power ISUZU TF SERIES 2004 Workshop Manual

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–85
DIAGNOSIS WITH Tech 2
If no codes are set:
Refer to F1: Data Display and identify the electrical
faults that are not indicated by trouble code.
Refer to “SYMPTOM DIAGNOSIS”.
If codes are set:
1. Record all trouble codes displayed by Tech 2 and
check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty
status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is
intermittent. In this case, refer to “DIAGNOSIS
AIDS”.
6. If a code is present, refer to DTC Chart for
diagnosis.
7. Check trouble codes again using the Tech 2.
Tech 2 CONNECTION
Tech 2 scan tool is used to electrically diagnose the
automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Te c h 2 .
1. Configuration of Tech 2
Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
Check the key switch is turn OFF.
Insert the PCMCIA card (1) into the Tech 2 (5).Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
Connect the DLC cable (4) to the Tech 2 (5).
Connect the SAE 16/19 adapter (3) to the data
link connector of the vehicle.
Turn the key switch of the vehicle ON and press
the “PWR” key of the Tech 2.
Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.

6E–86 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
TECH 2 OPERATING FLOW CART (START UP)
Select “4JA1-TC Bosch” or “4JH1-TC Bosch” in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.
Press (ENTER) to Co ntinue
Main Menu
F0: Dia gnostic
F1: Se rvice Programming Syste m (SPS)
F2: View Capture Data
F3: Too l Optio n
F4: Do wnlo a d/ Uploa d He lp
Press “ENTER” key.
Ve hi cl e Ide nt ifi ca ti o n
(3) 2003
(2) 2002
(1) 2001
(Y) 2000
(X) 1999
(W) 1998
Select “F0: Diagnostic”.
Select “(3) 2003”or later.
System Selection Menu
F0: Powe rtra in
F1: Chassis
F3: Body
Select “(TF/UC)”.
Vehicle Identification
4JH1-TC Bosch
4JA1-TC Bosch
4JH1-T Denso
3.5L V6 6VE1 Hita chi
AW30-40LE
A/T JR405E
Select “F0: Powertrain”.
Select “4JA1-TC Bosch” or “4JH1-TC Bosch”.
Vehicle Identification
(UB) Troo pe r, Bigho rn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Fro ntier, LAO-Ro de o
(TBR)
(N*) ELF, NPR, NQR

6E–92 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
mechanical trouble and an electrical trouble.
Connect Tech 2 and select "Powertrain", "4JA1-TC
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
F0: Lamps
F0: Glow Time Telltale Test
When the Tech 2 is operated, "Glow Time Indicator
Lamp" is turned on or off.
The circuit is correct if the "Glow Time Indicator Lamp"
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
Press "Active" key.
Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is correct if engine speed is changed in
accordance with this operation.
Press "Increase" key.
Then, Desired Idle speed is increases
50rpm-by-50rpm up to 1200rpm. Engine speed is
also
EGR Solenoid Test
Desired Mass Air Flow 470 mg/strk
Mass Air Flow 450 mg/strk
Engine Speed 700 rpm
Exhaust Gas Recirculation 95%
Engine Speed (RPM) Control
Engine Speed 850 rpm
Desired Idle Speed 850 rpm
Injection Quantity 7.5 mg/ strk

6E–100 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by
turning on the power of Tech-2, push the “Enter”
switch.
2. Turn on the ignition switch (without starting the
engine)
3. In the main menu of Diagnostic Tester, push “F1:
Service Programming System (SPS)”.
4. Push “F0: Request Info” of Tech-2.5. Where vehicle data has been already saved in Tech
2, the ex isting data come on display. In this
instance, as Tech-2 starts asking whether to keep
the data or to continue obtaining anew data from the
control unit, choose either of them
6. If you select “continue”, you have to select “Model
Year”, “Vehicle Type”.
7. After that. then push button and turn Ignition switch
tuned on, off, on following Tech-2 display. Tech-2
will read information from controller after this
procedure.
8. During obtaining information, Tech-2 is receiving
information from the control unit ECM and TCM (A/T
only) at the same time. With VIN not being
programmed into the new control unit at the time of
shipment, "obtaining information" is not complete
(because the vehicle model, engine model and
model year are specified from VIN). For the
procedure get additional information on vehicles,
instruction will be provided in dialog form, when
TIS2000 is in operation.
9. Following instructions by Tech-2, push the “Ex it”
switch of Tech-2, turn off the ignition of the vehicle
and turn off the power of Tech-2, thereby removing
from the vehicle.3. Data Exchange
1. Connect Tech-2 to P/C, turn on the power and click
the “Next” button of P/C.
2. Check VIN of the vehicle and choose “Next”.
3. Select “System Type” for required control unit.
Engine (Programming for ECM or PCM)
Transmission (Programming for TCM)
4. When a lack of data is asked from among the
following menu, enter accordingly.
Select following Menu
Model Year
Model
Engine type
Transmission type
Destination code (vehicles for general export)*1
Immobilizer
Etc.
* 1: How to read the destination code
Destination code can be read from ID Plate affix ed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
the figure, the destination code can be read as "RR3"
(Australia).

