ISUZU TF SERIES 2004 Workshop Manual

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-19
6. Secure the pulley directly in the vise between two
copper plates, and remove the nut and pulley.




066RS010
7. Remove four nuts(8) that secure the front cover
assembly and rear end cover, and an insulator(9).


066RW005

8. Use the puller to remove the rear end cover.
9. Rotor assembly




066RS012
10. Pull the rotor assembly(10) off the front cover
assembly(12) using a bench press(11).





066RW006

6D3-20 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Inspection and Repair
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500—600
sandpaper.



066RS014
2. Measure the slip ring diameter, and replace if it
exceeds the limit.


066RS015

3. Check resistance between slip rings, and replace i
f
there is no continuity.




066RS016
4. Check for continuity between slip ring and rotor
core.
In case of continuity, replace the rotor assembly.




066RS017

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-21
Stator Coil
1. Measure resistance between respective phases.
2. Measure insulation resistance between stator coil
and core with a mega–ohmmeter.
If less than standard, replace the coil.





066RS018
Brush
Measure the brush length.
If more than limit, replace the brush.
Standard: 10.mm (0.4134 in)
Limit: 8.4.mm (0.3307 in)






066RS019

Rectifier Assembly
Check for continuity across “P" and “E" in the
100W
range of multimeter.





066RW002
Change polarity, and make sure that there is continuity
in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the rectifie
r
assembly.
IC Regulator Assembly
Check for continuity across “B" and “F" in the
100W
range of multimeter.




066RS021
Change polarity, and make sure that there is continuity
in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the IC regulato
r
assembly.

6D3-22 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Reassembly
To reassemble, follow the disassembly steps in the
reverse order, noting the following points:
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in
the front cover.





066RS022
2. Install pulley on the rotor.
Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified
torque.
Torque: 111 N




m (11.3 kg




m/82 lb ft)





066RS010

Bench Test
Conduct a bench test of the generator.





066RS023
Preparation
Remove generator from the vehicle (see “Generator
removal").
1. Secure generator to the bench test equipment and
connect wires.
Terminal “IG" for energization
Terminal “L" for neutral (warning lamp)
Terminal “B" for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in
illustration.
Repair or replace the generator if its outputs are
abnormal.




B06RW001

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-23
Main Data and Specifications
General Specifications
Parts Number 102211-1740
Model ACJV74
Rated voltage 12 V
Rated output 90 A
Rotating direction (As viewed from pulled) Clockwise
Pulley effective diameter 57.5 mm (2.26 in)
Weight 5.1 kg (11 lb)

6D3-24 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
MEMO

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS


ABBREVIATION CHARTS ................................ 6E-5
COMPONENT LOCATOR ................................. 6E-6
ENGINE COMPONENT LOCATOR TABLE .. 6E-6
ECM CIRCUIT DIAGRAM ................................. 6E-10
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4). 6E-13
GROUND POINT CHART G.EXP (LHD) (2/4) .. 6E-14
GROUND POINT CHART G.EXP (LHD) (3/4) .. 6E-15
GROUND POINT CHART G.EXP (LHD) (4/4) .. 6E-16
GROUND POINT CHART G.EXP (RHD) (1/4) . 6E-17
GROUND POINT CHART G.EXP (RHD) (2/4) . 6E-18
GROUND POINT CHART G.EXP (RHD) (3/4) . 6E-19
GROUND POINT CHART G.EXP (RHD) (4/4) . 6E-20
LOCATION ........................................................ 6E-21
CABLE HARNESS & CONNECTOR
LOCATION ....................................................... 6E-22
CONNECTOR LIST ........................................... 6E-27
RELAY AND FUSE ............................................ 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-31
FUSE AND RELAY LOCATION
(LHD&RHD) ................................................... 6E-32
ECM WIRING DIAGRAM (1/10) ........................ 6E-33
ECM WIRING DIAGRAM (2/10) ........................ 6E-34
ECM WIRING DIAGRAM (3/10) ........................ 6E-35
ECM WIRING DIAGRAM (4/10) ........................ 6E-36
ECM WIRING DIAGRAM (5/10) ........................ 6E-37
ECM WIRING DIAGRAM (6/10) ........................ 6E-38
ECM WIRING DIAGRAM (7/10) ........................ 6E-39
ECM WIRING DIAGRAM (8/10) ........................ 6E-40
ECM WIRING DIAGRAM (9/10) ........................ 6E-41
ECM WIRING DIAGRAM (10/10) ...................... 6E-42
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL ......................................... 6E-43
GENERAL DESCRIPTION FOR ECM AND
SENSORS ........................................................ 6E-51

Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O
2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL ......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69

6E-2 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Visual/Physical Engine Compartment
Inspection ...................................................... 6E-74
Basic Knowledge of Tools Required............... 6E-71
Serial Data Communications .......................... 6E-71
On-Board Diagnostic (OBD) ........................... 6E-71
Comprehensive Component Monitor
Diagnostic Operation ..................................... 6E-71
The Diagnostic Executive ............................... 6E-72
Verifying Vehicle Repair ................................. 6E-73
Reading Flash Diagnostic Trouble Codes ...... 6E-73
Reading Diagnostic Trouble Codes Using
a Tech 2......................................................... 6E-73
On-Board Diagnosis (Self-Diagnosis)............. 6E-74
Diagnosis with Tech 2 .................................... 6E-75
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ............................................... 6E-79
TYPICAL SCAN DATA & DEFINITIONS
(O2 SENSOR DATA)........................................ 6E-81
MISCELLANEOUS TEST .................................. 6E-83
PLOTTING SNAPSHOT GRAPH ...................... 6E-85
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information)................ 6E-86
Flow Chart for Snapshot Replay
(Plotting Graph) ............................................. 6E-87
SNAPSHOT DISPLAY WITH TIS2000.............. 6E-88
SERVICE PROGRAMMING SYSTEM (SPS).... 6E-91
HOW TO USE BREAKER BOX ........................ 6E-94
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK ............................................................. 6E-97
NO CHECK ENGINE LAMP (MIL)..................... 6E-101
CHECK ENGINE LAMP (MIL) "ON" STEADY ... 6E-104
FUEL INJECTOR COIL TEST PROCEDURE
AND FUEL INJECTOR BALANCE
TEST PROCEDURE ......................................... 6E-106
FUEL SYSTEM ELECTRICAL TEST ................ 6E-111
FUEL SYSTEM DIAGNOSIS ............................. 6E-116
A/C SYSTEM CIRCUIT DIAGNOSIS ................ 6E-122
ECM DIAGNOSTIC TROUBLE CODES (DTC) 6E-130
MULTIPLE DTC SETS TROUBLESHOOTING
AIDS ................................................................. 6E-142
DTC P0101 (FLASH CODE 61) MASS
AIR FLOW SENSOR CIRCUIT
RANGE/PERFORMANCE ................................ 6E-146
DTC P0102 (FLASH CODE 61) MASS
AIR FLOW SENSOR CIRCUIT LOW INPUT ... 6E-149
DTC P0103 (FLASH CODE 61) MASS
AIR FLOW SENSOR CIRCUIT HIGH INPUT .. 6E-154
DTC P0112 (FLASH CODE 23) INTAKE AIR
TEMPERATURE (IAT) SENSOR LOW
INPUT ............................................................... 6E-158 DTC P0113 (FLASH CODE 23) INTAKE AIR
TEMPERATURE (IAT) SENSOR HIGH
INPUT ............................................................... 6E-163
DTC P0117 (FLASH CODE 14) ENGINE
COOLANT TEMPERATURER (ECT)
SENSOR LOW INPUT ..................................... 6E-168
DTC P0118 (FLASH CODE 14) ENGINE
COOLANT TEMPERATURER (ECT)
SENSOR HIGH INPUT..................................... 6E-173
DTC P0121 (FLASH CODE 21) THROTTLE
POSITION SENSOR (TPS) CIRCUIT
RANGE/PERFORMANCE ................................ 6E-179
DTC P0122 (FLASH CODE 21) THROTTLE
POSITION SENSOR (TPS) CIRCUIT
LOW INPUT ..................................................... 6E-183
DTC P0123 (FLASH CODE 21) THROTTLE
POSITION SENSOR (TPS) CIRCUIT
HIGH INPUT ..................................................... 6E-188
DTC P0131 (FLASH CODE 15) O2 SENSOR
CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) ....................................... 6E-193
DTC P0151 (FLASH CODE 15) O2 SENSOR
CIRCUIT LOW VOLTAGE
(BANK 2 SENSOR 1) ....................................... 6E-193
DTC P0132 (FLASH CODE 15) O2 SENSOR
CIRCUIT HIGH VOLTAGE
(BANK 1 SENSOR 1) ....................................... 6E-201
DTC P0152 (FLASH CODE 15) O2
SENSOR CIRCUIT HIGH VOLTAGE
(BANK 2 SENSOR 1) ....................................... 6E-201
DTC P0134 (FLASH CODE 15) O2 SENSOR
CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1) ....................................... 6E-207
DTC P0154 (FLASH CODE 15) O2 SENSOR
CIRCUIT NO ACTIVITY
DETECTED (BANK 2 SENSOR 1) ................... 6E-207
DTC P0171 (FLASH CODE 44) O2 SENSOR
SYSTEM TOO LEAN (BANK 1) ....................... 6E-211
DTC P0174 (FLASH CODE 44) O2 SENSOR
SYSTEM TOO LEAN (BANK 2) ....................... 6E-211
DTC P0172 (FLASH CODE 45) O2 SENSOR
SYSTEM TOO RICH (BANK 1) ........................ 6E-216
DTC P0175 (FLASH CODE 45) O2 SENSOR
SYSTEM TOO RICH (BANK 2) ........................ 6E-216
DTC P1171 (FLASH CODE 44) FUEL
SUPPLY SYSTEM LEAN DURING POWER
ENRICHMENT (TYPE A) ................................. 6E-221
DTC P1172 (FLASH CODE 44) FUEL SUPPLY
SYSTEM LEAN DURING POWER
ENRICHMENT (TYPE B) ................................. 6E-221

