Timing ISUZU TF SERIES 2004 Workshop Manual

6E–252 ENGINE DRIVEABILITY AND EMISSIONS
12 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 13
13 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 14
14 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 15
15 Check for proper ignition voltage output with a spark
tester.
Was the problem found?—Verify repair Go to Step 16
16 1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?—Verify repair Go to Step 17
17 Drain sample fuel, visual inspection.
Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspencion of alcohol contamination,
completely drain the fuel, replace by fuel from known
vehicle source.—Verify repair Go to Step 18
18 Check the ex haust system for a possible restriction:
Damaged or collapsed pipes
Internal muffler failure
Was a problem found?—Verify repair Go to Step 19
19 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Loose timing belt
Was a problem found?—Verify repair Go to Step 20
20 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 21 Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–257
14 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 15
15 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 16
16 1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?—Verify repair Go to Step 17
17 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?—Go to Step 19Go to Step 18
18 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.—Verify Repair—
19 Check for proper calibration of the fuel gauge.
Was a problem found?—Verify repair Go to Step 20
20 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Worn camshaft
Sticking or leaking valves
Valve timing
Was a problem found?—Verify repair Go to Step 21
21 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 22
22 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 23
23 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Verify Repair— Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–259
16 1. Remove ex cessive carbon buildup with a top
engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the ex haust emission test.
Does the vehicle pass the test? —System OK Go to Step 18
17 Perform the ex haust emission test.
Does the vehicle pass the test?—System OK Go to Step 18
18 Run Engine.
Check the fuel control Heated Ox ygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn’t check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may
have a white powdery coating. Silicon contamination
sends a rich ex haust signal which causes the ECM to
command and excessively lean air/fuel mix ture.
Was a problem found?—Verify repair Go to Step 19
19 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Go to Step 20Go to Step 21
20 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P1167 “Fuel
Supply System Rich During Deceleration Fuel Cut
Off”. Make any necessary repairs.
2. Perform the ex haust emission test.
Does the vehicle pass the test? —System OK Go to Step 22
21 1. Check items that can cause the engine to run
lean. Refer to Diagnostic Aids in DTC P1171 “Fuel
Supply System Lean During Power Enrichment”.
Make any necessary repairs.
2. Perform the ex haust emission test.
Does the vehicle pass the test?—System OK Go to Step 22
22 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Was a problem found?—Verify repair Go to Step 23
23 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 24 Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–263
10 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
Camshaft drive belt slipped or stripped
Was a problem found?—Verify repair Go to Step 11
11 Check leakage at exhaust system.
Check the intake and ex haust manifold for casting
flash. Refer to Engine Mechanical.
Was a problem found?—Verify repair Go to Step 12
12 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 13
13 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 14
14 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step Action Value(s) Yes No

6G-4 ENGINE LUBRICATION
Oil Pump
Oil Pump and Associated Parts
Legend
1 Oil Pump Assembly
2 Oil Pressure Switch3 Gasket
4 Sleeve



Disassembly
1. Remove crankshaft timing pulley.
2. Remove oil pan.
3. Remove oil strainer.
4. Remove oil pump assembly.
5. Remove oil pressure switch.
6. Remove gasket.
7. Remove sleeve.

ENGINE LUBRICATION 6G-5

Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found through inspection.
Body and Gears
The pump assembly must be replaced if one or more of the
conditions below is discovered during inspection:
Indentation of gear pair - Use feeler strip and straight edge.
Dimension: 0.03 mm to 0.10 mm
(0.0012 to 0.0039 in)



Oil Strainer
Check the oil strainer for cracking and scoring. If cracking and
scoring are found, the oil strainer must be replaced.




Reassembly
1. Install oil pressure switch to the oil pump.
Torque: 40 N




m (4.1 kgf




m)
2. Install the oil pump with the sleeve and the gasket.
Torque: 6 N




m (0.6 kgf




m)
3. Install oil strainer.
Torque: 8 N




m (0.8 kgf




m)
4. Install the oil pan.
Tighten the bolts:
15 N




m (1.5 kgf




m)
5. Install crankshaft timing pulley.
Tighten the bolts:
20 N




m (2.0 kgf




m)

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL:

1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading
1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes fi rst)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I
(DIESEL) I I I I I I I R I I I I I I I R I I I I * P Engine oil (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil (C24SE) Replace every 12,000km * D Engine oil (4JH1-TC) - R - R - R - R - R - R - R - R - R - R * D Engine oil (4JA1-TC) - - R - - R - - R - - R - - R - - R - - * D Engine oil (4JA1-T) RR R R RR RRRRRRRR R R R RRR * P Engine oil filter (6VE1) - R - R - R - R - R - R - R - R - R - R * P Engine oil filter (C24SE) Replace every 12,000km * D Engine oil filter (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R * D Engine oil filter (4JA1-TC) - - R - - R - - R - - R - - R - - R - - Oil leakage and contamination
(GASOLINE) - I - I - I - I - I - I - I - I - I - I
(DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage I I - I - I - I - I - I - I - I - I - I Fuel tank - - - | - - - | - - - | - - - | - - - | P O2 Sensor Replace every 160,000km P Valve clearances (6VE1) Check and adjust if noisy D Valve clearances A - - A - - - A - - - A - - - A - - - A P Spark plugs (C24SE) (for leaded
fuel use) - R - R - R - R - R - R - R - R - R - R
P Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
P Spark plugs (6VE1) Replace every 160,000km Spark plug wire | | - | - | - | - | - | - | - | - | - | Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R Fuel filter (DIESEL) - - R - - R - - R - - R - - R - - R - - Engi ne / Accessory dri ve belt
(GASOLINE) - - - - - - - - - R - - - - - - - - - R
Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (6VE1) - - - - - - - - - R - - - - - - - - - R (C24SE) - | - | - | - | - R - | - | - | - | - R Engine coolant level concentration
(DESEL) I I I I I I I I I R I I I I I I I I I R
Cooli ng sy stem for water l eakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
P Timing belt (C24SE) - - - - - - - - - - - - - - - I - - - - (Replace every 120,000km) P Timing belt (6VE1) Replace every 160,000km CLUTCH Cl utch fl ui d I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I