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–101
5. After choosing the data, click the “Nex t” button.
6. When all the necessary information is entered, the
“details” of software within the database that match
the entered data will appear for confirmation. Click
the “Program” switch and then download the new
software onto Tech-2.
7.“Data Transfer” comes on display. The progress of
downloading will be displayed on the screen in the
form of bar graph.
8. Upon finishing the data transfer, turn off the power
of Tech-2, removing from P/C.4. Programming of ECM
1. Check to see if batteries are fully charged, while
ABS connectors shall be removed from the vehicle.
2. Connect Tech-2 to Vehicle Diagnostic Connectors.
3. Turn on the power of Tech-2 and the title screen
comes on display.
4. Turn on the ignition (without allowing the engine to
start)
5. On the title screen of Tech-2, push the “Enter”
button.
6. Choose “F1: Service Programming System” on the
main screen and then choose “Fl: Program ECU”.
7. While data is being transferred, “Programming in
Progress” will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
“Reprogramming Was Successful”. Push the “Exit”
button to bring program to completion
9. Following “Procedure 2: Demand of Data”, try over
again “Information Obtaining” and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.

6E–104 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Breaker Box Connection Type B
Breaker box connection type B, check for “short to
power supply circuit” and “power, signal voltage check”
between the engine control module (ECM) and
electrical components.


(1) Engine Control Module (ECM)
(2) Harness Adapter
(3) Breaker Box(4) Digital Voltage Meter
(5) ECM - Harness Adapter Connection

6E–106 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6. The Tech2 parameters which is not within the typical
range may help to isolate the area which is causing the
problem.12. This vehicle is equipped with ECM which utilizes an
electrically erasable programmable read only memory
(EEPROM).
On-Board Diagnostic (OBD) System Check
Step Action Value(s) Yes No
11. Ignition “On”, engine “Off”.
2. Check the “CHECK ENGINE” lamp (MIL).
Does the “CHECK ENGINE” lamp turn “On”?—Go to Step 2Go to No
CHECK
ENGINE Lamp
21. Using the Tech 2, ignition “On” and engine “Off”.
2. Attempt to display “Data Display” with the Tech 2.
Does the Tech 2 display engine data? —Go to Step 3Go to Step 7
31. Using the Tech 2, ignition “On” and engine “Off”.
2. Select the “Miscellaneous Test” and perform the
“Check Light” in “Lamps”.
3. Operate the Tech 2 in accordance with the Tech 2
instructions.
Does the “CHECK ENGINE” lamp turn “Off”? —Go to Step 4Go to CHECK
ENGINE LAMP
On Steady
4Attempt to start the engine.
Does the engine start and continue to “Run”?
—Go to Step 5Go to Engine
Cranks But Will
Not Run
51. Using the Tech 2, ignition “On” and engine “Off”.
2. Select the “Read DTC Infor As Stored By ECU” in
“Diagnostic Trouble Code”.
3. Are any DTCs stored?—Go to DTC
ChartGo to Step 6
6Compare typical scan data values displayed on the
Te c h 2 “Data Display”.
Are the displayed values within the range?—Refer to
SYMPTOM
DIAGNOSISRefer to
TYPICAL
SCAN DATA
7Using the DVM and check the data link connector
power supply circuit.
1. Ignition “Off”, engine “Off”.
2. Check the circuit for open circuit.
Was the problem found?
—Repair faulty
harness and
verify repair Go to Step 8
V
B-58

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–107
8Using the DVM and check the data link connector
ground circuit.
1. Ignition “Off”, engine “Off”.
2. Check the circuit for open circuit.
Was the problem found?
—Repair faulty
harness and
verify repair Go to Step 9
9Using the DVM and check the data link connector
ground circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
Less than 1V Go to Step 10Repair faulty
harness and
verify repair
10Using the DVM and check the data link connector
communication circuit.
1. Ignition “On”, engine “Off”.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated fix ed battery voltage?
—Repair faulty
harness and
verify repair Go to Step 11 Step Action Value(s) Yes No
5 4
B-58
VV
5 4
B-58
V
6
B-58

