Timing ISUZU TF SERIES 2004 Owner's Manual

6A – 114 ENGINE MECHANICAL








23. Injection Pump
1. Install the O-ring (1) to the injection pump flange (2).
2. Attach the noise insulator rubber to the cylinder body .
3. Install the injection pump to the timing gear case.Align
the idler gear "B" (3) mark with the injection pump timing
gear (4) mark.












RTW36AMH000101



























4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.

Injection Pump Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)

5. Install the injection pump bracket (6) and the bracke
t
bolts (7) and (8) to the cylinder body.
Temporarily tighten the bracket bolts.
6. Tighten the bracket bolts (7) to the specified torque.
7. Tighten the bracket bolt (8) to the specified torque.
NOTE:
Tighten the bracket bolt (7) first.

Injection Pump Bracket Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




020RY00039

ENGINE MECHANICAL 6A – 115



RTW46ASH002201




















4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracke
t
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.


Injection pump Bracket Bolt Torque (6) N·m(kg·m/lbft)
19 (1.9/14)

Injection pump Bracket Bolt Torque (5) N·m(kg·m/lbft)
40 (4.1/30)



030RY00007














24. Water Pump
1. Apply the recommended liquid gasket or its equivalent
to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.


Water Pump Bolt Torque N·m(kg·m/lbft)
20 (2.0/14)













25.Timing Gear Case Cover
1.
Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.


Gear Case Cover Bolt Torque N·m(kg·m/lbft)
M8 19 (1.9/14)
M12 76 (7.7/56)

























26. Crankshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.


Crankshaft Damper Pulley Bolt Torque N·m(kg·m/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.


014R100014 020R300004

6A – 138 ENGINE MECHANICAL

Illustration Tool Number Tool Name
5-8840-2040-0 (4JA1L/TC)
5-8840-2313-0 (4JH1TC) Cylinder Liner Installer
5-8840-2038-0 Bearing Replacer; Camshaft
5-8840-2000-0 Pilot Bearing Remover
5-8522-0024-0 Pilot Bearing Installer
5-8840-2033-0 Oil Seal Installer
5-8840-9018-0 Piston Ring Compressor
5-8840-2359-0 Oil Seal Installer
9-8522-0020-0 Crankshaft Timing Gear Installer
5-8840-0266-0 Angle Gauge
5-8840-0214-0 Gear Stopper
5-8840-2039-0 (4JA1L/TC)
5-8840-2304-0 (4JH1TC) Cylinder Liner Remover

6C – 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW


RTW46CM F000201


The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.

FUEL SYSTEM 6C – 7
INJECTION PUMP


RTW46CLF000201

4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.

4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.

FUEL SYSTEM 6C – 21


020L200017


RTW46CSH000201
18. Timing Check Hole Cover
1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the
timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.


6C-7
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear “B” fixing hole to prevent the scissors gear from
turning.


29. Injection Pump Bracket
20. Injection Pump

6C – 22 FUEL SYSTEM


RTW46CSH000201
Installation


1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut N
m (kg
m/lb ft)
64 (6.5 / 47)
2) Bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.


020L200017






3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump
gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 
30) from the idle gear “B”.

6C-7




6) Tighten the injection pump fixing bolts to the specified
torque.
Injection Pump Bolts Torque N·m (kg·m/lb ft)
19 (1.9 / 14)

FUEL SYSTEM 6C – 23



4JA1T (L)
RTW46CSH000101





4JA1TC/4JH1TC
RTW36AMH000101


















2. Injection Pump Bracket
1) Install the injection pump bracket (6) and the bracket
bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque N·m(kg·m / lb ft)
(8) 19 (1.9 / 14)

(7) 40 (4.1 / 30)









3. Timing Check Hole Cover
Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque N·m(kg·m / lb ft)
8 (0.8 / 69)















4. Injection Pump Cover (4JA1TC/4JH1TC only)
5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque N·m(kg·m / lb ft)
19 (1.9 / 14)

Intake Manifold Nuts Torque N·m(kg·m / lb ft)
24 (2.4 / 17)

2) Install the EGR valve to the intake manifold and EGR
pipe temporarily.
3) Tighten the nuts and bolts to the specified torque

