battery ISUZU TF SERIES 2004 Workshop Manual

6E-246 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
8
1. Ignition "On", engine "Off".
2. Disconnect the CMP sensor connector.
3. Check the circuit for open, short to ground or short
to battery voltage circuit.
Was the DVM indicated specified value?
E-62
V



Approximately
5.0V Go to Step 11 Less than 1V:
Go to Step 9
More than
specified value:
Go to Step 10
9
Repair the open, short to sensor gorund or short to
ground circuit between the ECM and CMP sensor.
Was the problem solved?
E-61(B)
E-62




- Verify repair Go to Step 15
10
Repair the short to battery voltage circuit between the
ECM and CMP sensor.
Was the problem solved?
E-61(B)
E-62




- Verify repair Go to Step 15

6E-252 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
4
Check for poor/faulty connection at the ignition coil or
ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
E-60(A)
E-61(B)
E-53/E-54/E-55/
E-56/E-57/E-58
E-73/E-74











- Verify repair Go to Step 5
5
Visually check the ignition coil for the affected cylinder.
Was the problem found?
- Go to Step 12 Go to Step 6
6
Using the DVM and check the ignition coil signal
circuit for the affected cylinder.
1. Ignition "On", engine "Off".
2. Disconnect the ignition coil connector for the
affected cylinder.
3. Check the circuit for short to battery voltage circuit.
Was the DVM indicated battery voltage?
E-53/E-54/E-55/
E-56/E-57/E-58
V




-
Repair faulty
harness and
verify repair
Go to Step 7

6E-262 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
10
Using the DVM and check the EGR valve solenoid
signal circuit.
1. Ignition "Off", engine "Off".
2. Disconnect the EGR valve connector.
3. Check the circuit for short to battery voltage circuit.
Was the DVM indicated battery voltage?
E-76
V




-
Repair faulty
harness and
verify repair
Go to Step 11
11
Substitute a known good EGR valve and recheck.
Was the problem solved?
- Go to Step 12 Go to Step 13
12
Replace the EGR valve.
Was the problem solved?
- 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.
- Verify repair -

6E-278 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
9
Using the DVM and check the purge solenoid valve
signal circuit.
1. Ignition "On", engine "Off".
2. Disconnect the purge solenoid valve connector.
3. Check the circuit for short to battery voltage circuit.
Was the DVM indicated battery voltage?
E-66
V




-
Repair faulty
harness and
verify repair
Go to Step 10
10
Substitute a known good purge solenoid valve and
recheck.
Was the problem solved?
- Go to Step 11 Go to Step 12
11
Replace the purge solenoid valve.
Was the problem solved?
- Verify repair Go to Step 12
12
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 13
13
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 -

6E-288 3.5L ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0562 (FLASH CODE 66) SYSTEM
VOLTAGE LOW

Condition For Setting The DTC and Action Taken When The DTC Sets
Flash
Code Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
66 P0562 D System Voltage Low Battery voltage is below 6V for more than 20 seconds. No fail-safe function.


CIRCUIT DESCRIPTION
The engine control module (ECM) monitors the system
voltage on the ignition feed terminals to the ECM.
A
system voltage DTC will set whenever the voltage is
above a calibrated value.

DIAGNOSTIC AIDS
If the DTC sets when an accessory is operated, check
for a poor connection or defective accessory.


Diagnostic Trouble Code (DTC) P0562 (Flash Code 66)
System Voltage Low
Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go to On Board
Diagnostic (OBD)
System Check
2
1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor By Priority" in "F0:
Diagnostic Trouble Code".
Is the DTC P0562 stored as "Present Failure"?
- Go to Step 3 Refer to
Diagnostic Aids
and Go to Step 3
3
1. Using the Tech2, ignition "On" and engine "Off".
2. Select "Clear DTC Information" with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F5: Failed
This Ignition" in "F2: DTC Information"
Was the DTC P0562 stored in this ignition cycle?
- Go to Step 4 Refer to
Diagnostic Aids
and Go to Step 4
4
1. Using the Tech 2, ignition "On" and engine "On".
2. Monitor the "Ignition Voltage" in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage?
10 – 14.5V Go to Step 6 Go to Step 5
5
Using the DVM and check the battery voltage at the
battery terminal.
Does the tester indicate enough battery voltage?
10 – 14.5V Go to Step 6 Check the
charging system,
charge or replace
the battery

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-291
DIAGNOSTIC TROUBLE CODE (DTC) P0563 (FLASH CODE 66)
SYSTEM VOLTAGE HIGH

Condition For Setting The DTC and Action Taken When The DTC Sets
Flash
Code Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
66 P0563 A System Voltage High Battery voltage is above 16V for more than 20 seconds. No fail-safe function.

CIRCUIT DESCRIPTION
The engine control module (ECM) monitors the system
voltage on the ignition feed terminals to the ECM.
A
system voltage DTC will set whenever the voltage is
above a calibrated value.
DIAGNOSTIC AIDS
If the DTC sets when an accessory is operated, check
for a poor connection or defective accessory.


