switch ISUZU TF SERIES 2004 Workshop Manual

6A-4 ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.


Symptom Possible Cause Action
Headlights go out or dim considerably Battery run down or under charged Recharge or replace battery
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace

2. Ignition Trouble




Starting Motor Turns Over But
Engine Does Not Start Spark Test
Disconnect an ignition coil from any spark plug.
Connect the spark plug tester 5884003830, start the
engine, and check if a spark is generated in the spark
plug tester. Before starting the engine, make sure that
the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the part where insulation
of the ignition coil is broken while the engine is running.


Symptom Possible Cause Action
Spark jumps across gap Spark plug defective Clean or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or
engine Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with
module Replace
Poor connections in engine harness Correct
Engine Control Module cable
disconnected or defective Correct or replace

6C-10 ENGINE FUEL (6VE1 3.5L)
Fuel Pump Relay
General Description
In order to control the fuel pump and sender assembly
(FPAS) operation, the FPAS relay is provided. When
the starter switch is turned to “ON" position, the FPAS
relay operates the FPAS for 2 seconds.
When it is turned to “START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.

6D3-2 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter,
starter switch, starter relay, etc. These main
components are connected.
Starter
The cranking system employs a magnetic type
reduction starter in which the motor shaft is also used
as a pinion shaft. When the starter switch is turned on,
the contacts of magnetic switch are closed, and the
armature rotates. At the same time, the plunger is
attracted, and the pinion is pushed forward by the shif
t
lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so tha
t
the armature is not driven.

6D3-4 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Diagnosis

Symptom Possible Cause Action
Starter does not run Charging failure Repair charging system
Battery Failure Replace Battery
Terminal connection failure Repair or replace terminal connector
and/or wiring harness
Starter switch failure Repair or replace starter switch
Starter failure Repair or replace starter

6D3-6 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Disassembled View



065R100012
Legend (7) Housing
(1) Lead Wire (8) Over Running Clutch
(2) Through Bolt (9) Return Spring
(3) Yoke Assembly (10) Steel Ball
(4) Yoke Cover (11) Idle Pinion
(5) Brush and Brush Holder (12) Retainer
(6) Armature (13) Magnetic Switch

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-7
Disassembly
1. Remove the lead wire (1) from the magnetic switch.
2. Remove the through bolts (2).



065RY00053
Legend
(1) Lead Wire
(2) Through Bolt


3. Remove the yoke from the magnetic.
4. Remove the yoke cover.
5. Use the long nose pliers to remove the brush and
brush holder.



065RY00054





065RY00055
Legend
(1) Spring
(2) Brush


6. Remove the armature.
7. Remove the housing.
8. Remove the overrunning clutch from the housing.



065RY00056

6D3-8 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
9. Remove the return spring from the magnetic switch.



065R100014
10. Remove the steel ball from the overrunning clutch.



065RY00058

11.Remove the idle pinion from the magnetic switch.




065R100015
12. Remove the retainer from the magnetic switch.



065R100016
13. Remove the magnetic switch.

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-11
Brush Spring
Use spring balancer to measure the spring setting force
when remove the spring from the brush.
Standard: 17.65–23.54 N (38.9–51.9 lb)
Limit: 11.77 N (25.9 lb)
Magnetic Switch
Temporarilly connect the magnetic switch between the
overrunning clutch and housing.
Perform the steps described below in 3 to 5 seconds.
1. Pull in test
Connect the ground (-) to terminal C and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal 50.




065R100017
2. Hold in test
Observe that the pinion stays when the lead wire is
disconnected from terminal C.




065R100018

3. Return test
Connect the ground (-) to terminal 50 and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal C and the pinion
pulls away when the lead wire is disconnected from
terminal 50.




065R100019
Field Coil
1. Check for continuity between the end of the field coil
and yoke body.
Replace the field coil, if there is continuity.





065RY00065

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-15
Charging System
General Description
The IC integral regulator charging system and its main
components are connected as shown in illustration.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eigh
t
diodes to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal o
f
generator.

General On–Vehicle Inspection
The operating condition of charging system is indicated
by the charge warning lamp. The warning lamp comes
on when the starter switch is turned to “ON" position.
The charging system operates normally if the lamp
goes off when the engine starts.
If the warning lamp shows abnormality or i
f
undercharged or overcharged battery condition is
suspected, perform diagnosis by checking the charging
system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
“ON" position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L" on connector side.
If lamp comes on:
Repair or replace the generator.




F06RW009

6D3-16 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using
wrench then remove drive belt (1).
3. Disconnect the wire from terminal “B" and
disconnect the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).





060RW002
Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to “ON"
and connect a voltmeter between connecto
r
terminal L (2) and ground or between terminal IG (1)
and ground.




066RW001
If voltage is not present, the line between battery
and connector is disconnected and so requires
repair.
3. Reconnect the wiring connector to the generator,
run the engine at middle speed, and turn off all
electrical devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair o
r
replace the generator.
5. Connect an ammeter to output terminal o
f
generator, and measure output current under load
by turning on the other electrical devices (eg.,
headlights). At this time, the voltage must not be
less than 13V.
Installation
1. Install generator assembly to the position to be
installed.
2. Install generator assembly and tighten the fixing
bolts to the specified torque.
Torque:
M10 bolt: 52 N




m (5.3 kg




m/38 lb ft)
M8 bolt: 25 N




m (2.5 kg




m/18 lb ft)
3. Connect wiring harness connector and direc
t
terminal “B".
4. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.
5. Reconnect battery ground cable.