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-3
DTC P0201 (FLASH CODE 31) INJECTOR 1
CONTROL CIRCUIT ........................................ 6E-226
DTC P0202 (FLASH CODE 31) INJECTOR 2
CONTROL CIRCUIT ........................................ 6E-226
DTC P0203 (FLASH CODE 31) INJECTOR 3
CONTROL CIRCUIT ........................................ 6E-226
DTC P0204 (FLASH CODE 31) INJECTOR 4
CONTROL CIRCUIT ........................................ 6E-226
DTC P0205 (FLASH CODE 31) INJECTOR 5
CONTROL CIRCUIT ........................................ 6E-226
DTC P0206 (FLASH CODE 31) INJECTOR 6
CONTROL CIRCUIT ........................................ 6E-226
DTC P0336 (FLASH CODE 29) CRANKSHAFT
POSITION SENSOR CIRCUIT
RANGE/PERFORMANCE (58X) ...................... 6E-234
DTC P0337 (FLASH CODE 29) CRANKSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL
(58X) ................................................................. 6E-234
DTC P0341 (FLASH CODE 41) CAMSHAFT
POSITION SENSOR CIRCUIT
RANGE/PERFORMANCE ............................... 6E-243
DTC P0342 (FLASH CODE 41) CAMSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL .... 6E-243
DTC P0351 (FLASH CODE 42) IGNITION 1
CONTROL CIRCUIT ........................................ 6E-249
DTC P0352 (FLASH CODE 42) IGNITION 2
CONTROL CIRCUIT ........................................ 6E-249
DTC P0353 (FLASH CODE 42) IGNITION 3
CONTROL CIRCUIT ........................................ 6E-249
DTC P0354 (FLASH CODE 42) IGNITION 4
CONTROL CIRCUIT ........................................ 6E-249
DTC P0355 (FLASH CODE 42) IGNITION 5
CONTROL CIRCUIT ........................................ 6E-249
DTC P0356 (FLASH CODE 42) IGNITION 6
CONTROL CIRCUIT ........................................ 6E-249
DTC P0404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFORMANCE (OPEN VALVE)....... 6E-258
DTC P1404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFORMANCE (CLOSED VALVE) .. 6E-258
DTC P0405 (FLASH CODE 32) EGR
CIRCUIT LOW.................................................. 6E-263
DTC P0406 (FLASH CODE 32) EGR
CIRCUIT HIGH ................................................. 6E-268
DTC P0444 EVAP PURGE SOLENOID
VALVE CIRCUIT LOW VOLTAGE ................... 6E-274
DTC P0445 EVAP PURGE SOLENOID
VALVE CIRCUIT HIGH VOLTAGE .................. 6E-274
DTC P0500 (FLASH CODE 24) VEHICLE
SPEED SENSOR (VSS) CIRCUIT
RANGE/PERFORMANCE ................................ 6E-279 DTC P0562 (FLASH CODE 66) SYSTEM
VOLTAGE LOW .............................................. 6E-288
DTC P0563 (FLASH CODE 66) SYSTEM
VOLTAGE HIGH .............................................. 6E-321
DTC P0601 (FLASH CODE 51) ENGINE
CONTROL MODULE (ECM) MEMORY
CHECKSUM ..................................................... 6E-293
DTC P0602 PROGRAMMING ERROR............. 6E-295
