lock ISUZU TF SERIES 2004 Workshop Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 1590 of 4264
6E –218 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
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 DTC P0380 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66) Glow Relay Circuit Voltage Low
Step Action Value(s) Yes No
1Was 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 As Stored By ECU ” in
“ F0: Diagnostic Trouble Codes ”.
Is the DTC P0380 (Symptom Code 4) stored as
“ Present Failure ”? —Go to Step 3 Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech 2, ignition “On ” and engine “Off ”.
2. Select “F1: Clear DTC Information ” in “F0:
Diagnostic Trouble Codes ” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU ” in the “F0:
Diagnostic Trouble Codes ”.
Was the DTC P0380 (Symptom Code 4) stored in this
ignition cycle? —Go to Step 4 Refer to
Diagnostic Aids and Go to Step
4
4 Check for poor/faulty connection at the glow relay or ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
— Verify repair Go to Step 5
5 Using the DVM and check the glow relay. 1. Ignition “Off ”, engine “Off ”.
2. Remove the glow relay from the relay box .
3. Check the relay coil.
Was the DVM indicated specified value?
Approx imately 105 Go to Step 6 Replace glow
relay and verify repair
94
3
4
2
1
X-5
C-57
Grow Relay
Page 1595 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–223
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, andpoor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P0381 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67)
Glow Plug Indicator Circuit Voltage Low
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0381 (Symptom Code 4) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0381 (Symptom Code 4) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “On”?—Go to Step 5Go to Step 6
5 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “Off”?—Go to Step 9Go to Step 7
6 Check the glow plug indicator lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 7
Page 1600 of 4264
6E–228 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored.
If the EGR EVRV circuit is open or short ground circuit,
DTC P0400 (Symptom Code 4) is stored.
If the EGR EVRV circuit is short to voltage circuit, DTC
P0400 (Symptom Code 8) 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.
EGR valve sticking.
Faulty intake air duct connection.
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 DTC P0400 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
32 P0400 3 ON Ex ha ust Ga s Recircula tio n
Flow Excessive Detected1. Intake air temperature is
between 15 deg.C and 100
deg.C.
2. Engine coolant tempera-
ture is betwee n 55 de g.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Baro me tric pre ssure is
betwee n 850hpa a nd
1100hpa.
4. Small amount of mass air
flo w. (Desired ma ss air flo w
- mass air flow is more than
150mg/strk)Fuel inje ctio n qua ntity is
reduced.
4 ON Ex ha ust Ga s Recircula tio n
Circuit Sho rt to Ground or
Ope n CircuitEGR EVRV circuit open or
sho rt to ground circuit.Fuel inje ctio n qua ntity is
reduced and EGR EVRV 10%
conditio ns a s substitute.
5 ON Ex ha ust Ga s Recircula tio n
Flow Insufficient Detected1. Intake air temperature is
betwee n 15de g.C and 100
deg.C.
2. Engine coolant tempera-
ture is betwee n 55 de g.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Baro me tric pre ssure is
betwee n 850hpa a nd
1100hpa.
4. Large mount of mass air
flo w. (Desire d ma ss air
flo w - mass a ir flow is
below 150 mg/strk)Fuel inje ctio n qua ntity is
reduced.
8 ON Ex ha ust Ga s Recircula tio n
Circuit Sho rt to BatteryEGR EVRV circuit sho rt to
voltage circuit.Fuel inje ctio n qua ntity is
reduced & EGR EVRV 10%
conditio ns a s substitute.
Page 1601 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E –229
Diagnostic Trouble Code (DTC) P0400 (Symptom Code 3) (Flash Code 32)
Exhaust Gas Recirculation Flow Excessive Detected
Step Action Value(s) Yes No
1Was 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 As Stored By ECU ” in
“ F0: Diagnostic Trouble Codes ”.
Is the DTC P0400 (Symptom Code 3) stored as
“ Present Failure ”? —Go to Step 3 Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech 2, ignition “On ” and engine “Off ”.
2. Select “F1: Clear DTC Information ” in “F0:
Diagnostic Trouble Codes ” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU ” in the “F0:
Diagnostic Trouble Codes ”.
Was the DTC P0400 (Symptom Code 3) stored in this
ignition cycle? —Go to Step 4 Refer to
Diagnostic Aids and Go to Step
4
4 Remove the MAF & IAT sensor assembly and check for the following conditions.
Objects blocking the air cleaner.
Objects blocking the MAF sensor.
Vacuum leaking at intake duct.
Objects blocking the turbocharger.
If a problem is found, repair as necessary.
