fuse ISUZU TF SERIES 2004 Owners Manual

6E–316 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6 Using the DVM and check the neutral switch (inhibitor switch) power supply circuit.
1. Ignition “On”, engine “Off”.
2. Remove the neutral switch (inhibitor switch) connector from the switch.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10-14.5V Go to Step 8Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)” and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).
Is the action complete? — Verify repair —
8 Using the DVM and check the neutral switch (inhibitor switch) circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM connected) Ref. Page 6E-104
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage circuit.
Was the DVM indicated specified value?
Breaker box is not available: 1. Ignition “On”, engine “Off”.
2. Back probe the DVM to the neutral switch (inhibitor switch) and check the circuit for open or
short to voltage circuit.
Was the DVM indicated specified value?
Neutral (P or
N): 10-14.5V Other than
neutral (P or
N): Less than
1V Go to Step 11 Fix ed at 10-
14.5V: Go to Step 9
Fix ed at less
than 1V: Go to
Step 10
Step Action Value(s) Yes No
V
E-12
M/T
V
3
E-51
A/T
E-687Br eak er Box




V
8
2
VV
E-11
E-51
M/T
A/T

6E–356 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 4)
(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P1690 (SYMPTOM CODE 8)
(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The Check Engine Lamp (Malfunction Indicator Lamp
=MIL) should always be illuminated and steady with
ignition “On”. Ignition feed voltage is supplied to the
Check Engine Lamp bulb through the meter fuse. The
ECM turns the Check Engine Lamp “On” by grounding
the check engine lamp driver circuit for a certain time.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
77 P1690 4 OFF Che ck Engine La mp (MIL)
Circuit Voltage LowChe ck engine la mp circuit
open or short to ground cir-
cuit.No fa il-sa fe fun ctio n.
8 OFF Che ck Engine La mp (MIL)
Circuit Voltage HighChe ck engine la mp circuit
sho rt to ground circuit.

6E–362 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.
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 fuel amount enough?
—Go to Step 5Add fuel to the
tank
5 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 6
6 Check the “ECM” fuse (10A) and “Engine” fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 7
7 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 8
8 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 9
9 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 10

ENGINE MECHANICAL (6VE1 3.5L) 6A-5
3. Trouble In Fuel System
Symptom Possible Cause Action
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 faultyRefer to “Electronic Fuel Injection"
section

4. Engine Lacks Compression
Symptom Possible Cause Action
Engine lacks compression Spark plug loosely fitted Tighten to specified torque
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 or broken 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 gage needle
reaches the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls belo
w
the limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

6A-84 ENGINE MECHANICAL (6VE1 3.5L)
NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps.
6. Measure the width of the plastigage and determine
the oil clearance. If the oil clearance exceeds the
limit, replace the rod bearing as a set.
Standard : 0.019 mm




0.043 mm
(0.0007 in




0.0017 in)
Limit : 0.08 mm (0.003 in)





015RS008
7. Clean the plastigage from the bearings and the
crankshaft pins.
Con




rod Bearing Selection
Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).
NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.





015RS034


1 Size Mark Big end Bore
Diameter Crankshaft Pin
Diameter Connecting Rod
Bearing Thickness
(Reference) Color of
Size Mark Oil Clearance
(Reference)
A 56.994-57.000
(2.2439-2.2441) 1.512-1.516
(0.0595-0.0597) Yellow 0.025-0.054
(0.0010-0.0021)
B 56.988-56.994
(2.2436-2.2439) 53.922-53.937
(2.1229-2.1235) 1.508-1.512
(0.0594-0.0595) Green 0.027-0.056
(0.0011-0.0022)
C 56.982-56.988
(2.2434-2.2436) 1.504-1.508
(0.0592-0.0594) Pink 0.029-0.058
(0.0011-0.0023)

Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin

Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin
hole with normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.

Attach the piston to the connecting rod with the
piston front mark and the connecting rod fron
t
mark on the same side.

