injector ISUZU TF SERIES 2004 Owners Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 2629 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–53
Fuel Metering System Components
The fuel metering system is made up of the following
parts.
Fuel injector
Throttle body
Fuel rail
Fuel pressure regulator
ECM
Crankshaft position (CKP) sensor
Idle air control (IAC) valve
Fuel pump
Fuel Injector
The group fuel injection fuel injector is a solenoid
operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Ex cess fuel
not used by the injectors passes through the fuel
pressure regulator before being returned to the fuel
tank.
Fuel Pressure Regulator
The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the
other side. The fuel pressure regulator maintains the
fuel pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separately.
If the pressure is too low or poor performance, DTC
P0131 or P1171 will be the result. If the pressure is too
high, DTC P0132 or P1167 will be the result. Refer to
Fuel System Diagnosis for information on diagnosing
fuel pressure conditions.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator
maintains a constant fuel pressure at the injectors.
Remaining fuel is then returned to the fuel tank.
Fuel Pump Electrical Circuit
When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits
until the engine is cranked. When the engine is cranked
and the 58X crankshaft position signal has been
detected by the ECM, the ECM supplies 12 volts to the
fuel pump relay to energize the electric in-tank fuel
pump.
An inoperative fuel pump will cause a “no-start”
condition. A fuel pump which does not provide enoughpressure will result in poor performance.
Thottle Body Unit
The throttle body has a throttle plate to control the
amount of air delivered to the engine. The Thottle
position sensor and IAC valve are also mounted on the
throttle body.
Vacuum ports located behind the throttle plate provide
the vacuum signals needed by various components.
Engine coolant is directed through a coolant cavity in
the throttle body to warm the throttle valve and to
prevent icing.
Page 2647 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–71
F0: Diagnostic Trouble Code
The purpose of the “Diagnostic Trouble Codes” mod e i s
to display stored trouble code in the ECM.
When “Clear DTC Information” is selected, a “Clear
DTC Information”, warning screen appears.
This screen informs you that by cleaning DTC's “all
stored DTC information in the ECM will be erased”.
After clearing codes, confirm system operation by test
driving the vehicle.
Use the “DTC Information” mode to search for a specific
type of stored DTC information.
History
This selection will display only DTCs that are stored in
the ECM's history memory. It will not display Type B
DTCs that have not requested the MIL (“Check EngineLamp”). It will display all type A and B DTCs that
requested the MIL and have failed within the last 40
warm-up cycles. In addition, it will display all type C and
D DTCs that have failed within the last 40 warm-up
cycles.
MIL SVC or Message Request
This selection will display only DTCs that are requesting
the MIL. Type C and Type D DTCs cannot be displayed
using the MIL. Type C and D DTCs cannot be displayed
using this option.
This selection will report type B DTCs only after the MIL
has been requested.
Last Test Failed
This selection will display only DTCs that have failed the
last time the test run. The last test may have run during
a previous ignition cycle of a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
must have occurred during the current ignition cycle to
appear as last test fail.
Test Failed Since Code Cleared
The selection will display all active and history DTCs
that have reported a test failure since the last time
DTCs were cleared. DTCs that last failed more that 40
warm-up cycles before this option is selected will not be
displayed.
No Run Since Code Cleared
This selection will display up to DTCs that have not run
since the DTCs were last cleared. Since any displayed
DTCs have not run, their condition (passing or failing) is
unknown.
Failed This Ignition
This selection will display all DTCs that have failed
during the present ignition cycle.
F1: Data Display
The purpose of the “Data Display” mode is to
continuously monitor data parameters.
The current actual values of all important sensors and
signals in the system are display through F1 mode.
See the “Typical Scan Data” section.
F2: Snapshot
“Snapshot” allows you to focus on making the condition
occur, rather than trying to view all of the data in
anticipation of the fault.
The snapshot will collect parameter information around
a trigger point that you select.
F3: Miscellaneous Test:
The purpose of “Miscellaneous Test” mode is to check
for correct operation of electronic system actuators.
F0: Diagnostic Trouble Code
F0: Read DTC Infor By Priority
F1: Clear DTC Information
F2: DTC Information
F0: History
F1: MIL SVS or Message Requested
F2: Last Test Failed
F3: Test Failed Since Code Cleared
F4: Not Run Since Code Cleared
F5: Failed This Ignition
F1: Data Display
F0: Engine Data
F1: O2 Sensor Data
F2: Snapshot
F3: Miscellaneous Test
F0: Lamps
F0: Malfunction Indicator Lamps
F1: Relays
F0: Fuel Pump Relay
F1: A/C Clutch Relay
F2: EVAP
F0: Purge Solenoid
F3: IAC System
F0: IAC Control
F1: IAC Reset
F4: Injector Balance Test
Page 2648 of 4264
6E–72 ENGINE DRIVEABILITY AND EMISSIONS
TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were
noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a
properly-running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approx imately
80 deg.)