Was the problem found? —Verify repair Go to Step 5
5 Remove the MAF & IAT sensor assembly and visually check.
Was the problem found? —Go to Step 6 Go to Step 8
6 Substitute a known good MAF & IAT sensor assembly and recheck.
Was the problem solved? —Go to Step 7 Go to Step 8
7 Replace the MAF & IAT sensor assembly. Is the action complete? —Verify repair —
8 Using the DVM and check the EGR EVRV. 1. Ignition “Off ”, engine “Off ”.
2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid coil.
Does the tester indicate standard resistance?
Approx imately 14 at 20 °CGo to Step 11 Go to Step 9
1
2
EGR EVRV
1
2
Page 1613 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–241
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
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 DTC P0500 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0500 (Symptom Code 1) (Flash Code 24)
Vehicle Speed Sensor Circuit High Input
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
24 P0500 1 ON
at next
ignitio n
cy cleVehicle Spe ed Se nsor Circuit
High InputVehicle speed is more than
200km/h.ECM uses v ehicle spe ed 5km/
h condition as substitute.
AON
at next
ignitio n
cy cleVehicle Speed Sensor Input
Signal Frequency Too HighInput signal frequency is too
high.ECM uses v ehicle spe ed 5km/
h condition as substitute.
BON
at next
ignitio n
cy cleVehicle Spe ed Se nsor Inco r-
re ct Signal1. Engine speed is more than
3200rpm (4JA1-TC) o r
3600rpm (4JH1-TC).
2. Fuel injection quantity is
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
3. Vehicle speed is below
1.5km/h.Fuel injection quantity is
re duced.
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0500 (Symptom Code 1) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0500 (Symptom Code 1) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
Page 1626 of 4264
6E–254 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
or low, DTC P0560 (Symptom Code A) will be 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 and PSG-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 “System Voltage” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35)
System Voltage Too High
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0560 (Symptom Code 1) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0560 (Symptom Code 1) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Was the battery jump start cable incorrectly
connecting?—Verify
procedure Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage? 10 - 14.5V Go to Step 6Check the
charging
system
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
Page 1633 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–261
Circuit Description
The ECM monitors the ignition switch signal on the feed
terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC
P0561 (Symptom Code B) will be 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 “Ignition Status” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0561 (Symptom Code A) (Flash Code 18)
Ignition Switch Circuit Malfunction
Diagnostic Trouble Code (DTC) P0561 (Symptom Code B) (Flash Code 18)
Ignition Switch Circuit Malfunction
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0561 (Symptom Code A) or P0561
(Symptom Code B) stored as “Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0561 (Symptom Code A) or P0561
(Symptom Code B)stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Check the “Engine fuse (10A)”.
If the fuse is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 5
Page 1641 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–269
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 DTC P0645 display on the Tech2 while moving
connectors and wiring harnesses.
Diagnostic Trouble Code (DTC) P0645 (Sy mptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0645 (Symptom Code 4) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0645 (Symptom Code 4) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Check for poor/faulty connection at the A/C
compressor relay or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
—Verify repair Go to Step 5
5 Using the DVM and check the A/C compressor relay.
1. Ignition “Off”, engine “Off”.
2. Remove the A/C compressor relay from the relay
box .
3. Check the relay coil.
Was the DVM indicated specified value?
120-150Go to Step 6Replace A/C
compressor
relay and verify
repair
C-56
X-14
A/C Compressor Relay
Page 1646 of 4264
6E–274 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM monitors the brake switch signal on the feed
terminal to the ECM. If brake switch 1 or 2 circuit with
malfunction, DTC P0703 (Symptom Code A) or P0703
(Symptom Code B) will be 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 “Brake Switch 1” and “Brake Switch 2” display on
the Tech2 while moving connectors and wiring
harness related to the sensor.
Diagnostic Trouble Code (DTC) P0703 (Symptom Code A) (Flash Code 25)
Brake Switch Circuit Malfunction
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
25 P0703 A ON Bra ke Switch Circuit
Malfunctio n1. Thro ttle po sitio n is more
tha n 0%.
2. Engine speed is more than
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM since the ignition
sw it ch w a s tur ne d o n.No fa il-sa fe fun ctio n.
B ON Bra ke Switch Circuit
Malfunctio n1. Thro ttle po sitio n is more
tha n 0%.
2. Engine speed is more than
693rpm (4JA1-TC) or 665
rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM.
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0703 (Symptom Code A) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
Page 1653 of 4264
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–281
DIAGNOSTIC TROUBLE CODE (DTC) P0704 (SYMPTOM CODE 6)
(FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM monitors the clutch switch signal on the feed
terminal to the ECM. If clutch switch circuit with
malfunction, DTC P0704 (Symptom Code 6) will be
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 “Clutch Switch” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
57 P0704 6 ON Clutch Switch Input Circuit
Malfunctio nClutch signa l do es no t change
between vehicle speed
1.5km/h and 80km/h since
ignitio n switch was tune d on. No fa il-sa fe fun ctio n.