6D1-2 ENGINE ELECTRICAL (6VE1 3.5L)
Battery
General Description
There are six battery fluid caps on the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small
vent holes on the side. These vent holes permit the
escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages ove
r
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to sel
f
discharge than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permi
t
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary.


2. Fluid Level Check
The fluid level should be between the upper level line(1)
and lower level line(2) on side of battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.



RTW36DSH000101
3. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure
(2) below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE – Drop charging voltage to
15V and charge for 10 – 15 hours. Then go to
Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V –
Continue charging at the same rate for an
additional 3–1/2 hours. Then go to Step 5.
d. VOLTAGE BELOW 12V – Replace Battery.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS


ABBREVIATION CHARTS ................................ 6E-5
COMPONENT LOCATOR ................................. 6E-6
ENGINE COMPONENT LOCATOR TABLE .. 6E-6
ECM CIRCUIT DIAGRAM ................................. 6E-10
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4). 6E-13
GROUND POINT CHART G.EXP (LHD) (2/4) .. 6E-14
GROUND POINT CHART G.EXP (LHD) (3/4) .. 6E-15
GROUND POINT CHART G.EXP (LHD) (4/4) .. 6E-16
GROUND POINT CHART G.EXP (RHD) (1/4) . 6E-17
GROUND POINT CHART G.EXP (RHD) (2/4) . 6E-18
GROUND POINT CHART G.EXP (RHD) (3/4) . 6E-19
GROUND POINT CHART G.EXP (RHD) (4/4) . 6E-20
LOCATION ........................................................ 6E-21
CABLE HARNESS & CONNECTOR
LOCATION ....................................................... 6E-22
CONNECTOR LIST ........................................... 6E-27
RELAY AND FUSE ............................................ 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-31
FUSE AND RELAY LOCATION
(LHD&RHD) ................................................... 6E-32
ECM WIRING DIAGRAM (1/10) ........................ 6E-33
ECM WIRING DIAGRAM (2/10) ........................ 6E-34
ECM WIRING DIAGRAM (3/10) ........................ 6E-35
ECM WIRING DIAGRAM (4/10) ........................ 6E-36
ECM WIRING DIAGRAM (5/10) ........................ 6E-37
ECM WIRING DIAGRAM (6/10) ........................ 6E-38
ECM WIRING DIAGRAM (7/10) ........................ 6E-39
ECM WIRING DIAGRAM (8/10) ........................ 6E-40
ECM WIRING DIAGRAM (9/10) ........................ 6E-41
ECM WIRING DIAGRAM (10/10) ...................... 6E-42
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL ......................................... 6E-43
GENERAL DESCRIPTION FOR ECM AND
SENSORS ........................................................ 6E-51

Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O
2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL ......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69

6E-6 3.5L ENGINE DRIVEABILITY AND EMISSIONS
COMPONENT LOCATOR
ENGINE COMPONENT LOCATOR TABLE



 



Legend
(1) Engine Control Module (ECM)
(2) Throttle Position Sensor (TPS)
(3) Idle Air Control (IAC) Valve
(4) Battery
(5) Relay & Fuse Box
(6) Auto Cruise Actuator
(7) Mass Air Flow (MAF) & Intake Air Temperature
(IAT) Sensor Assembly

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-29

No. Connector face No. Connector face
E-78

O2 sensor LH-Front P-1
SilverBattery (+)
E-79


Neutral start switch P-2
SilverRelay & Fuse box
F-2
White
Fuel pump & sensor P-5
SilverBattery (-)
H-4

White Engine ~ Engine room P-8

WhiteACG (L)
H-6
White
Engine room ~ INST P-10
SilverEngine ground
H-7
White
Engine room ~ INST X-2

BlackRelay ; Fuel pump
H-9
Blue
Engine room ~ Chassis X-13

BlackRelay ; ECM MAIN
H-18
White
Engine room ~ INST X-14

BlackRelay ; A/C Compressor
H-22

White
Engine ~ Engine room C X-15
BlackRelay ; Thermo
H-23

White Engine ~ Engine room B X-17
BlackDIODE

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



LHD
RHD

RTW48ALF000201 & 825R300008