fuel cap ISUZU TF SERIES 2004 Owner's Guide

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-121
Step Action Value(s) YES NO
18
1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with the Tech 2.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits? 290-376 kPa
(42-55 psi) Go to Step 19 Go to Step 20
19 Locate and correct the restriction in the fuel return
line.
Is the action complete? — Verify repair —
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found? — Verify repair Go to Step 11
21
Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22 Go to Step 23
22
1. Command the fuel pump “ON" with the Tech 2.
2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed the
second specified value.
Does the fuel pressure indicated by the fuel pressure
gauge rise above the first specified value? 376 kPa (55
psi). 414 kPa
(60 psi). Go to Step 11 Go to Step 7
23
1. Command the fuel pump “ON" with the Tech 2.
2. Remove the fuel filler cap and listen for the sound
of the fuel pump running.
3. Turn the pump off.
Was the fuel pump running? — Go to Step 7 Go to Fuel
System
Electrical Test
Chart

6E-146 3.5L ENGINE DRIVEABILITY AND EMISSIONS
CIRCUIT DESCRIPTION
The mass air flow (MAF) sensor measures the amount
of air which passes through it into the engine during a
given time. The Engine Control Module (ECM) uses the
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity
of air entering the engine indicates an acceleration o
r
high load situation, while a small quantity or air indicates
deceleration or idle.
The MAF sensor produces a frequency signal which
can be monitored using a Tech 2. The frequency will
vary within a range of around 4 to 7 g/s at idle to around
25 to 40 g/s at maximum engine load. DTC P0101 will
be set if the signal from the MAF sensor does not match
a predicted value based on throttle position and engine
RPM.
DIAGNOSTIC AIDS
An intermittent may be caused by the following:
 Poor connections.
 Mis-routed harness.
 Rubbed through wire insulation.
 Broken wire inside the insulation.
Refer to Intermittents under service category
Symptoms.
Any un-metered air may cause this DTC to set. Check
for the following:
 The duct work at the MAF sensor for leaks.
 An engine vacuum leak.
 The PCV system for vacuum leaks.
 An incorrect PCV valve.
 The engine oil dip stick not fully seated.
 The engine oil fill cap loose or missing.


Diagnostic Trouble Code (DTC) P0101 (Flash Code 61)
Mass Air Flow Sensor Circuit Range/Performance
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. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor By Priority" in "F0:
Diagnostic Trouble Code".
Is the DTC P0101 stored as "Present Failure"?
- Go to Step 3 Refer to
Diagnostic Aids
and Go to Step 3
3
1. Using the Tech2, ignition "On" and engine "Off".
2. Select "Clear DTC Information" with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F5: Failed
This Ignition" in "F2: DTC Information"
Was the DTC P0101 stored in this ignition cycle?
- Go to Step 4 Refer to
Diagnostic Aids
and Go to Step 4

6E-222 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Condition For Setting The DTC and Action Taken When The DTC Sets
Flash
Code Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P1171 D Fuel Supply System
Lean During Power
Enrichment (Bank 1) 44

P1172 D Fuel Supply System
Lean During Power
Enrichment (Bank 2) 1. No DTC relating to MAF sensor, IAT sensor, ECT sensor,
TPS, CMP sensor, CKP sensor, VSS, injector control
circuit, ignition control circuit, O2 sensor circuit low voltage
& high voltage (bank 1 & 2) and O2 sensor circuit no
activity (bank 1 & 2).
2. Engine speed is between 1000rpm and 6000rpm.
3. Intake air temperature is below 70
C.
4. Engine coolant temperature is between 30
C and 120
C.
5. Engine load is between 150 and 255.
6. Throttle position output is more than 2.22V and fluctuation
is below 0.28V.
7. Except fuel cut operation.
8. O2 sensor output voltage below 250mV for 10 seconds. No fail-safe function.


