brake ISUZU TF SERIES 2004 Workshop Manual

6E–298 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1120 (Sy mptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake Switch Error
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 P1120 (Symptom Code D) 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 P1120 (Symptom Code D) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Visually check the TPS.
Check for the following conditions.
Accelerator pedal sticking.
If a problem is found, repair as necessary.
Was the problem found? —Verify repair Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
Does the Tech 2 indicate correct “Throttle Position”
from 0% to 100% depending on accelerator pedal
operation?—Go to Step 7Go to Step 6
6 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Throttle Position” in the data display.
3. Adjust the TPS within 0% to 100%.
Was the problem solved?—Verify repair Go to Step 11
7 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Brake Switch 1” and “Brake Switch 2”
in the data display.
Does the Tech 2 indicate “Inactive” when the brake
pedal was not stepped on?—Go to Step 13Go to Step 8
8 Adjust the brake switch.
Was the problem solved?—Verify repair Go to Step 9
9 Substitute a known good brake switch and recheck.
Was the problem solved?—Go to Step 10Go to Step 13
10 Replace the brake switch.
Is the action complete?—Verify repair—
11 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 12Go to Step 13
12 Replace the TPS.
Is the action complete?—Verify repair—

ENGINE MECHANICAL (6VE1 3.5L) 6A-11
Symptom Possible Cause Action
Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too
low or wrong engine oil Change or replenish
Resistance in exhaust system
increased Clean exhaust system or replace
defective parts
Throttle Position Sensor adjustment
incorrect Replace with Throttle Valve ASM
Throttle Position Sensor circuit open
or shorted Correct or replace
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82
C (180
F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too
high Correct level of engine oil
EGR valve defective Replace

6A-18 ENGINE MECHANICAL (6VE1 3.5L)
Fuel Consumption Excessive
Symptom Possible Cause Action
Trouble in fuel system Mixture too rich or too lean due to
trouble in fuel injection system Refer to “Abnormal Combustion"
Fuel cut function does not work Refer to “Abnormal Combustion"
Trouble in ignition system Misfiring or abnormal combustion due
to trouble in ignition system Refer to “Hard Start" or “Abnormal
Combustion"
Others Engine idle speed too high Reset to Section 6E
Returning of accelerator control
sluggish Correct
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear
incorrect Caution operator of incorrect gear
selection
Lubrication Problems
Symptom Possible Cause Action
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting rod
bearing worn Replace
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or
cylinder body clogged Clean or correct

6D1-4 ENGINE ELECTRICAL (6VE1 3.5L)
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the “PARK"
position.
If the vehicle is equipped with a manual
transmission, place the shift lever in the
“ NEUTRAL" position.
Turn “OFF" the ignition.
Turn “OFF" all lights and any other accessory
requiring electrical power.
2. Look at the built –in hydrometer.
If the indication area of the built –in hydrometer is
completely clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other. This
will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm
(18 in.) from the battery of the vehicle whose battery
is being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned “OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.


Battery Removal

P1010001

1. Remove negative cable.
2. Remove positive cable (2).
3. Remove retainer screw and rods.
4. Remove retainer.
5. Remove battery.
Battery Installation
1. Install battery.
2. Install retainer.
3. Install retainer screw and rods.
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable.
5. Install negative cable.

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-334 3.5L 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
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
1. Using a Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the specified value or wire.
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
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 7
7
1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?
- Verify repair Go to Step 8
8
Check the CKP sensor signal or installation condition.
Refer to DTC P0336 "Crankshaft Position Sensor
Circuit Range/Performance" and DTC P0337
"Crankshaft Position Sensor Circuit No Signal".
Was a problem found?
- Verify repair Go to Step 9
9
Check for proper ignition voltage output with a spark
tester.
Was the problem found?
- Verify repair Go to Step 10

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-337
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM
DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed
may vary in RPM. Either condition may be severe
enough to stall the engine.





X

time rpm
Rough Idle
Stall



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
1. Check for incorrect idle speed. Ensure that the
following conditions are present.

