fuel type ISUZU TF SERIES 2004 User Guide

6E–70 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR INJECTION
PUMP
Outline
Instead of the previous face cam type, the radial plunger
distributor type injection pump utilizes a cam ring to
enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
smoke, low noise, high output and clear ex haust
emissions.
Cross-section View
(1) Drive Shaft
(2) Feed Pump
(3) Pump Camshaft Speed Sensor
(4) Pump Control Unit (PSG)
(5) Distributor Head
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve
(8) Constant Pressure Valve (CPV)
(9) Timing Control Valve (TCV)
(10) Timer
(11) Radial Plunger High Pressure Pump
(1) Drive Shaft
(2) Feed Pump
(3) Pump Camshaft Speed Sensor
(4) Pump Control Unit (PSG)
(5) Distributor Head
(6) Constant Pressure Valve (CPV) Holder
(7) High Pressure Solenoid Valve
(8) Constant Pressure Valve (CPV)
(9) Timing Control Valve (TCV)
(10) Timer
(11) Radial Plunger High Pressure Pump

6E –174 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) 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. Check the circuit for short to voltage circuit.
Was the DVM indicated specified value?
Breaker box is not available: 1. Check the circuit for short to voltage circuit.
Was the DVM indicated specified value?
Less than 1V Go to Step 8Go to Step 7
7 Repair the short to voltage circuit between the ECM and PSG (pump control unit).
Was the problem solved?
— Verify repair Go to Step 8
8 Replace the injection pump assembly. Is the action complete? —Verify repair —
Step Action Value(s) Yes No
105Breaker Box
V
V
105
C-57
105
5
E-6
C-57

6E –176 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6 Using the DVM and check the MAB (fuel cutoff
solenoid valve) circuit.
Breaker box is available:
1. Ignition “Off ”, engine “Off ”.
2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103
3. Disconnect the PSG (pump control unit) connector.
4. Check the circuit for open or short to ground circuit.
Was the problem found?
Breaker box is not available: 1. Ignition “Off ”, engine “Off ”.
2. Disconnect the PSG (pump control unit) connector.
3. Check the circuit for open or short to ground circuit.
Was the problem found?
— Repair faulty
harness and verify repair Go to Step 7
7 Replace the injection pump assembly. Is the action complete? —Verify repair —
Step Action Value(s) Yes No
E-6105Breaker Box




5105
E-6
C-57

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–181
5 V i s u a l l y / p h y s i c a l l y i n s p e c t f o r t h e f o l l o w i n g c o n d i t i o n s .
Restrict fuel supply system. Check for a pinched
fuel ho se /pi pe.
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
f u e l.
If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 6
6 Replace the fuel fi lt er.
Was the problem solved? - Verify repair Go to Step 7
7 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
f u e l.
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 8
8 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 9
9 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Go to Step 10Go to Step 11 Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–209
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The CKP sensor is located on top of the flywheel
housing of the flywheel and fix ed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel ex citer ring and is
used to determine the engine speed and engine
cylinder top dead center.
If the CKP sensor harness or sensor malfunction is
detected during engine run, DTC P0335 (Symptom
Code B) is stored.
If the CKP sensor harness or sensor malfunction is
detected during engine cranking, DTC P0335
(Symptom Code D) is stored.
If the CKP sensor signal frequency is ex cessively high
or engine over-running, DTC P0335 (Symptom Code E)
is stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the “Engine Speed” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0335 (Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit Malfunction
Diagnostic Trouble Code (DTC) P0335 (Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
43 P0335 B ON Crankshaft Position Sensor
Circuit Ma lfunction1. Engine speed is more than
665rpm.
2. CKP sensor pulse width
e rro r.When pump camshaft speed
senso r is OK:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
When pump camshaft speed
senso r is not OK:
1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
D ON Crankshaft Position Sensor
Circuit Ma lfunction1. No pump camshaft speed
se nsor erro r.
2.“Cranksha ft Position Se n-
so r Circuit Ma lfunction
(Symptom Code B)” is not
stored.
3. Engine speed is 0rpm.
4. Do uble d pump camsha ft
speed is more than 50rpm.When pump camshaft speed
senso r is OK:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
Other tha n pump camsha ft
speed sensor is OK:
Fuel inje ctio n qua ntity is
reduced.
E ON Engine Speed Input Circuit
Range/PerformanceEngine spe ed is more tha n
5700rpm.When intermittent malfunction:
1. MAB (fuel cutoff solenoid
valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
When preliminary malfunction:
ECM use s do uble d pump cam-
sha ft spe ed as substitute
engine speed.
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

6E–306 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P1335 (SYMPTOM CODE A)
(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The CKP sensor is located on top of the flywheel
housing of the flywheel and fix ed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel ex citer ring and is
used to determine the engine speed and engine
cylinder top dead center.
The ECM converts sine wave signal to square wave
signal. And this signal is provided from the ECM to
pump control unit (PSG).
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
43 P1335 A ON Engine Speed Output Circuit
Malfunctio nThe PSG (pump control unit)
is recognized defective
engine speed signal form the
ECM.Fuel inje ctio n qua ntity is
reduced.

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–363
10 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 11
11 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 12
12 Substitute a known good CKP sensor and recheck.
Was the problem solved?—Go to Step 13Go to Step 14
13 Replace the CKP sensor.
Is the action complete?—Veri fy repai r—
14 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 16
15 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 17
16 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 18 Step Action Value(s) Yes No

6E–364 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
17 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 18
18 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
More than 2.1
Mpa (21.0 kg/
cm
2) Verify repair Go to Step 19
19 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
—Go to Step 20Repair as
necessary Step Action Value(s) Yes No

6E–366 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
HARD START SYMPTOM
DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.
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 6
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 . C h e c k t h e d i s p l a y e d v a l u e .
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 20Go to Step 9
9 1. Using the Tech 2, ignition “On”.
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 ignition switch
“On”?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 20Go to Step 10