Tech 2 ParameterUnitsIdle2000rpmDescription
1 Engine Speed rpm775 - 8751950 - 2050 The actual engine speed is measured by ECM from the
CKP sensor 58X signal.
2 Desired Idle Speed rpm825800 - 850 The desired engine idle speed that the ECM
commanding. The ECM compensates for various engine
loa ds.
3 Engine Coolant
Te mpe rature°C or °F80 - 9080 - 90 The ECT is measured by ECM from ECT sensor output
voltage. When the engine is normally warm upped, this
data displays approximately 80 °C or more.
4 Sta rt Up ECT (Engine
Coolant Temperature)°C or °FDepends on ECT
a t start-upDepends on ECT
at sta rt-upStart-up ECT is measured by ECM from ECT sensor
output voltage when engine is started.
5Inta ke Air
Temperature °C or °FDe pe nds on
ambient tempDepends on
ambient tempThe IAT is mea sure d by ECM from IAT sensor o utput
voltage. This data is changing by intake air temperature.
6 Sta rt Up IAT (Inta ke
Air Temperature)°C or °FDepends on IAT at
sta rt-upDepends on IAT at
start-upStart-up IAT is me asured by ECM fro m IAT se nso r o utput
voltage when engine is started.
7 Manifold Absolute
Pre ssurekPa31 - 3625 - 30The MAP (kPa ) is me asure d by ECM fro m MAP o utput
voltage. This data is changing by inlet manifold pressure.
8 Barometric Pressure kPaDe pe nds on
altitudeDepends on
altitudeThe ba rome tric pre ssure is me asured by ECM fro m the
MAP sensor output voltage monitored during key up and
w ide o pe n thro ttle. This data is cha nging by a ltitude.
9 Throttle Position %02-4 Throttle position operating angle is measured by the
ECM from throttle position output voltage. This should
displa y 0% at idle a nd 99 - 100% at full throttle .
10 Calculated Air Flow g/s3.5 -4.508.0 - 10.0 This displays calculated air mount from MAP sensor
output. This data is changing by inlet manifold pressure .
11 Air Fuel Ratio14.6:114.6:1 This displays the ECM commanded value. In closed loop,
this should normally be displayed around 14.2:1 - 14.7:1.
12 Spark Advance °CA8 - 1525 - 32 This displays the amount of spark advance being
commanded by the ECM.
13 Engine Load %2 - 55 - 10 This displays is calculated by the ECM form engine
speed and MAF sensor reading. Engine load should
incre ase with an incre ase in engine spe ed or air flo w
amount.
14 Injection Pulse Width ms1.0 - 3.0 3.0 - 4.0 This displays the amount of time the ECM is
commanding each injector On during each engine cycle.
A lo nger injecto r pulse width will ca use more fuel to be
delivered. Injector pulse width should increase with
increased engine load.
15 Fuel System Status Open Loop/
Close LoopClo se Loo pClose Loop 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
o utput) are me t, the syste m e nte rs “Closed Lo op”
o pera tio n. In “Close d Lo o p”, the ECM ca lculate s the air
fuel ratio based on the signal from the oxygen sensors.
16 Knock Present Yes/NoNoNo This displays knock sensor detection status. When
engine knock is occurred, displays "Yes".
17 Knock Counter-- This displays the number of knock during a ignition cycle.
18 Kno ck Reta rd °CA00 This displa ys the commande d ignitio n spa rk timing re tard
timing based on the signal from the knock sensor.
19 A/C Clutch Re la y On/OffOffOff This display s whe the r the ECM has co mma nde d the A/C
co mpre ssor clutch “On” or “Off”.
Page 2651 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–75
17 Fuel Trim Ce ll15 - 201 - 2 This displays dependent on engine speed and calculated
intake air flow reading. A plot of engine speed versus
inta ke a ir flo w a mo unt is div ide d into the ce lls. Fuel trim
ce ll indica te s w hich cell is currently a ctiv e.
18B1S1 O2 Sensor
(Bank1 Sensor 1)mV50 - 95050 -950 This displays the exhaust oxygen sensor output voltage.
Should fluctuate constantly within a range between
10mV (lean exhaust) and 1000mV (rich exhaust) while
operating in closed loop.