6E–114 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONSECM Diagnostic Trouble CodesFlash
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)
65 P0100 7 ON Mass Air Flow (MAF) Sensor
Voltage Supply Circuit High
InputMAF sensor power supply
voltage is more than 5.2V.ECM uses mass air flow
1600mg/strk & EGR 10%
conditions as substitute.MAF sensor power supply
voltage is below 5.2V.1. Sensor power supply
circuit short to battery
voltage circuit.
2. MAF sensor malfunction.
3. ECM malfunction.83 —
9 ON Mass Air Flow (MAF) Sensor
Voltage Supply Circuit Low
InputMAF sensor power supply
voltage is below 4.6V.MAF sensor power supply
voltage is more than 4.6V.1. Sensor power supply
circuit short to ground
c i r c u i t .
2. MAF sensor malfunction.
3. ECM malfunction.83 —
B ON Mass Air Flow (MAF) Sensor
Output Circuit Low Input1. Engine speed is between
600rpm and 5000rpm.
2. MAF sensor output is
below -33.7mg/strk.MAF sensor output is more
than -27.4mg/strk.1. Sensor power supply
circuit open circuit.
2. Sensor signal circuit
open or short to ground
c i r c u i t .
3. Sensor heater harness
o p e n c i r c u i t .
4. Poor connector
c o n n e c t i o n .
5. MAF sensor malfunction.
6. ECM malfunction.8 3 /
88P0110(1)
C ON Mass Air Flow (MAF) Sensor
Output Circuit High Input1. Engine speed is between
600rpm and 5000rpm.
2. MAF sensor output is
more than 1378mg/strk
(4JA1-TC) or 1784mg/
strk (4JH1-TC).MAF sensor output is below
1378mg/strk (4JA1-TC) or
1784mg/strk (4JH1-TC).1. Sensor signal circuit
short to voltage circuit.
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. MAF sensor malfunction.
4. ECM malfunction.8 8 /
92P0110(1)
34 P0105 1 ON Vacuum Pressure Sensor
Circuit High InputVacuum sensor output
voltage is more than 4.4V.1. Fuel injection quantity is
r e d u c e d .
2. ECM use 615hpa
conditions for
turbocharger waste gate
control.Vacuum sensor output
voltage is below 4.4V.1. Sensor signal circuit
short to voltage circuit.
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. Vacuum sensor
m a l f u n c t i o n .
4. ECM malfunction.8 5 /
93P0115(1) —
2 ON Vacuum Pressure Sensor
Circuit Low InputVacuum sensor output
voltage is below 0.5V.Vacuum sensor output
voltage is more than 0.5V.1. Sensor power supply
circuit open circuit.
2. Sensor signal circuit
open or short to ground
c i r c u i t .
3. Poor connector
c o n n e c t i o n .
4. Vacuum sensor
m a l f u n c t i o n .
5. ECM malfunction.8 2 /
85——

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–115
34 P0105 7 ON Vacuum Pressure Sensor
Voltage Supply Circuit High
InputVacuum sensor power
supply voltage is more than
5.2V.1. Fuel injection quantity is
r e d u c e d .
2. ECM use vacuum sensor
output voltage 5.0V
condition as substitute.Vacuum sensor power
supply voltage is below 5.2V.1. Sensor power supply
circuit short to battery
voltage circuit.
2. Vacuum sensor
m a l f u n c t i o n .
3. ECM malfunction.82 — —
9 ON Vacuum Pressure Sensor
Voltage Supply Circuit Low
InputVacuum sensor power
supply voltage is below 4.5V.Vacuum sensor power
supply voltage is more than
4.5V.1. Sensor power supply
circuit short to ground
c i r c u i t .
2. Vacuum sensor
m a l f u n c t i o n .
3. ECM malfunction.82 — —
23 P0110 1 ON Intake Air Temperature (IAT)
Sensor Circuit High InputIAT sensor output voltage is
more than 4.7V.ECM use 0 deg. C conditions
as substitute.IAT sensor output voltage is
below 4.7V.1. Sensor signal circuit
open or short to voltage
c i r c u i t .
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. Poor connector
c o n n e c t i o n
4. IAT sensor malfunction.
5. ECM malfunction.8 4 /
92P0100(B)/







P0100(C)
2 ON Intake Air Temperature (IAT)
Sensor Circuit Low InputIAT sensor output voltage is
below 0.3V.IAT sensor output voltage is
more than 0.3V.1. Sensor signal circuit
short to ground circuit.
2. IAT sensor malfunction.
3. ECM malfunction.84 —
14 P0115 1 ON Engine Coolant Temperature
(ECT) Sensor Circuit High
InputECT sensor output voltage is
more than 4.7V.1. ECM uses fuel
temperature as
s u b s t i t u t e .
2. ECM uses 60 deg. C
condition for injection
t i m i n g c o n t r o l .
3. ECM uses -25 deg. C
condition (4JA1-TC) or -
15 deg. C condition
(4JH1-TC) for glow time
control.ECT sensor output voltage is
below 4.7V.1. Sensor signal circuit
open or short to voltage
c i r c u i t .
2. Sensor ground circuit
open or short to voltage
c i r c u i t .
3. Poor connector
c o n n e c t i o n
4. ECT sensor malfunction.
5. ECM malfunction.8 9 /
93P0105(1)
2 ON Engine Coolant Temperature
(ECT) Sensor Circuit Low
InputECT sensor output voltage is
below 0.3V.ECT sensor output voltage is
more than 0.3V.1. Sensor signal circuit
short to ground circuit.
2. ECT sensor malfunction.
3. ECM malfunction.89 —
15 P0180 B ON Fuel Temperature Sensor
Circuit Range/PerformanceFT sensor output is high
temperature (more than 150
deg. C) or low temperature
(below -40 deg. C).The ECM use 75 deg. C
conditions as substitute.FT sensor output is correct
temperature range between
150 deg. C and -40 deg. C.1 . E C M m a l f u n c t i o n .
2. PSG (pump control unit)
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)