clutch ISUZU TF SERIES 2004 Owners Manual

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–13
(1) Engine Control Module (ECM)
(1) Engine Coolant Temperature (ECT) Sensor
(2) Thermo Unit for Water Temperature Gauge
(1) Vehicle Speed Sensor (VSS)
21
(1) EGR EVRV
(2) To Vacuum Pump
(3) To EGR Valve
(1) Crankshaft Position (CKP) Sensor
(2) Clutch Housing
321
12

6E–40 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
CONNECTOR LIST
No. Connector face No. Connector face
B-24
Green Meter-BC-56
ECM-A
B-54
White J/B I2C-57
ECM-B
B-56
White J/B I4C-77
Clutch switch
B-58
Black Check connectorC-94
White TCM
B-62
White Ignition switch (IGSUB : G1)C-95
White TCM
B-63
White Ignition switch (IGSUB : G2)C-107
White J/B E2
B-68
ImmobilizerC-108
White J/B E1
C-2
Silver Engine room-RH groundC-109
Silver Body-LH ; ground
C-36
Silver Engine room-LH ; GroundC-115
Brown EVRV
C-44
White Stop lamp switchC-116

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–41
No. Connector face No. Connector face
C-118
A/C Resister & Neutral switchE-23
Gray Idle SW
C-123 E-41
Black Coolant temp sensor
C-124 E-44
Gray Vehicle speed sensor
E-3
Black Magnetic clutch AC COMPE-49
Gray Glow plug
E-6 E-51
Black Inhibiter switch
E-9 H-4
White Engine room ~ Mission
E-10
Silver Engine groundH-6
White Engine room ~ INST
E-11
Natural
green Neutral switchH-7
White Engine room ~ INST
E-12
Natural
green Neutral switchH-18
White Engine room ~ INST
E-22
Brown TPS 1 mainH-22
White Engine ~ Engine room C

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–53
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNA L
View Looking Into ECM Case
Signal or Continuity Tester Position
Pin
No. B/Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRange (+) (-)
1 1 ECM Gro und BLK Continuity
with
gro und---Discon-
ne ctOhm 1 GND
2 2 ECM Gro und BLK Continuity
with
gro und---Discon-
ne ctOhm 2 GND
3 3 Batte ry Powe r Supply BLU/
REDLess than
1V10-14V Connect DC V 3 GND
25 25 No Conne ctio n - - - - - - - - -
26 26 No Conne ctio n - - - - - - - - -
27 27 Engine Spee d Output
(To Ta cho Me te r)LGN - - Approx.
23Hz by
w a v e fo rm
or approx.
6.3V Approx.
67Hz by
wave form
or approx.
6.8V Co nnect AC V 27 GND
28 28 No Conne ctio n - - - - - - - - -
29 29 No Conne ctio n - - - - - - - - -
30 30 Brake Switch 1 Signal GRN Less than
1VPedal is not stepped on: Less than 1V
Pedal is stepped on: 10-14VCo nnect DC V 30 GND
31 31 Clutch Switch Signal
(MT Only )YEL Less than
1VPedal is not stepped on: 10-14V
Pedal is stepped on: Less than 1VCo nnect DC V 31 GND
32 32 No Conne ctio n - - - - - - - - -
33 33 A/C ON Signa l Re la y GRN/
YELLess than
1VA/C re que st switch is turne d on: 10-
14V
A/C request switch is turned off: Less
than 1VCo nnect DC V 33 GND
34 34 No Conne ctio n - - - - - - - - -
35 35 To Da ta Link Co nnec-
tor No. 6 & Immobi-
lize r Contro l Unit (ICU
B8)YEL--------
36 36 No Conne ctio n - - - - - - - - -
37 37 No Conne ctio n - - - - - - - - -
38 38 Throttle Po sitio n Sen-
so r (TPS) Output Sig-
na lGRN/
ORGLess than
1VLess than 1V Approx.
0.5VCo nnect DC V 38 49
39 39 Key Sw itch Input Sig-
nal Via Engine FuseWHT Less than
1V10-14V Co nnect DC V 39 GND
40 40 No Conne ctio n - - - - - - - - -