Diagnostic Trouble Code (DTC) P0563 (Flash Code 66)
System Voltage High

Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go to On Board
Diagnostic
(OBD) System
Check
2
1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor By Priority" in "F0:
Diagnostic Trouble Code".
Is the DTC P0563 stored as "Present Failure"?
- Go to Step 3 Refer to
Diagnostic Aids
and Go to Step
3
3
1. Using the Tech2, ignition "On" and engine "Off".
2. Select "Clear DTC Information" with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F5: Failed This
Ignition" in "F2: DTC Information"
Was the DTC P0563 stored in this ignition cycle?
- Go to Step 4 Refer to
Diagnostic Aids
and Go to Step
4
4
1. Using the Tech 2, ignition "On" and engine "On".
2. Monitor the "Ignition Voltage" in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage?
Less than 16VGo to Step 5 Check the
charging
system and Go
to Step 5
5
Is the battery jamp start cable incorrectly connecting?
- Verify
procedure Go to Step 6
6
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 7

6E-300 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
9

Using the DVM and check the IAC Valve circuit.
Breaker box is available:
1. Ignition "Off", engine "Off".
2. Install the breaker box as type B. (ECM connection)
3. Using the Tech 2, ignition "On" and engine "Off".
4. Select the "Miscellaneous Test" and perform the
"IAC Control" in the "IAC System".
5. Operate the Tech 2 in accrodance with procedure.
Does the DVM indicate correct characteristic as
shown in the following table, when the IAC Valve is
operating step by step?
B13B14 Breaker BoxB17 B16
VVVV


Measurement Point IACV steps at 0, 20, 40,
160 IACV steps at 10, 30, 50,
150
Coil A High (Breaker Box 53 & GND) Less than 1V Battery voltage
Coil A Low (Breaker Box 56 & GND) Battery voltage Less than 1V
Coil B High (Breaker Box 54 & GND) Less than 1V Battery voltage
Coil B Low (Breaker Box 57 & GND) Battery voltage Less than 1V

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-301
Step Action Value (s) Yes No
Breaker box is not available:
1. Using the Tech 2, ignition "On" and engine "Off".
2. Select the "Miscellaneous Test" and perform the
"IAC Control" in the "IAC System".
3. Operate the Tech 2 in accordance with procedure.
Does the DVM indicate correct characteristic as
shown in the following table, when the IAC Valve is
operating step by step?
E-61(B)
VVVV









Measurement Point IACV steps at 0, 20, 40,
160 IACV steps at 10, 30, 50,
150
Coil A High (ECM E61 connector 13 & GND) Less than 1V 10 - 14.5 V
Coil A Low (ECM E61 connector 16 & GND) 10 - 14.5 V Less than 1V
Coil B High (ECM E61 connector 14 & GND) Less than 1V 10 - 14.5 V
Coil B Low (ECM E61 connector 17 & GND) 10 - 14.5 V Less than 1V
-
Go to Step 14 Fixed at less than
1V: Go to Step
10
Fixed at battery
voltage: Go to
Step 11

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-331
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The
engine never start.)
NOTE: 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.
Should Tech2 display "SPS Procedure was not
successful", engine will not start, but no DTCs are
present, low battery voltage or poor electrical
connections should be the primary
suspects.Perform the SPS procedure again after
rectifying the fault/s.
NOTE: The vehicle with immobilizer system, this
system may be activated. Check the immobilizer
system diagnosis.


Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go 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 4 Go to Visual /
physical Check
4
Check the "Meter" fuse (15A), "Engine" fuse (15A),
"IGN Coil" fuse (15A) and "Fuel Pump" fuse (20A). If
the fuse is burnt out, repair as necessary.
Was the problem found?
- Verify repair Go to Step 5
5
Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
Was a problem found?
- Verify repair Go to Step 6
6
Check the fuel quality.
Is the customer using proper fuel?
- Go to Step 7
Replace fuel
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 the IAC passage or
throttle bore, excessive 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/brake booster hose.
Was a problem found?
- Verify repair Go to Step 8

6E-368 3.5L ENGINE DRIVEABILITY AND EMISSIONS
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE (ECM)
NOTE:
To prevent possible electrostatic discharge
damage, follow these guidelines:

Do not touch the control module connector pins
or soldered components on the control module
circuit board.

Do not open the replacement part package until
the par is ready to be installed.

Before removing the part from the package,
ground the package to a known good ground on
the vehicle.

If the part has been handled while sliding across
the seat, or while sitting down from a standing
position, or while walking a distance, touch a
known good ground before installing the part.

NOTE:
To prevent internal ECM damage, the ignition must
be in the "OFF" position in order to disconnect o
r
reconnect power to the ECM (for example: battery
cable, ECM pigtail, ECM fuse, jumper cables, etc.).

NOTE:
When replacing the production ECM with a service
ECM, it is important to transfer the broadcast code
and production ECM number to the service ECM
label. This will allow positive identification of ECM
parts throughout the service life of the vehicle.

Location
On the common chamber.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the two connectors from the ECM.
3. Remove four bolts.
4. Remove the ECM from common chamber.






Installation Procedure
1. Put on the ECM on the common chamber.
2. Tighten the ECM by four bolts.
3. Connect the two connectors to the ECM.
4. Connect the negative battery cable.

NOTE:
The replacement ECM must be programmed.
Service Programming System (SPS) and
Immobilizer programming (if equipped) is
/are
necessary. In case "SPS procedure does not
succeed" or "engine does not run but No DTC afte
r
SPS", low vehicle battery voltage or disconnected
electrical connector (e.g. poor connection of data
link connector) are supposed. Perform the SPS
procedure once again by correct conditions. The
programming ECM will be recovered normally.