19B1 Sho rt Te rm Fuel
Trim (Bank 1)%-6 - 0-6 - 0 The short term fuel trim to a bank represents a short term
co rrection to the ba nk fue l de liv e ry by the ECM in
response to the amount of time the bank fuel control
oxygen sensor voltage spends above or below the
450mV threshold. If the oxygen sensor voltage has
ma inly rema ine d less tha n 450mV, indicating a lea n a ir/
fue l, short te rm fuel trim will incre a se into the positiv e
range above 0% and the ECM will pass fuel. If the
oxygen sensor voltage stays mainly above the threshold,
short term fuel trim will decrease below 0% into the
negative range while the ECM reduces fuel delivery to
compensate for the indicated rich condition. Under
ce rtain co nditions such a s e xte nde d idle a nd high
ambient temperatures, canister purge may cause short
term fuel trim to rea d in the ne ga tiv e ra nge during no rma l
operation. Fuel trim values at maximum authority may
indica te an ex cessiv ely rich o r lea n sy stem.
20B1 Lo ng Term Fue l
Trim (Bank 1)%-10 - 0-5 - 0 The long te rm fue l trim is deliv ere d fro m the sho rt term
fuel term values and represents a long term correction of
fuel delivery for bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
the ECM commanded air fuel ratio. A negative value
indica tes tha t the fuel syste m is rich a nd fue l de live ry is
being reduced (decreased injector pulse width). A
positive value indicates that a lean condition exists and
the ECM is compensating by add fuel (increased injector
pulse width). Be ca use lo ng term fue l trim te nds to fo llow
short term fuel trim, a value in the negative range due to
canister purge at idle should not be considered unusual.
Fuel trim values at maximum authority may indicate an
excessively rich or lean system.
21Injection Pulse Widthms3.0 - 1.03.0 - 4.0 This displays the amount of time the ECM is
co mma nding e ach injecto r On during ea ch e ngine cycle.
A longer injector pulse width will cause more fuel to be
delivered. Injector pulse width should increase with
increased engine load.
22Power EnrichmentYe s / N oNoNo The ECM provides the extra amount of fuel when it
detects a rapid increase in the throttle position and air
flo w (Po wer Enrichment). Under this co ndition the ECM
should detect a “rich condition (high oxygen sensor
voltage).
23Decelera tion Fue l
Cut o ff Active /
InactiveInactiveIna ctiveThe ECM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air
flow. When deceleration is very fast, the ECM may cut off
fue l co mple te ly. Until e na ble co nditions me et the e ngine
rev olution less tha n 1000rpm o r MAP le ss tha n 10kPa .
24Time From Start--This displays the engine time elapsed since the engine
w as sta rte d. If the engine is stoppe d, engine run time will
be rese t to 00:00:00
Tech 2 ParameterUnitsIdle2000rpmDescription
Page 2653 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–77
F4: Injector Balance Test
When the Tech 2 is operated, selected injector turns ON
or OFF.
The circuit is normal if engine vibration is changed at
selected cylinder in accordance with this operation
when engine is idling.
Press “Injector Off” key.
Then, engine speed drops and vibration occurs when
a cylinder is selected.
Press “Quit” Key.Injector Balance Test
Engine Speed 800 RPM
Desired Idle Speed 762 RPM
Engine Coolant Temperature 80
Start Up ECT 50
Intake Air Temperature 30
Start Up IAT 25
Manifold Absolute Pressure 35kPa
Injector 1 On
Page 2674 of 4264
6E–98 ENGINE DRIVEABILITY AND EMISSIONS
FUEL METERING SYSTEM CHECK
Some failures of the fuel metering system will result in
an “Engine Cranks But Will Not Run” symptom. If this
condition ex ists, refer to the Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the ECM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump.
Followings are applicable to the vehicles with
closed Loop System:
If a malfunction occurs in the fuel metering system, it
usually results in either a rich HO2S signal or a lean
HO2S signal. This condition is indicated by the HO2S
voltage, which causes the ECM to change the fuel
calculation (fuel injector pulse width) based on the
HO2S reading. Changes made to the fuel calculation
will be indicated by a change in the long term fuel trim
values which can be monitored with a Scan Tool. Ideal
long term fuel trim values are around 0%; for a lean
HO2S signal, the ECM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not ex actly the
same. If the evaporative emission canister purge is 02
status may be rich condition. 02 status indicates the
lean condition, refer to DTC P1171 for items which can
cause a lean HO2S signal.
FUEL INJECTOR COIL TEST PROCEDURE
AND FUEL INJECTOR BALANCE TEST
PROCEDURE
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
2. Relieve the fuel pressure by connecting 5-8840-
0378-0 T-Joint to the fuel pressure connection on the
fuel rail.
Caution: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge is
complete.
Place the fuel pressure gauge bleed hose in an
approved gasoline container.
With the ignition switch OFF open the valve on the
fuel pressure gauge.
