air condition ISUZU TF SERIES 2004 Workshop Manual

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–407
EXCESSIVE WHITE SMOKE
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 customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Check the engine coolant consumption to verify that it
leaks to combustion chamber or ex haust through the
gasket.
Was a problem found?—Verify repair Go to Step 6
6 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 7
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8
8 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 30Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12

6E–408 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 30
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Glow Time Relay” in the data display.
Does the Tech 2 indicate correct “Glow Time Relay”
status depending on the time from engine “Run”?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 30Go to Step 15
15 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Glow Time Relay” in the data display
and then, does the supply voltage correctly supply
to the glow plug?
—Go to Step 16Repair voltage
supply circuit
and verify repair
16 Check the glow plugs for continuity.
If a problem is found, repair as necessary.
Was a problem found?
—Verify repair Go to Step 17
17 Remove the CKP sensor from the flywheel housing
and check for the following conditions.
Objects sticking the CKP sensor.
Objects sticking the CKP sensor pulser.
If a problem is found, repair as necessary.
Was the problem found? —Verify repair Go to Step 18
18 Check the CKP sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 19 Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–409
19 Substitute a known good CKP sensor and recheck.
Was the problem solved?—Go to Step 20Go to Step 21
20 Replace the CKP sensor.
Is the action complete?—Veri fy repai r—
21 1. Using the Tech 2 and ignition “On” and engine
“Run”.
2. Monitor the following parameters in the data
display.
“Desired Injection Quantity” & “Injection Quantity”
“Desired Injection Start” & “Actual Injection Start”
Are the large gap or unstable parameter displayed
between “Desired” and “Actual”?
—Go to Step 23Go to Step 22
22 Check the ex haust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 23
23 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 24
24 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 25 Step Action Value(s) Yes No
When idling or part-throttle When accelerated


HighDesi red
Low
Ti m e Actu al
High
LowDe si red
Actu al
Time

6E–410 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
25 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 26
26 Remove the injection nozzles from the engine and
check for the following conditions.
Improper splay condition.
Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
injection nozzle
and verify repair Go to Step 27 Step Action Value(s) Yes No
1st Stage 2nd Sta ge
4JA1-TCApproximatly
19.0 MpaApprox ima tly
33.5 Mpa
4JH1-TCApproximatly
19.5 MpaApprox ima tly
33.8 Mpa

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–413
EXCESSIVE BLACK SMOKE
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 customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 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 6
6 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 7
7 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8
8 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 21Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10

6E–414 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 21
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2 and ignition “On” and engine
“Run”.
2. Monitor the following parameters in the data
display.
“Desired Injection Quantity” & “Injection Quantity”
“Desired Injection Start” & “Actual Injection Start”
Are the large gap or unstable parameter displayed
between “Desired” and “Actual”?
—Go to Step 20Go to Step 15 Step Action Value(s) Yes No
When idling or part-throttle When accelerated


HighD esired
Low
Ti m e Actu al
High
LowD esired
Actual
Tim e

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–415
15 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or ex cessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 16
16 Check the ex haust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 17 Step Action Value(s) Yes No

Vacuum Pump Small Window

6E–416 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
17 Remove the injection nozzles from the engine and
check for the following conditions.
Improper splay condition.
Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
injection nozzle
and verify repair Go to Step 18
18 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
More than 20
Mpa Verify repair Go to Step 19
19 Check the inlet/ex haust valve clearance for each
valves.
Are the valve clearances within the specified value?
0.4mm at cold
(In/Ex ) Go to Step 20Adjust and
verify repair
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
Tech 2 data
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
1st Stage 2nd Sta ge
4JA1-TCApproximatly
19.0 MpaApprox ima tly
33.5 Mpa
4JH1-TCApproximatly
19.5 MpaApprox ima tly
33.8 Mpa

6A-26 ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Disconnect O
2 sensor connector.
3. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end o
f
exhaust front pipe.




RTW36FSH000201
5. Remove heat protector two fixing bolts then the
heat protector.
6. Remove a bolt on engine LH side for ai
r
conditioner (A/C) compressor bracket and loosen
two bolts for A/C compressor then move A/C
compressor to front side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust
manifold fixing nuts to the specified torque with
new nuts.
Torque: 52 N




m (5.3 kg




m/38 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N




m (6.8 kg




m/49 lb ft)
Nuts: 43 N




m (4.4 kg




m/32 lb ft)




RTW36FSH000201
4. Install the torsion bar and readjust the vehicle
height. Refer to installation and vehicle heigh
t
adjustment procedure for front suspension.
5. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
Torque : 40 N




m (4.1 kg




m/30 lb ft)
6. Reconnect O
2 sensor connector.
7. Install air cleaner duct assembly.

6A-28 ENGINE MECHANICAL (6VE1 3.5L)
Crankshaft Pulley
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner assembly.
3. Remove radiator upper fan shroud from radiator.
4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.


850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt

5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5884001330 crankshaft holder, hold crankshaf
t
pulley then remove center bolt and pulley.
Installation
1. Install crankshaft pulley using 5884001330
crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
Torque: 167 N




m (17.0 kg




m/123 lb ft)
2. Install cooling fan assembly and tighten bolts/nuts
to the specified torque.
Torque: 25 N




m (2.5 kg




m/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 N




m (1.0 kg




m/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.