air condition ISUZU TF SERIES 2004 Workshop Manual

6E-360 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Step Action Value (s) Yes No
11
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 12
12
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 13
13
Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?
- Go to Step 15 Go to Step 14
14
Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
- Verify repair -
15
Check for proper calibration of the fuel gauge.
Was a problem found?
- Verify repair Go to Step 16
16
Check for the following engine mechanical problems
(refer to Engine Mechanical):

Low compression.

Worn camshaft.

Sticking or leaking valves.

Valve timing.
Was a problem found?
- Verify repair Go to Step 17
17
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 18
18
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 19

6E-362 3.5L ENGINE DRIVEABILITY AND EMISSIONS
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM
DEFINITIONS: Vehicle fails an emission test. There is
excessive "rotten egg" smell. (Excessive odors do no
t
necessarily indicate excessive emissions.)



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
Is the customer continual accelerated On/Off in cold
condition?
- System OK Go to Step 5
5
Is the customer used lead fuel?
- Replace to
Unlead fuel Go to Step 6
6
Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found?
- Verify repair &
Go to Step 17 Go to Step 7
7
1. Check fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 8
8
Check the fuel pressure. Refer to 6E-116 page Fuel
System Pressure Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 9
9
1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 10
10
Check the injector connectors, if any of the injectors
are connected an incorrect cylinder, correct as
necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 11
11
Perform the Injector Coil/Balance Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 12
12
Check for a problem with the engine cooling system.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 13
13
Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 14

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-363
Step Action Value (s) Yes No
14
Check the EVAP purge solenoid valve operation.
Is the valve operated normally?
- Verify repair &
Go to Step 17 Verify repair &
Go to Step 15
15
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal catalytic converter failure.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 16
16
1. Remove excessive carbon buildup with a top
engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test?
- System OK Go to Step 18
17
Perform the exhaust emission test.
Does the vehicle pass the test?
- System OK Go to Step 18
18
Check the fuel control Heated Oxygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn't check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may have
a white powdery coating. Silicon contamination sends
a rich exhaust signal which causes the ECM to
command and excessively lean air/fuel mixture.
Was a problem found?
- Verify repair Go to Step 19
19
Monitor "B1S1 (Bank 1 Sensor 1) Status" and "B2S1
(Bank 2 Sensor 1) Status" on the Tech 2.
Is the "B1S1 (Bank 1 Sensor 1) Status" or "B2S1
(Bank 2 Sensor 1) Status" in the rich condition?
- Go to Step 20 Go to Step 21
20
Check items that can cause the engine to run rich.
Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
Was a problem found?
- Verify repair Go to Step 22
21
Check items that can cause the engine to run lean.
Refer to DTC P0171 "O2 Sensor System Too Lean
(Bank 1)" or DTC P0174 "O2 Sensor System Tool
Lean (Bank 2)".
Was a problem found?
- Verify repair Go to Step 22
22
Check for the following engine mechanical problems
(refer to Engine Mechanical):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft. -Sticking or leaking valves.

Valve timing. -Broken valve springs.
Was a problem found?
- Verify repair Go to Step 23

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-365
DIESELING, RUN-ON SYMPTOM
DEFINITIONS: Engine continues to run after key is
turned OFF, but runs very rough. If engine runs
smoothly, check the ignition switch and adjustment.



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 for a short between voltage circuit and the
ignition feed circuit.
Was a problem found?
- Verify repair Go to Step 5
5
Check the fuel leaking from injector. Perform the
Injector Coil/Balance Test.
Refer to 6E-106 page.
Was a problem found?
- Verify repair Go to Step 6
6
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 7
7
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 8
8
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-366 3.5L ENGINE DRIVEABILITY AND EMISSIONS
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in
the exhaust system, making a loud popping noise.



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 for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 5
5
Check the ignition coils for cracks or carbon tracking.
If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 6
6
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 7
7
Check the fuel pressure. Refer to Fuel System
Pressure Test.
Was a problem found?
- Verify repair Go to Step 8
8
Refer to 6E-116 page Fuel System Diagnosis to
determine if there is a problem with fuel delivery.
Was a problem found?
- Verify repair Go to Step 9
9
Check the CKP sensor signal, shield wire, 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 10

6G-4 ENGINE LUBRICATION (6VE1 3.5L)
Disassembly
1. Remove crankshaft timing pulley.
2. Remove crankcase with oil pan.
3. Remove oil pipe.
4. Remove oil strainer.
5. Remove oil pump assembly.
6. Remove plug.
7. Remove spring.
8. Remove relief valve.
9. Remove oil pump cover.
10. Remove driven gear.
11. Remove drive gear.
12. Remove oil seal.
13. Remove O-ring.
Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
 Check to see that the relief valve slides freely.
 The oil pump must be replaced if the relief valve
does not slide freely.
 Replace the spring and/or the oil pump assembly
(5) if the spring is damaged or badly worn.