6E–58 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNA L
View Looking Into ECM Case
Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)
1 1 ECM Gro und BLK Co ntinu-
ity with
ground---Discon-
ne ctOh m 1 GND
2 2 ECM Gro und BLK Co ntinu-
ity with
ground---Discon-
ne ctOh m 2 GND
3 3 Batte ry Powe r Sup-
plyBLU/
REDLe ss
tha n 1V10-14V Co nnect DC V 3 GND
2525No Connection---------
2626No Connection---------
27 27 Engine Spee d Output
(To Ta cho Mete r)LGN - - Approx .
23Hz by
wave
fo rm or
approx.
6.3V Approx.
67Hz by
wave
fo rm or
approx.
6.8V Co nnect AC V 27 GND
2828No Connection---------
29 29 Throttle Positio n Sig-
na l To TCM (A16)
(AT Only )- Appro x . 140Hz by wav e fo rm (Idle:
Off duty 10% / WOT: Off duty 90%)- ---
30 30 Bra ke Switch 1 Sig-
na lGRN Le ss
tha n 1VPedal is not stepped on: Less than
1V
Pedal is stepped on: 10-14VCo nnect DC V 30 GND
31 31 Clutch Switch Signa l
(MT Only )YEL Less
tha n 1VPedal is not stepped on: 10-14V
Pe da l is ste ppe d o n: Le ss tha n 1VCo nnect DC V 31 GND
3232No Connection---------
33 33 A/C ON Signa l Rela y GRN/
YELLe ss
tha n 1VA/C request switch is turned on: 10-
14V
A/C reque st switch is turne d off:
Less than 1VCo nnect DC V 33 GND
3434No Connection---------
35 35 To Data Link Co n-
necto r No. 6 & Immo-
bilize r Co ntrol Unit
(ICU B8)YEL--------
3636No Connection---------

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–89
18 Brake Switch 2 Active/
InactiveInactive Inactive Inactive This displays operating status of the brake switch. This
should display "Active" when the brake pedal is stepped
on.
19 Clutch Sw itch Activ e /
InactiveInactive Inactive Inactive This displays operating status of the clutch switch. This
should display "Active" when the clutch pedal is stepped
on.
20 Neutra l Switch On/Off On On On This displa ys o pe rating status of the neutra l switch. This
should display "On" when the gear position is neutral.
21 A/C Informa tion
SwitchActive 12V/
Inactive 0VInactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
should display "Active 12V" when the air conditioner switch
is switched on.
22 Dia gnostic Re quest Activ e 0V/
Inactive 12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis display s the dia gnostic reque st signal. This sho uld
display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 14 10 - 14 10 - 14 This displays the system voltage measured by the ECM at
ignition feed.
24 Ma in Re la y Activ e /
InactiveActive Active Active This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Activ e 0V/
Inactive12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
uppe d.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This sho uld display "On" whe n the glo w la mp is turne d o n.
28 Desired Engine Idle
Speedrpm 730 730 730 The desired engine idle speed that the ECM commanding.
The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Re que st Activ e 0V/
Inactive 12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis displays operating status of the A/C compressor. This
should display "Active 0V" when the compressor relay is
operated.
30 Immo bilize r Activ e /
InactiveInactive Inactive Inactive This should display "Inactive" when the immobilizer is
correctly operated.
31 Immo bilize r Signal Rece iv ed/
Not
Rece iv edNo t
Receive dNo t
Re ceive dNot
Re ce iv e dThis sho uld displa y "No t Receive d" whe n the immo bilize r is
not activated.
32 Immo bilize r Function
ProgrammedYes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
programmed.
33 EGR Pulse Ratio
(Ex ha ust Ga s
Recirculatio n)% 70 70 70 This displays the duty signal from the ECM to control the
EGR flow amount. Tech 2 Parameter Units Idle 1500rpm 2000rpm Description

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–91
18 Brake Switch 2 Active/
InactiveInactive Inactive Inactive This displays operating status of the brake switch. This
should display "Active" when the brake pedal is stepped
on.
19 Clutch Switch (M/T
On ly )Active/
InactiveInactive Inactive Inactive This displays operating status of the clutch switch. This
should display "Active" when the clutch pedal is stepped
on.
20 Neutra l Switch On/Off On On On This displa ys o pe rating status of the neutra l switch. This
should display "On" when the gear position is neutral (M/T)
or P, N positio n (A/T).
21 A/C Informa tion
SwitchActive 12V/
Inactive 0VInactive 0V Inactive 0V Inactive 0V This displays the air conditioner request signal. This
should display "Active 12V" when the air conditioner switch
is switched on.
22 Dia gnostic Re quest Activ e 0V/
Inactive 12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis displays the diagnostic request signal. This should
display "Inactive 12V" when the Tech 2 is connected.
23 System Voltage V 10 - 15 10 - 15 10 - 15 This displays the system voltage measured by the ECM at
ignition feed.
24 Ma in Re la y Activ e /
InactiveActive Active Active This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
25 Glow Time Relay Activ e 0V/
Inactive12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis displays operating status for the glow relay. This
should display "Inactive 12V" when the engine is warm
uppe d.
26 Check Engine Light On/Off Off Off Off This displays operating status for the Check Engine Lamp.
This should display "On" when the Check Engine Lamp is
turned on.
27 Glow Time Telltale On/Off Off Off Off This displays operating status for the glow indicator lamp.
This sho uld display "On" whe n the glo w la mp is turne d o n.
28 Desired Engine Idle
Speedrpm 700 700 700 The desired engine idle speed that the ECM commanding.
The ECM compensates for various engine loads based on
engine coolant temperature.
29 A/C Re que st Activ e 0V/
Inactive 12VIna ctiv e
12VInactive
12VIna ctiv e
12VThis displays operating status of the A/C compressor. This
should display "Active 0V" when the compressor relay is
operated.
30 Immo bilize r Activ e /
InactiveInactive Inactive Inactive This should display "Inactive" when the immobilizer is
correctly operated.
31 Immo bilize r Signal Rece iv ed/
Not
Rece iv edNo t
Receive dNot
Re ceive dNot
Re ce iv e dThis sho uld displa y "No t Receive d" whe n the immo bilize r is
not activated.
32 Immo bilize r Function
ProgrammedYes/ No Yes Yes Yes This should display "Yes" when the immobilizer is correctly
programmed.
33 EGR Pulse Ratio
(Ex ha ust Ga s
Recirculatio n)% 85 - 90 85 - 90 85 - 90 This displays the duty signal from the ECM to control the
EGR flow amount. Tech 2 Parameter Units Idle 1500rpm 2000rpm Definition

