coolant ISUZU TF SERIES 2004 Owner's Manual

6B – 10 ENGINE COOLING

WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.




Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.





031R300003
2. Water Outlet Pipe
1) Disconnect the turbocharger-cooling pipe from outlet pipe.
2) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud

5. Fan and Fan Clutch 1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.

030R300001 7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.

030R300002

ENGINE COOLING 6B – 11
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.

Cracks in the water pump body

Coolant leakage from the seal unit

Excessive radial play or abnormal noise in the fan center
when rotate by hand

Excessive thrust play in the fan center (Standard play: less
than 0.2mm)

Cracks or corrosion in the impeller





























Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque N·m(kg·m/lb ft)
20 (2.0/14)

2. Fan Drive Belt and Pulley
1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the
generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt mid-
portion to check the drive belt deflection.
Fan Drive Belt Deflection mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
030R300002


030R300001














3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque N·m(kg·m/lb in)
8(0.8/69)

4. Upper Fan Shroud

6B – 12 ENGINE COOLING



031R300003
5. Thermostat
Install the thermostat to the thermostat housing.
6. Water Outlet Pipe
1) Install the water outlet pipe with new gasket to the thermostat housing.
2) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque N ·m(kg ·m/lb ft)
19(1.9/14)

3) Connect the turbocharger-cooling pipe to outlet pipe.
7. Radiator Upper Hose
1) Connect the radiator upper hose to the water outlet pipe.
2) The knob of clamp shall be dircted to holizonal side.
3) Replenish the engine coolant.

ENGINE COOLING 6B – 13
THERMOSTAT
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.

Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.


2. Water Outlet Pipe 3) Disconnect the turbocharger-cooling pipe from outlet pipe.
4) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.

031R300003

Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.


031RY00005
Operating Test of Thermostat
1. Completely submerge the thermostat in water.
2. Heat the water. Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
C (
F)
82 (180)

4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature
C (
F)
95 (203)

Valve Lift At Fully Open Position mm (in)
9.5 (0.37)

6B – 14 ENGINE COOLING

Thermometer
 Agitating rod
 Wooden piece
















Installation
1. Thermostat
Install the thermostat to the thermostat housing.
2. Water Outlet Pipe
3) Install the water outlet pipe with new gasket to the thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque N ·m(kg ·m/lb ft)
19(1.9/14)

5) Connect the turbocharger-cooling pipe to outlet pipe.
031R300003


3. Radiator Upper Hose
1) Connect the radiator upper hose to the water outlet pipe.
2) The knob of clamp shall be directed to holizonal side.
3) Replenish the engine coolant.

ENGINE COOLING 6B – 17
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.


Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 93.3





122.7 (13.5





17.8)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.





110RS006

Valve opening vacuum kPa (psi) 1.96




4.91 (0.28




0.71)


Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.

Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all signs of scale and rust.

Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
 Leakage from the radiator
 Leakage from the coolant pump
 Leakage from the water hoses

ENGINE COOLING 6B – 19




RTW36BSH000101

8. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.

Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.


Engine coolant change
Refer to 6B-8 (Draining and Refilling Cooling System).

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

6E–2 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
On-Board Diagnostic (OBD) System Check 6E-106
NO CHECK ENGINE LAMP (MIL) ............. 6E-109
Circuit Description ..................................... 6E-109
Diagnostic Aids .......................................... 6E-109
No Check Engine Lamp (MIL) ................... 6E-110
CHECK ENGINE LAMP (MIL) “ON” STEADY 6E-112
Circuit description ...................................... 6E-112
Diagnostic Aids .......................................... 6E-112
Check Engine Lamp (MIL) On Steady ....... 6E-113
ECM Diagnostic Trouble Codes ................ 6E-114
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 9) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE B) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT LOW INPUT ............................. 6E-128
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................ 6E-128
Circuit Description ..................................... 6E-129
Diagnostic Aids .......................................... 6E-129
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit High Input ..................................... 6E-129
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 9) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit Low Input ...................................... 6E-132
Diagnostic Trouble Code (DTC) P0100
(Symptom Code B) (Flash Code 65) Mass
Air Flow (MAF) Sensor Output Circuit Low
Input ......................................................... 6E-134
Diagnostic Trouble Code (DTC) P0100 (Symptom
Code C) (Flash Code 65) Mass Air Flow (MAF)
Sensor Output Circuit High Input ............. 6E-137
DIAGNOSTIC TROUBLE CODE (DTC) P0105
(SYMPTOM CODE 1) (FLASH CODE 34)
VACUUM PRESSURE SENSOR CIRCUIT HIGH
INPUT ...................................................... 6E-140
DIAGNOSTIC TROUBLE CODE (DTC) P0105
(SYMPTOM CODE 2) (FLASH CODE 34)
VACUUM PRESSURE SENSOR CIRCUIT
LOW INPUT ............................................. 6E-140
DIAGNOSTIC TROUBLE CODE (DTC) P0105
(SYMPTOM CODE 7) (FLASH CODE 34) VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT HIGH INPUT ............. 6E-140
DIAGNOSTIC TROUBLE CODE (DTC) P0105
(SYMPTOM CODE 9) (FLASH CODE 34)
VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT .............. 6E-140
Circuit description ...................................... 6E-141
Diagnostic Aids .......................................... 6E-141
Diagnostic Trouble Code (DTC) P0105
(Symptom Code 1) (Flash Code 34) Vacuum
Pressure Sensor Circuit High Input ......... 6E-142
Diagnostic Trouble Code (DTC) P0105
(Symptom Code 2) (Flash Code 34) Vacuum
Pressure Sensor Circuit Low Input ........... 6E-145
Diagnostic Trouble Code (DTC) P0105
(Symptom Code 7) (Flash Code 34) Vacuum
Pressure Sensor Voltage Supply Circuit
High Input ................................................. 6E-148
Diagnostic Trouble Code (DTC) P0105
(Symptom Code 9) (Flash Code 34) Vacuum
Pressure Sensor Voltage Supply Circuit Low
Input .......................................................... 6E-150
DIAGNOSTIC TROUBLE CODE (DTC) P0110
(SYMPTOM CODE 1) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT) SENSOR
CIRCUIT HIGH INPUT ............................ 6E-152
DIAGNOSTIC TROUBLE CODE (DTC) P0110
(SYMPTOM CODE 2) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT) SENSOR
CIRCUIT LOW INPUT ............................. 6E-152
Circuit Description ...................................... 6E-152
Diagnostic Aids .......................................... 6E-153
Diagnostic Trouble Code (DTC) P0110
(Symptom Code 1) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit High Input 6E-153
Diagnostic Trouble Code (DTC) P0110
(Symptom Code 2) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit Low Input 6E-157
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 1) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE SENSOR
CIRCUIT HIGHINPUT ............................. 6E-160
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 2) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE SENSOR
CIRCUIT LOW INPUT ............................. 6E-160
Circuit Description ...................................... 6E-160
Diagnostic Aids .......................................... 6E-161
Diagnostic Trouble Code (DTC) P0115
(Symptom Code 1) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
HighInput ................................................. 6E-161
Diagnostic Trouble Code (DTC) P0115

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