Engine fully warm.

Accessories are OFF. 2. Using a Tech 2, monitor
IAC position.
Is the IAC position within the specified values?
10 - 20 StepsGo to Step 6 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 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 6
6
1. Using a Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the specified value or wire.
Was the problem found?
- Verify repair Go to Step 7

6E-350 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
9
1. Using the Tech 2, ignition "On" and engine "Off".
2. Monitor the "Throttle Position" in the data display.
Does the Tech 2 indicate correct "Throttle Position"
from 0% to 100% depending on accelerator pedal
operation?
- Go to Step 11 Go to Step 10
10
1. Using the Tech 2, ignition "On" and engine "Off".
2. Monitor the "Throttle Position" in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Is the action complete?
- Verify repair -
11
Check for the following conditions.

Objects blocking the throttle valve.

Vacuum leaking at throttle body.
If a problem is found, repair as necessary.
Was the problem found? - Verify repair Go to Step 12
12
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 13
13
Perform the Injector Coil/Balance Test.
Refer to 6E-106 page
Was a problem found.
- Verify repair Go to Step 14
14
1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly.
Was a problem found?
- Verify repair Go to Step 15
15
Check for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 16
16
1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?
- Verify repair Go to Step 17

6-8 ENGINE DIAGNOSIS (C24SE)
Condition Possible cause Correction
Engine overheating Level of Engine Coolant too low Replenish
Thermo switch or fan motor
defective Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filter cap defective Replace
Level of oil in engine crankcase
too low or wrong oil in engine Change or replenish
Resistance in exhaust system
increased Clean exhaust system or replace
defective parts
Throttle Position Sensor
adjustment incorrect Adjust Wide Open Throttle switch
setting
Throttle Position Sensor circuit
open or shorted Correct or replace
Cylinder head gasket damaged Replace
Cooling Fan clutch defective Replace
Fan belt slipping Adjust tension of V-belt or replace
V-belt
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 92
C (197.6
F))
Engine lacks compression - Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommend pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase
too high Correct level of engine oil

Engine Noisy
Abnormal engine noise often consists of various
noises originating in rotating parts, sliding parts and
other moving parts of the engine. It is, therefore,
advisable to locate the source of noise systematically.

Condition Possible cause Correction
Noise from crank journals or from
crank bearings
(Faulty crank journals and crank
bearings usually make dull noise
that becomes more evident when
accelerating) Oil clearance increased due to
worn crank journals or crank
bearings Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crankshaft out of round Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crank bearing seized Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing

ENGINE DIAGNOSIS (C24SE) 6-13
Fuel Consumption Excessive
Condition Possible cause Correction
Trouble in fuel system Mixture too rich or too lean due to
trouble in fuel injection system Refer to "Abnormal Combustion"
Fuel cut function does not act Refer to "Abnormal Combustion"
Trouble in ignition system Misfiring or abnormal combustion
due to trouble in ignition system Refer to Hard Start or Abnormal
Combustion Troubleshooting
Guide
Others Engine idle speed too high Reset Idle Air Control Valve
Returning of accelerator control
sluggish Correct
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear
incorrect Caution operator of incorrect gear
selection
Oil Problems
Condition Possible cause Correction
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting
rod bearing worn Replace
Oil contamination Wrong oil in use Replace with new engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
rebore cylinders
Oil not reaching valve system Oil passage in cylinder head or
cylinder body clogged Clean or correct

Engine Oil Pressure Check
1. Check for dirt, gasoline or water in the engine
oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the "Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the
"ADD" and the "FULL" marks on the oil level
dipstick.
If the oil level does not reach the "ADD" mark on
the oil level dipstick, engine oil must be added. 3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
normal operating temperature (About 80
C).
6. Measure the oil pressure.
Oil pressure should be:
150 kPa(21.8 psi) at idle speed.
7. Stop the engine.
8. Remove the oil pressure gauge
9. Install the oil pressure unit.
10. Start the engine and check for leaks.