with this step!
What you should do
You perform preliminary checks for several reasons:

To detect if the cause of the complaint is
VISUALLY OBVIOUS

To identify parts of the system that work correctly

To accumulate enough data to correctly and
accurately search for a ISUZU Service Bulletin.
The initial checks may vary depending on the
complexity of the system and may include the following
actions:

Operate the suspect system

Make a visual inspection of harness routing and
accessible/visible power and ground circuits

Check for blown fuses

Make a visual inspection for separated connectors

Make a visual inspection of connectors (includes
checking terminals for damage and tightness)

Check for any DTCs stored by the on-board
computers

Sense unusual noises, smells, vibrations o
r
movements

Investigate the vehicle service history (call othe
r
dealerships, if appropriate)
What resources you should use
Whenever appropriate, you should use the following
resources for assistance in performing preliminary
checks:

Tech 2 or other technical equipment for viewing
DTCs

Service manual information:
 Component locations
 Harness routing
 Wiring schematics
 Procedures for viewing DTCs

Dealership service history file

Vehicle road test

Identical vehicle or system for comparison

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-113
Step Action Value (s) Yes No
5
Using the DVM and check the fuel pump relay.
1. Ignition "Off", engine "Off".
2. Remove the fuel pump relay from the relay box.
3. Check the relay coil.
Was the DVM indicated specified value?
X-2


1
3 2
4






Approximately
140

Go to Step 6 Replace fuel
pump relay and
verify repair
6
Using the DVM and check the fuel pump relay power
supply circuit.
1. Ignition "On", engine "Off".
2. Remove the fuel pump relay from the relay box.
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
X-2


V



10 – 14.5V Go to Step 8 Go to Step 7
7
Repair the open or short to ground circuit between the
"ECM" fuse (15A) and fuel pump relay.
Is the action complete?
- Verify repair -
8
Using the DVM and check the fuel pump relay ground
circuit.
1. Ignition "Off", engine "Off".
2. Disconnect the ECM connector.
3. Remove the fuel pump relay from the relay box.
4. Check the circuit for open or short to ground circuit.
Was the problem found?
E-61(B)
X-2









- Repair faulty
harness and
verify repair Go to Step 9

6E-124 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
8
Check for poor/faulty connection at the A/C
compressor, A/C compressor relay or ECM connector.
If a poor/faulty connection is found, repair as
necessary.
Was the problem found?
E-2


X-14







E-61(B)



- Verify repair Go to Step 9
9
 Using the DVM and check the A/C compressor relay.
1. Ignition "Off", engine "Off".
2. Remove the A/C compressor relay from the relay
box.
3. Check the relay coil.
Was the DVM indicated specified value?
X-14






Approximately
140

Go to Step 10 Replace A/C
compressor relay
and verify repair
10
Using the DVM and check the A/C compressor relay
power supply circuit.
1. Ignition "On", engine "Off".
2. Remove the A/C compressor relay from the relay
box.
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
X-14





VV

10 – 14.5V Go to Step 12 Go to Step 11
11
Repair the open or short to ground circuit between the
"A/C" fuse (10A) and A/C compressor relay.
Is the action complete?
- Verify repair -

6E-126 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
15
Check for poor/faulty connection at the thermo relay,
triple pressure switch, thermostat or ECM connector. If
a poor/faulty connection is found, repair as necessary.
Was the problem found?
E-61(B)
X-15







C-24C-55









- Verify repair Go to Step 16
16
 Using the DVM and check the thermo relay.
1. Ignition "Off", engine "Off".
2. Remove the thermo relay from the relay box.
3. Check the relay coil.
Was the DVM indicated specified value?
X-15






Approximately
140

Go to Step 17 Replace thermo
relay and verify
repair
17
 Using the DVM and check the thermo relay power
supply circuit.
1. Ignition "On", engine "Off".
2. Remove the thermo relay from the relay box.
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
X-15





VV

10 – 14.5V Go to Step 19 Go to Step 18
18
Repair the open or short to ground circuit between the
"A/C" fuse (10A) and thermo relay.
Is the action complete?
- Verify repair -

ENGINE DIAGNOSIS (C24SE) 6-3
3.Trouble in Fuel System
Condition Possible cause Correction
Starting motor turns over and
spark occurs but engine does not
start. Fuel tank empty Fill
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control
system circuit clogged Correct or replace
Multiport Fuel Injection System
faulty Refer to "Electronic Fuel Injection"
section
4.Engine Lacks Compression
Condition Possible cause Correction
Engine lacks compression Spark plug loosely fitted or spark
plug gasket defective Tighten to specified torque or
replace gasket
Spark plug wire incorrect Connect properly or replace
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.

Engine Compression Test Procedure
1. Start and run the engine until the engine
reaches normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and
fuse box. 6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
7. Install cylinder compression gauge into spark
plug hole.
8. With the throttle valve opened fully, keep the
starter engaged until the compression gauge
needle reaches the maximum level. Note the
reading.
9. Repeat the test with each cylinder.
The pressure difference between the individual
cylinders should not exceed 100kPa (14.5 psi).

ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
CONTENTS
C24SE ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATIONS CHARTS ......................... 6E-6
ECM Circuit Diagram (1/2) ............................ 6E-11
ECM Circuit Diagram (2/2) ............................ 6E-12
GROUND POINT CHART - LHD G.EXP (1/4) 6E-13
GROUND POINT CHART - RHD G.EXP (1/4) 6E-17
LOCATION ................................................... 6E-21
CABLE HARNESS & CONNECTOR
LOCATION .............................................. 6E-23
CABLE HARNESS & CONNECTOR
LOCATION
LHD ................................... 6E-24
CABLE HARNESS & CONNECTOR
LOCATION
RHD ................................... 6E-25
CONNECTOR LIST ...................................... 6E-28
RELAY AND FUSE ....................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-30
FUSE AND RELAY LOCATION (LHD & RHD) 6E-32
ECM WIRING DIAGRAM (1/9) ..................... 6E-33
ECM WIRING DIAGRAM (2/9) ..................... 6E-34
ECM WIRING DIAGRAM (3/9) ..................... 6E-35
ECM WIRING DIAGRAM (4/9) ..................... 6E-36
ECM WIRING DIAGRAM (5/9) ..................... 6E-37
ECM WIRING DIAGRAM (6/9) ..................... 6E-38
ECM WIRING DIAGRAM (7/9) ..................... 6E-39
ECM WIRING DIAGRAM (8/9) ..................... 6E-40
ECM WIRING DIAGRAM (9/9) ..................... 6E-41
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-42
GENERAL DESCRIPTION FOR ECM AND
SENSORS ............................................... 6E-48
Engine Control Module (ECM) ................... 6E-48
Manifold Absolute Pressure (MAP) Sensor 6E-48
Throttle Position Sensor (TPS) .................. 6E-49
Idle Air Control (IAC) Valve ....................... 6E-49
Crankshaft Position (CKP) Sensor ............ 6E-50
Knock Sensor (KS) .................................... 6E-50
Engine Coolant Temperature (ECT) Sensor 6E-50
Intake Air Temperature (IAT) Sensor ........ 6E-51
Vehicle Speed Sensor (VSS) .................... 6E-51
Heated Ox ygen (O
2) Sensor ..................... 6E-51
GENERAL DESCRIPTION FOR FUEL
METERING .............................................. 6E-52Battery Voltage Correction Mode ............... 6E-52
Clear Flood Mode ...................................... 6E-52
Deceleration Fuel Cutoff (DFCO) Mode .... 6E-52
Engine Speed/ Vehicle Speed/ Fuel Disable
Mode ........................................................ 6E-52
Acceleration Mode ..................................... 6E-52
Fuel Cutoff Mode ....................................... 6E-52
Starting Mode ............................................ 6E-52
Run Mode .................................................. 6E-52
Fuel Metering System Components .......... 6E-53
Fuel Injector ............................................... 6E-53
Fuel Pressure Regulator ............................ 6E-53
Fuel Rail ..................................................... 6E-53
Fuel Pump Electrical Circuit ....................... 6E-53
Thottle Body Unit ....................................... 6E-53
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM ................................. 6E-54
Spark Plug ................................................. 6E-54
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ............................... 6E-57
EVAP Emission Control System Purpose .. 6E-57
EVAP Emission Control System Operation 6E-57
System Fault Detection .............................. 6E-57
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM .................................................. 6E-59
Crankcase Ventilation System Purpose .... 6E-59
A/C CLUTCH DIAGNOSIS ........................ 6E-60
A/C Clutch Circuit Operation ...................... 6E-60
A/C Clutch Circuit Purpose ........................ 6E-60
A/C Request Signal ................................... 6E-60
ISUZU STRATEGY BASED DIAGNOSTICS 6E-61
Overview .................................................... 6E-61
STRATEGY BASED DIAGNOSTICS CHART 6E-61
Diagnostic Thought Process ...................... 6E-62
1. Verify the Complaint .............................. 6E-62
2. Perform Preliminary Checks .................. 6E-62
3. Check Bulletins and Troubleshooting Hints 6E-63
4. Perform Service Manual Diagnostic Checks 6E-63
5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-63
5c. Technician Self Diagnoses .................. 6E-63
5d. Intermittent Diagnosis .......................... 6E-64

ENGINE DRIVEABILITY AND EMISSIONS 6E–29
No. Connector face No. Connector face
E-84
Knock sensorP-1
Silver Battery (+)
E-85
MAP sensorP-2
Silver Relay & Fuse box
F-2
White Fuel pump & sensorP-5
Silver Battery (-)
H-4
White Engine room ~ MissionP-6
Silver Body earth (Ground)
H-6
White Engine room ~ INSTP-10
Silver Engine ground
H-7
White Engine room ~ INSTX-2
Black Relay; Fuel pump
H-9
Blue Engine room ~ ChassisX-11
Black Relay; Heater
H-18
White Engine room ~ INSTX-14
Black Relay; A/C Compressor
H-31
Engine room ~ Mission
H-34
Engine ~ Engine room