Torque N
m (kg
m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
CONTENTS
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATION CHARTS ........................ 6E-9
4JA1-TC .................................................... 6E-10
4JH1-TC .................................................... 6E-11
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-14
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-15
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-16
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-17
GROUND POINT CHART GENERAL EXPORT
(LHD) (1/4) ............................................... 6E-18
LOCATION ................................................ 6E-34
PARTS LOCATION ................................... 6E-39
CONNECTOR LIST ................................... 6E-40
RELAY AND FUSE .................................... 6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-44
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45
ECM WIRING DIAGRAM (1/7) .................. 6E-46
ECM WIRING DIAGRAM (2/7) .................. 6E-47
ECM WIRING DIAGRAM (3/7) .................. 6E-48
ECM WIRING DIAGRAM (4/7) .................. 6E-49
ECM WIRING DIAGRAM (5/7) .................. 6E-50
ECM WIRING DIAGRAM (6/7) .................. 6E-51
ECM WIRING DIAGRAM (7/7) .................. 6E-52
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-53
GENERAL DESCRIPTION FOR ECM AND
SENSORS ............................................... 6E-64
Engine Control Module (ECM) ................... 6E-64
Pump Control Unit (PSG) & Data Ex change
Between Control Module ......................... 6E-64
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ....................... 6E-65
Throttle Position Sensor (TPS) .................. 6E-66
Crankshaft Position (CKP) Sensor ............ 6E-66
Engine Coolant Temperature (ECT) Sensor 6E-67
Vehicle Speed Sensor (VSS) .................... 6E-67
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION) ..... 6E-68
GENERAL DESCRIPTION FOR
INJECTION PUMP .................................. 6E-70Outline ....................................................... 6E-70
Cross-section View .................................... 6E-70
Low Pressure Fuel Circuit .......................... 6E-71
High Pressure Fuel Circuit ......................... 6E-72
Pump Camshaft Speed Sensor ................. 6E-72
High Pressure Solenoid Valve ................... 6E-73
Timing Control Valve (TCV) ....................... 6E-74
ISUZU Strategy Based Diagnostics .............. 6E-76
Overview .................................................... 6E-76
STRATEGY BASED DIAGNOSTICS CHART 6E-76
Diagnostic Thought Process ...................... 6E-77
1. Verify the Complaint .............................. 6E-77
2. Perform Preliminary Checks .................. 6E-77
3. Check Bulletins and Troubleshooting Hints 6E-78
4. Perform Service Manual Diagnostic Checks 6E-78
5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-78
5c. Technician Self Diagnoses .................. 6E-78
5d. Intermittent Diagnosis .......................... 6E-79
5e. Vehicle Operates as Designed ............ 6E-80
6. Re-examine the complaint ..................... 6E-81
7. Repair and Verify Fix ............................. 6E-81
GENERAL SERVICE INFORMATION ....... 6E-82
ON-BOARD DIAGNOSTIC (OBD) ............. 6E-82
TECH 2 OPERATING FLOW CART
(START UP) ............................................. 6E-86
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ................................... 6E-88
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ................................... 6E-90
MISCELLANEOUS TEST .......................... 6E-92
Plotting Snapshot Graph ............................ 6E-93
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) .......... 6E-94
Flow Chart for Snapshot Replay
(Plotting Graph) ....................................... 6E-95
SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-96
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK .................................................... 6E-105
Circuit Description ...................................... 6E-105
Diagnostic Aids .......................................... 6E-105
Test Description ......................................... 6E-105

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–3
(Symptom Code 2) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
LowInput .................................................. 6E-165
DIAGNOSTIC TROUBLE CODE (DTC) P0180
(SYMPTOM CODE B) (FLASH CODE 15)
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE ....................... 6E-168
Circuit Description ..................................... 6E-168
Diagnostic Aids .......................................... 6E-168
Diagnostic Trouble Code (DTC) P0180
(Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit
Range/Performance ................................ 6E-169
DIAGNOSTIC TROUBLE CODE (DTC) P0215
(SYMPTOM CODE A) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION ....................................... 6E-170
DIAGNOSTIC TROUBLE CODE (DTC) P0215
(SYMPTOM CODE B) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
CIRCUIT HIGH INPUT ............................ 6E-170
DIAGNOSTIC TROUBLE CODE (DTC) P0215
(SYMPTOM CODE C) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE ALWAYS
ACTIVE .................................................... 6E-170
DIAGNOSTIC TROUBLE CODE (DTC) P0215
(SYMPTOM CODE D) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION ....................................... 6E-170
Circuit Description ..................................... 6E-171
Diagnostic Aids .......................................... 6E-171
Diagnostic Trouble Code (DTC) P0215
(Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ........... 6E-171
Diagnostic Trouble Code (DTC) P0215
(Symptom Code B) (Flash Code 52) Fuel
Cutoff Solenoid Valve Circuit High Input . 6E-173
Diagnostic Trouble Code (DTC) P0215
(Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active ....... 6E-175
Diagnostic Trouble Code (DTC) P0215
(Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ........... 6E-177
DIAGNOSTIC TROUBLE CODE (DTC) P0216
(SYMPTOM CODE A) (FLASH CODE 54)
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION ....................................... 6E-178
DIAGNOSTIC TROUBLE CODE (DTC) P0216
(SYMPTOM CODE B) (FLASH CODE 54)
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION ....................................... 6E-178
Circuit Description ..................................... 6E-179
Diagnostic Aids .......................................... 6E-179Diagnostic Trouble Code (DTC) P0216
(Symptom Code A) (Flash Code 54) Injection
Timing Control Circuit Malfunction ........... 6E-180
Diagnostic Trouble Code (DTC) P0216
(Symptom Code B) (Flash Code 54) Injection
Timing Control Circuit Malfunction ........... 6E-180
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 3) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID "A" RANGE/PERFORMANCE 6E-183
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 4) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID"A" LOW ................................ 6E-183
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 4) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID "A" LOW ............................... 6E-183
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 5) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID "A" RANGE/PERFORMANCE 6E-183
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 6) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID "A" MALFUNCTION ............. 6E-183
DIAGNOSTIC TROUBLE CODE (DTC) P0243
(SYMPTOM CODE 8) (FLASH CODE 64)
TURBOCHARGER WASTEGATE
SOLENOID"A" HIGH ............................... 6E-183
Circuit description ...................................... 6E-184
Diagnostic Aids .......................................... 6E-184
Diagnostic Trouble Code (DTC) P0243
(Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid
"A" Range/Performance ........................... 6E-185
Diagnostic Trouble Code (DTC) P0243
(Symptom Code 4) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Low 6E-187
Diagnostic Trouble Code (DTC) P0243
(Symptom Code 5) (Flash Code 64)
Turbocharger Wastegate Solenoid "A"
Range/Performance ................................ 6E-190
Diagnostic Trouble Code (DTC) P0243
(Symptom Code 6) (Flash Code 64)
Turbocharger Wastegate Solenoid "A"
Malfunction .............................................. 6E-192
Diagnostic Trouble Code (DTC) P0243
(Symptom Code 8) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" High 6E-194
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE 6)
(FLASH CODE 53) INJECTION PUMP