051RS002
Body (14) and Gears (10, 11)
The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
 Badly worn or damaged driven gear (10).
 Badly worn drive gear (11) driving face.
 Badly scratched or scored body sliding face (14) o
r
driven gear (10).
 Badly worn or damaged gear teeth.
Measure the clearance between the body and the
driven gear with a feeler gauge.
Standard : 0.10 mm–0.18 mm
(0.0039 in.–0.0070 in)
Limit : 0.20mm (0.0079 in)





051RS004
 Measure the clearance between the drive gear and
driven gear with a feeler gauge.
Standard : 0.11 mm–0.24 mm
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)




051RS003

6-4 ENGINE DIAGNOSIS (C24SE)
Rough Engine Idling or Engine Stalling
Condition Possible cause Correction
Trouble in fuel injection system Idle air control valve defective Replace
Throttle shutting off incomplete Correct or replace
Throttle position sensor circuit
open or shorted Correct or replace
Fuel injector circuits open or
shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Manifold Absolute Pressure
Sensor cable disconnected or
broken Correct or replace
Manifold Absolute Pressure
Sensor defective Replace
Engine Coolant Temperature
Sensor cable disconnected or
broken Correct or replace
Engine Coolant Temperature
Sensor defective Replace
Intake Air Temperature sensor
cable disconnected or broken Correct or replace
Intake Air Temperature sensor
defective Replace
Knock Sensor (KS) circuits open
or shorted Correct or replace
KS defective Replace
KS Module circuits open or
ground Correct or replace
KS Module defective Replace
Vehicle Speed Sensor circuit open
or shorted Correct or replace
Vehicle Speed Sensor defective Replace
Trouble in emission control
system Engine Control Module defective Replace
Canister purge solenoid circuit
open Correct
Canister purge solenoid defective Replace
Evaporative Emission Canister
Purge control valve defective Replace
Trouble in ignition system Refer to Hard Start
Troubleshooting Guide
Others Engine lacks compression Refer to Hard Start
Troubleshooting Guide
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace

ENGINE DIAGNOSIS (C24SE) 6-5
Rough Engine Running
Condition Possible cause Correction
Engine misfires regularly Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose
leaking Replace
Spark plug wire incorrect Connect properly or replace
Fuel injector(s) defective Replace
Engine control module faulty Replace
Engine knocks regularly Spark plugs running too hot Install colder type spark plugs
Powertrain control module faulty Replace
Engine lacks power Spark plugs fouled Clean
Spark plug wire incorrect Connect properly or replace
Fuel injectors defective Replace
Manifold Absolute Pressure
(MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defective Correct or replace
Engine Coolant Temperature
Sensor or Engine Coolant
Temperature Sensor circuit
defective Correct or replace
Engine Control Module faulty Replace
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defective Correct or replace
Throttle Position Sensor or
Throttle Position Sensor circuit
defective Correct or replace
Knock Sensor or Knock Sensor
circuits defective Correct or replace
Knock Sensor Module or Knock
Sensor Module circuits defective Correct or replace

6-6 ENGINE DIAGNOSIS (C24SE)
Hesitation
Condition Possible cause Correction
Hesitation on acceleration Throttle Position Sensor
adjustment incorrect Replace throttle valve assembly
Throttle Position Sensor circuit
open or shorted Correct or replace
Excessive play in accelerator
linkage Adjust or replace
Manifold Absolute Pressure
(MAP) Sensor circuit open or
shorted Correct or replace
MAP Sensor defective Replace
Intake Air Temperature (IAT)
Sensor circuit open or shorted Correct or replace
Knock Sensor (KS) Circuit open or
shorted Correct or replace
KS defective Replace
KS Module circuits open or
shorted Correct or replace
KS Module defective Replace
IAT Sensor defective Replace
Hesitation at high speeds
(Fuel pressure too low) Fuel tank strainer clogged Clean or replace
Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve
leaking Replace
Hesitation at high speeds
(Fuel injector not working
normally) Power supply or ground circuit for
Multiport Fuel Injection System
shorted or open Check and correct or replace
Cable of Multiport Fuel Injection
System disconnected or defective Correct or replace
Hesitation at high speeds Engine Control Module defective Replace
Throttle Position Sensor circuit
open or shorted Correct or replace
Throttle Position Sensor defective Replace
Engine Coolant Temperature
Sensor circuit open or shorted Correct or replace
Engine Coolant Temperature
Sensor defective Replace
MAP Sensor cable open or
shorted Correct or replace
MAP Sensor defective Replace
IAT Sensor circuit open or shorted Correct or replace
IAT Sensor defective Replace
KS Circuit open or shorted Correct or replace
KS defective Replace
KS Module circuit open or shorted Correct or replace
KS Module defective Replace
Throttle valve not wide opened Check and correct or replace
Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace

ENGINE DIAGNOSIS (C24SE) 6-7
Engine Lacks Power
Condition Possible cause Correction
Trouble in fuel system Fuel Pressure Control Valve not
working normally Replace
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not
working normally Correct or replace
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuit Clean or replace
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Engine Control Module supplied
poor voltage Correct circuit
Throttle Position Sensor cable
disconnected or broken Correct or replace
Throttle Position Sensor defective Replace
Manifold Absolute Pressure
Sensor not working normally Replace
Intake Air Temperature sensor not
working normally Replace
Engine Coolant Temperature
Sensor circuit open or shorted Correct or replace
Engine Coolant Temperature
Sensor defective Replace
Engine Control Module defective Replace
Trouble in intake or exhaust
system Air Cleaner Filter clogged Replace filter element
Air duct kicked or flattened Correct or replace
Ignition failure
- Refer to Hard Start
Troubleshooting Guide
Heat range of spark plug
inadequate Install spark plugs of adequate
heat range
Electronic Ignition System with
module Replace