DTC P1508 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM LOW/CLOSED ............... 6E-296
DTC P1509 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM HIGH/OPEN ................... 6E-296
DTC P1601 (FLASH CODE 65) CAN BUS
OFF .................................................................. 6E-304
DTC U2104 (FLASH CODE 67) CAN BUS
RESET COUNTER OVER-RUN ...................... 6E-310
DTC P1626 IMMOBILIZER NO SIGNAL ........... 6E-317
DTC P1631 IMMOBILIZER WRONG
SIGNAL ............................................................ 6E-323
DTC P1648 IMMOBILIZER WRONG
SECURITY CODE ENTERED .......................... 6E-325
DTC P1649 IMMOBILIZER FUNCTION NOT
PROGRAMMED ................................................ 6E-327
SYMPTOM DIAGNOSIS ................................... 6E-329
PRELIMINARY CHECKS .............................. 6E-329
VISUAL/PHYSICAL CHECK .......................... 6E-329
INTERMITTENT ............................................. 6E-329
ENGINE CRANKS BUT WILL NOT RUN ......... 6E-331
HARD START SYMPTOM ................................ 6E-334
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM ........................... 6E-337
SURGES AND/OR CHUGS SYMPTOM ........... 6E-341
HESITATION, SAG, STUMBLE SYMPTOM ..... 6E-345
CUTS OUT, MISSES SYMPTOM ..................... 6E-347
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM ....................................................... 6E-352
DETONATION/SPARK KNOCK SYMPTOM..... 6E-356
POOR FUEL ECONOMY SYMPTOM ............... 6E-359
EXCESSIVE EXHAUST EMISSIONS OR
ODORS SYMPTOM ......................................... 6E-362
DIESELING, RUN-ON SYMPTOM .................... 6E-365
BACKFIRE SYMPTOM ..................................... 6E-366
ON-VEHICLE SERVICE PROCEDURE ........... 6E-368
ENGINE CONTROL MODULE (ECM) .............. 6E-368
CRANKSHAFT POSITION (CKP) SENSOR ..... 6E-369
CAMSHAFT POSITION (CMP) SENSOR ......... 6E-369
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR .......................................................... 6E-370
MASS AIR FLOW (MAF) SENSOR & INTAKE AIR
TEMPERATURE (IAT) SENSOR ...................... 6E-370

6E-4 3.5L ENGINE DRIVEABILITY AND EMISSIONS
THROTTLE POSITION SENSOR (TPS)........... 6E-371
IDLE AIR CONTROL (IAC) VALVE ................... 6E-371
HEATED OXYGEN SENSOR (HO2S) .............. 6E-372
EVAP CANISTER PURGE VALVE
SOLENOID ....................................................... 6E-373
FUEL PRESSURE RELIEF ............................... 6E-374
FUEL RAIL ASSEMBLY .................................... 6E-374
FUEL INJECTORS ............................................ 6E-375
FUEL PRESSURE REGULATOR ..................... 6E-377
IGNITION COIL ................................................. 6E-379
SPARK PLUGS ................................................. 6E-380
SPECIAL TOOLS .............................................. 6E-382