3. Record the lowest voltage displayed by the DVM
after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
The voltage displayed by the DVM should be
within the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector
windings changes.Resistance OhmsVoltage Specification at
10°C-35°C (50°F-95°F)
11.8-12.6 5.7-6.6
Page 2675 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–99
An erratic voltage reading (large fluctuations in
voltage that do not stabilize) indicates an
intermittent connection within the fuel injector.
5. Injector Specifications:7. The Fuel Injector Balance Test portion of this chart
(Step 7 through Step 11) checks the mechanical (fuel
delivery) portion of the fuel injector. An engine
cooldown period of 10 minutes is necessary in order
to avoid irregular fuel pressure readings due to “Hot
Soak” fuel boiling.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
NOTE: These figures are ex amples only.Highest Acceptable Voltage
Reading Above/Below
35°C/10°C (95°F/50°F)Acceptable
Subtracted Value
9.5Volts 0.6Volt
CYLINDER
1234
1st Reading (1) 296kPa
(43psi)296kPa
(43psi)296kPa
(43psi)296kPa
(43psi)
2nd Reading (2) 205kPa
(29psi)205kPa
(29psi)196kPa
(28psi)274kPa
(39psi)
Amount of Drop
(1st Reading-2nd Reading)91kPa
(14psi)91kPa
(14psi)100kPa
(15psi)22kPa
(4psi)
Av. Drop = 166kPa/24psi
10kPa/1.5psi
= 156 - 176kPa or
22.5 - 25.5psiFaulty, Lean
(Too Little Fuel
Drop)Faulty, Lean
(Too Little Fuel
Drop)Faulty, Lean
(Too Little Fuel
Drop)Faulty, Lean
(Too Little Fuel
Drop)
Page 2676 of 4264
6E–100 ENGINE DRIVEABILITY AND EMISSIONS
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Turn the engine OFF.
NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Test
Description Number 2.
3. Connect the 5-8840-2618-0 Fuel Injector Tester to
B+ and ground, and to the 5-8840-2589-0 Injector
Adapter Cable.
4. Remove the harness connector of the Fuel
Injector and connect the 5-8840-2589-0 Injector
Adapter Cable for F/I check.
5. Set the amperage supply selector switch on the
fuel injector tester to the “Coil Test” 0.5 amp
position.
6. Connect the leads from the 5-8840-2392-0 Digital
Voltmeter (DVM) to the fuel injector tester. Refer
to the illustrations associated with the test
description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature.
Is the engine coolant temperature within the specified
values?10°C (50°F)
to
35°C (95°F) Go to Step 3Go to Step 5
3 1. Set the injector adapter cable to injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector adapter cable to the nex t injector
and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values? 5.7-6.6V Go to Step 4Go to Step 7
4 Replace the faulty fuel injector(S). Refer to Fuel
Injector.
Is the action complete?—Go to Step 7—
Page 2677 of 4264
ENGINE DRIVEABILITY AND EMISSIONS 6E–101
5 1. Set the Injector Adapter Cable to injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the Injector Adapter Cable to the nex t injector
and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value? 9.5V Go to Step 4Go to Step 6
6 1. Identify the highest voltage reading recorded
(other than those above 9.5V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted value in step 2
greater than the specified value? 0.6V Go to Step 4Go to Step 7
7Caution: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any
fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the Towel in an
approved container when the connection of the
fuel pressure gauge is complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the Scan Tool.
3. Place the bleed hose of the fuel pressure gauge
into an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading
on the fuel pressure gauge.
Is the fuel pressure within the specified values?296kPa-
376kPa
(43-55psi) Go to Step 8Go to Fuel
System
Diagnosis
8 Turn the fuel pump OFF.
Does the fuel pressure remain constant?
—Go to Step 9Go to Fuel
System
Diagnosis Step Action Value(s) Yes No
Page 2678 of 4264
6E–102 ENGINE DRIVEABILITY AND EMISSIONS
9 1. Connect the 5-8840-0378-0 Fuel Injector Tester
and 5-8840-2589-0 Injector Adapter Cable to the
fuel injector harness connector.
2. Set the amperage supply selector switch on the
fuel injector tester to the “Balance Test” 0.5-2.5
amp position.
3. Using the Scan Tool turn the fuel pump ON then
OFF in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push
to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the
first pressure reading for one fuel injector. The
result is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values.
This is the total pressure drop.
11. Divide the total pressure drop by the number of
fuel injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value?10kPa
(1.5psi) Go to Step 10Go to OBD
System Check
10 Re-test any fuel injector that does not meet the
specification. Refer to the procedure in Step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value?10kPa
(1.5psi) Go to Step 11Go to
Symptoms
11 1. Replace the faulty fuel injector(s). Refer to Fuel
Injector.
2. Disconnect the 5-8840-2589-0 Injector Adapter
Cable for F/I check and re-connect the original F/I
check connector.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No