switch ISUZU TF SERIES 2004 Workshop Manual

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–377
SURGES AND/OR CHUGS SYMPTOM
DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
time rpm
Su rge
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. 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 4Go to Visual /
physical Check
4 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel 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 or ex cessive 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.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 6
6 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 7
7 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “A/C Information Switch” in the data
display.
Does the Tech 2 indicate correct “A/C Information
Switch” status depending on A/C switch position?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 8

6E–378 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
8 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 29
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 19Go to Step 15
15 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 16
16 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 17
17 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 18Go to Step 29
18 Replace the TPS.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No

6E–384 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
8 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 9
9 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 14Go to Step 10
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 31
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 19Go to Step 15
15 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 16
16 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 17
17 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 18Go to Step 31
18 Replace the TPS.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–391
16 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 21Go to Step 17
17 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 18
18 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 19
19 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 20Go to Step 31
20 Replace the TPS.
Is the action complete?—Veri fy repai r—
21 Remove the CKP sensor from the flywheel housing
and check for the following conditions.
Objects sticking the CKP sensor.
Objects sticking the CKP sensor pulser.
If a problem is found, repair as necessary.
Was the problem found? —Verify repair Go to Step 22
22 Check the CKP sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 23
23 Substitute a known good CKP sensor and recheck.
Was the problem solved?—Go to Step 24Go to Step 25
24 Replace the CKP sensor.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–397
10 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 11
11 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 12
12 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 13Go to Step 29
13 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
14 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 19Go to Step 15
15 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 16
16 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 17
17 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 18Go to Step 30
18 Replace the TPS.
Is the action complete?—Veri fy repai r— Step Action Value(s) Yes No

6E–402 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
POOR FUEL ECONOMY SYMPTOM
DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)
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. 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 4Go to Visual /
physical Check
4 Check owner's driving habits.
Is the A/C “On” full time?
Are tires at the correct pressure?
Are ex cessively heavy loads being carried?
Is acceleration too much, too often?—Go to Step 5Go to Step 6
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete?—System OK—
6 Check for low engine coolant level.
Was a problem found? —Verify repair Go to Step 7
7 Check for incorrect or faulty engine thermostat. Refer
to Engine Cooling.
Was a problem found?—Verify repair Go to Step 8
8 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 10Go to Step 9
9 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.—Veri fy repai r—
10 Check for proper calibration of the fuel gauge.
Was a problem found? —Verify repair Go to Step 11
11 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
Was a problem found?—Verify repair Go to Step 12
12 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Neutral Switch” in the data display.
Does the Tech 2 indicate correct “Neutral Switch”
status depending on any shift positions?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 13

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–403
13 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “A/C Information Switch” in the data
display.
Does the Tech 2 indicate correct “A/C Information
Switch” status depending on A/C switch position?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 14
14 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 or ex cessive 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.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 15
15 1. Using the Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 16
16 1. Using the Tech 2, display the FT sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
If a problem is found, repair as necessary.
Was the problem found?—Go to Step 31Go to Step 17
17 1. Using the Tech 2, ignition “On” and engine “Run”.
2. Monitor the “Mass Air Flow” in the data display.
Does the Tech 2 indicate correct “Mass Air Flow”
depending on accelerator pedal operation? —Go to Step 22Go to Step 18
18 Remove the MAF & IAT sensor assembly and check
for the following conditions.
Objects blocking at the MAF sensor element.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 19
19 Check the MAF sensor harness for the following
conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 20 Step Action Value(s) Yes No

6E–404 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
20 Substitute a known good MAF & IAT sensor assembly
and recheck.
Was the problem solved?—Go to Step 21Go to Step 31
21 Replace the MAF & IAT sensor assembly.
Is the action complete?—Veri fy repai r—
22 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
Does the Tech 2 indicate correct “Pedal/Throttle
Position” from 0% to 100% and correct “Idle Switch”
status depending on accelerator pedal operation?—Go to Step 27Go to Step 23
23 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Monitor the “Pedal/Throttle Position” and “Idle
Switch” in the data display.
3. Adjust the accelerator cable or TPS within 0% to
100%.
Was the problem solved?—Verify repair Go to Step 24
24 Check the TPS harness for the following conditions.
Check for poor connector connection.
Check for misrouted harness.
Check for any accessory parts which may cause
electric interference.
If a problem is found, repair as necessary.
Was a problem found? —Verify repair Go to Step 25
25 Substitute a known good TPS and recheck.
Was the problem solved?—Go to Step 26Go to Step 31
26 Replace the TPS.
Is the action complete?—Veri fy repai r—
27 Remove the injection nozzles from the engine and
check for the following conditions.
Improper splay condition.
Operating pressure is incorrect.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
injection nozzle
and verify repair Go to Step 28 Step Action Value(s) Yes No
1st Stage 2nd Sta ge
4JA1-TCApproximatly
19.0 MpaApprox ima tly
33.5 Mpa
4JH1-TCApproximatly
19.5 MpaApprox ima tly
33.8 Mpa

EXHAUST SYSTEM 6F – 7

GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.

4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.







RTW46ELF001201

EXHAUST SYSTEM 6F – 11
INSPECTION
4JA1T(L)



Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance  at 20°C
37 ~ 44

If the resistance is not within specification, replace it.



EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure








4JA1TC/4JH1TC




RTW46ESH000301


EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance  at 20°C
14

If the resistance is not within specification, replace it.

EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.

Negative Pressure 4JH1TC

Less than 250 mmHg Not operation
More than 300 mmHg Operation

Negative Pressure 4JA1TC

Less than 100 mmHg Not operation
More than 170 mmHg Operation
Less then 180 mmHg Not operation
More than 240 mmHg Operation