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–123
46 P0645 4 ON A/C Compressor Relay
Circuit Voltage LowA/C compressor relay circuit
open or short to ground
circuit.No fail-safe function. A/C compressor relay circuit
is correct condition.1. A/C compressor relay
circuit open or short to
g r o u n d c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. A/C compressor relay
m a l f u n c t i o n .
4. ECM malfunction.41 —
8 ON A/C Compressor Relay
Circuit Voltage High A/C compressor relay circuit
short to voltage circuit.ECM malfunction.
——
25 P0703 A ON Brake Switch Circuit
Malfunction1. Throttle position is more
t h a n 0 % .
2. Engine speed is more
than 693rpm (4JA1-TC)
or 665rpm (4JH1-TC).
3. Vehicle speed is more
t h a n 0 k m / h .
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.No fail-safe function. Brake switch 1 signal and
brake switch 2 signal are
correctly inputted to the
ECM.1. Brake switch 1 circuit
open, short to ground or
short to voltage circuit.
2. Poor connector
c o n n e c t i o n .
3. Brake switch 1
m a l f u n c t i o n .
4. ECM malfunction.30 —
B ON Brake Switch Circuit
Malfunction1. Throttle position is more
t h a n 0 % .
2. Engine speed is more
than 693rpm (4JA1-TC)
or 665rpm (4JH1-TC).
3. Vehicle speed is more
t h a n 0 k m / h .
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM.1. Brake switch 2 circuit
open or short to ground
c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. Brake switch 2
m a l f u n c t i o n .
4. ECM malfunction.65 —
57 P0704 6 ON Clutch Switch Input Circuit
MalfunctionClutch signal does not
change between vehicle
speed 1.5km/h and 80km/h
since ignition switch was
tuned on. No fail-safe function. Clutch signal correctly
changes.1. Clutch switch circuit
open, short to ground or
short to voltage circuit.
2. Poor connector
c o n n e c t i o n .
3. Clutch switch
m a l f u n c t i o n .
4. ECM malfunction.31 — —
86 P1105 1 ON Barometric Pressure Sensor
Circuit High InputBarometric pressure sensor
output voltage is more than
4.4V.ECM uses 1013hpa
condition as substitute.Barometric pressure sensor
output voltage is below 4.4V.ECM malfunction.
——
2 ON Barometric Pressure Sensor
Circuit Low InputBarometric pressure sensor
output voltage is below 1.5V.Barometric pressure sensor
output voltage is more than
1.5V.ECM malfunction.
—— Flash
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)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–281
DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6)
(FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM monitors the clutch switch signal on the feed
terminal to the ECM. If clutch switch circuit with
malfunction, DTC P0704 (Symptom Code 6) will be
stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the “Clutch Switch” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
57 P0704 6 ON Clutch Switch Input Circuit
Malfunctio nClutch signa l do es no t change
between vehicle speed
1.5km/h and 80km/h since
ignitio n switch was tune d on. No fa il-sa fe fun ctio n.

6E–282 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0704 (Symptom Code 6) (Flash Code 57)
Clutch Switch Input Circuit Malfunction
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0704 (Symptom Code 6) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0704 (Symptom Code 6) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Check for poor/faulty connection at the clutch switch
or ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
—Verify repair Go to Step 5
5 Using the DVM and check the clutch switch.
1. Ignition “Off”, engine “Off”.
2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Was the DVM indicated specified value?
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity Go to Step 6Replace pedal
switch and
verify repair
311
2
C-56 C-77
Clutch Sw itch