IMMOBILIZER SYSTEM 11A-31

Diagnostic procedure


Once the cause of DTC is repaired or gone,
engine can be operated normally, and present
DTC becomes history code.


History code is canceled by no repeat failure on 25
consequence ignition key on afterward.


History code cannot be canceled by batter
y
connector disconnected.
Clearing Diagnostic Trouble Codes
IMPORTANT:
Do not clear DTCs unless directed to do
so by the service information provided for each
diagnostic procedure. When DTCs are cleared, the
Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
Verifying Vehicle Repair
Verification of vehicle repair will be more
comprehensive for vehicles with immobilizer system
diagnostic. Following a repair, the technician should
perform the following steps:
1.
Review and record the Fail Records for the DTC
which has been diagnosed.
2.
Clear DTC(s).
3.
Operate the vehicle within conditions noted in the
Fail Records.
4.
Monitor the DTC status information for the DTC
which has been diagnosed until the diagnostic test
associated with that DTC runs.
Following these steps are very important in verifying
repairs on immobilizer systems. Failure to follow these
steps could result in unnecessary repairs.
Diagnostic Aids
Check the condition for system parts.



Installation condition, poor connection, damage,
system parts malfunction. Harness, Fuse, Relay,
Immobilizer coil (antenna), Key, Meter, Immobilize
r
control unit (ICU), Engine control module (ECM).
NOE: Breakage of immobilizer fuse does not operate
immobilizer system. Check engine lamp flashes at this
time.

Check the Electro-Magnetic Interference (EMI)



Location of vehicle check

Move the vehicle to a new location and perform
the check again.


Non-OEM Parts.

Switch is "OFF" or remove the Non-OEM parts and
perform the check again.


Other

Remove the accessory and another key from key.

Check the other items.



Battery voltage is low.


Immobilizer programming functions.

Must be programmed immobilizer system.


Registration for security code, immobilizer control
unit parts number.


Key switch operation.

Immobilizer system may detect a history DTC b
y
the timing of ON-OFF of a key switch.


Active the immobilizer system.


Keyless entry system is malfunction.


Anti theft system is malfunction.

Check the operation

Check the operation "Lock / unlock" by using transmitte
r
(key) on the vehicle.

TRANSFER CONTROL SYSTEM 7D1-13
2H to 4H retrial

Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
warning
light 4WD
switch Actuator
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummyRemarks
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----
4H start
of
operation Off Off Off Off 4H
position
for 0.1
second 1,0,1,0 Open Open Open -----
Start of
operation Blinking
(2HZ) Off Off Off No
operation1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
while
driving
During
operation
(Synchro)
(Go to 4H
if synchro
complete) Blinking
(2HZ) Off Off Off No
operation1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1 Open Open Open 2H to 4H
using
synchro
and retrial
X 2
Abandon
ed
operation
(2H) Blinking
(4HZ) Off Off Off No
operation1,0,1,0 Open Open Open Return to
2H
2H
indication
after
10second
s
Off Off Off Off No
operation1,0,1,0 Open Open Open -----

 Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.

7D1-16 TRANSFER CONTROL SYSTEM
Item 4WD
lamp 4L lampNeutral
lamp Check
4WD
lamp 4WD
switch Actuator
detectio
n (limit)
switches
LS1,
LS2,
LS3. and
LS4
1 = on
2 = off Transfer
4WD
switch Transfer
neutral
switch SOF
actuator
switch
Or
Axle
dummy Remarks
2H start of
operation On On Off Off 2H
position
for 0.1
second 1,1,0,1 Closed Open Closed Switch
operation
sensor
During
operation Blinking
(2HZ) Blinking
(2HZ) Off Off No
operation1,1,0,1 Closed Open Closed 4L to 4H
while
driving
During
operation
(Passing
through
N) On Blinking
(2HZ) Off Off No
operation1,1,0,0 Closed Closed Closed 4L to 4H
through
neutral
During
operation
(Passing
through
N) Off Blinking
(2HZ) Off Off No
operation0,1,0,0 Closed Closed Closed 4L to 4H
through
neutral
During
operation
(4H
waiting) Off Blinking
(2HZ) Off Off No
operation0,0,1,1 Closed Closed Closed 4L to 4H
while
waiting
During
operation
(Axle) Off while
waiting for
start of H
shift Blinking
(2HZ)
while
waiting for
start of H
shift Off Off No
operation0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed 2H to 4H
while
driving
During
operation
(Axle) Blinking
(2HZ) at
end of H
shift Off at end
of H shiftOff Off No
operation0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0 Closed Open Closed Axle
driving
Axle
waiting
Blinking
(2HZ) Off Off Off No
operation1,0,1,0 Open Open Closed -----
2H Off Off Off Off No
operation1,0,1,0 Open Open Open -----


Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.