CIRCUIT DESCRIPTION
The engine control module (ECM) internal circuitry can
identify if the vehicle fuel system is capable of supplying
adequate amounts of fuel during heavy acceleration
(power enrichment). The ECM monitors the voltage o
f
the oxygen sensor during power enrichment. When a
power enrichment mode of operation is requested
during “closed loop" operation (by heavy acceleration),
the ECM will provide more fuel to the engine. Unde
r
these conditions the ECM should detect a “rich"
condition (high oxygen sensor voltage). If this “rich"
exhaust is not detected at this time, a DTC P1171 o
r
P1172 will set. A plugged fuel filter, restricted fuel line,
restricted in-tank filter or defective fuel pump can
prevent adequate amouts of fuel from being supplied
during power enrichment mode.

DIAGNOSTIC AIDS
 A restricted fuel filter or fuel line, restricted in-tank
filter, or a defective fuel pomp may supply adequate
amounts of fuel at idle, but may not be able to supply
enough fuel during heavy acceleration.
 Water or alcohol in the fuel may cause low HO2S
voltage during acceleration.
 Check for faulty or plugged fuel injector(s).
 Check for low fuel.

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

6E-374 3.5L ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance o
f
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel filler cap.
2. Remove the fuel pump relay.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.



FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
 Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
 Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
 Fittings should be capped and holes plugged
during servicing to prevent dirt and othe
r
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.

5. Disconnect the connectors from, solenoid valve,
sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do no
t
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retaine
r
clip must be replaced.
3. Drain residual fuel into an approved container.




060RW044
8. If removal of the fuel pressure regulator is
necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.

Installation Procedure
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

ENGINE MECHANICAL (C24SE) 6A-11
Main Data and Specifications
Engine - General C24SE
Engine type Four-cycle, water cooled cross-flow with single over head
camshaft
Micro-computer control, fuel injection
Combustion chamber type (Volume) Hemispherical (43.3cm3)
Timing train system Belt drive
No. of cylinders-bore
stroke mm (in) 4-87.5
100.0 (3.44
3.93)
Bore Spacing(C/L to C/L) 93.0 mm (3.66 in)
Firing Order 1-3-4-2
Bore
Stroke mm (in) 87.5
100.0 (3.44
3.93)
Total piston displacement cm3 (in3) 2,405(146.80)
Combustion Chamber Volume 43.3cm3
No. of piston ring Compression ring: 2, Oil ring: 1
Compression pressure kg/cm2 (psi/pa) 12.2-16.3 (174-232/1200-1600)
Ignition timing (BTDC) No adjustment
Idling speed: rpm(WO/AC,W/AC) A/C off 825
Valve clearances (At cold)
Intake mm (in) 0 (0) (Hydraulic valve lash adjustment)
Exhaust mm (in) 0 (0) ( " )
Open at (BTDC) deg 1730’
Close at (ABDC) deg 7630’
Exhaust valves
Open at (BBDC) deg 5830’
Close at (ATDC) deg 3530’
Ignition system Fully transistorized battery ignition
Distributor type Not applicable, Electronic Spark Timing control
Distributor advance type Not applicable, Electronic Spark Timing control
Spark plug type RN9YC4
Spark plug gap mm (in) 1.0--1.1 (0.039--0.043)
Lubrication system
Lubricating method Fully flow pressure circulation
Special engine oil (API grade) SE, SF, SG or SH grade
Oil pressure kg/cm2 (psi/Pa) rpm 4-4.6 (56.9-65.4/400-450)
Oil pump type Gear
Oil filter type Cartridge full flow
Oil capacity lit. (US/UK gal.) 4.25
Cooling system
Radiator type Corrugated fin with reserve tank
Coolant capacity lit.
(US/UK gal.) 2.3 (0.66/0.55)
Water pump type Centrifugal
Thermostat Wax pellet with jiggle hole

6A-12 ENGINE MECHANICAL (C24SE)
Engine - General C24SE
Fuel system Electronically controlled Multi Port Fuel Injection System
Fuel pump type Electric
Fuel pressure kg/cm2 (psi/Pa) 3.4 (48.4/334)
Fuel filter type Cartridge paper element
Air cleaner type Dry paper element
Battery Type/V-Ax No. of units 34B19L/50D20L
Alternator
Capacity V-A(W) 12-90 (1080), 12-100 (1200)
Starter
Output V-kW 1.4
Exhaust system CO Adjustment (1) Applicable to Open Loop System (Not equipped H2OS)
(2) Not applicable to Closed Loop System (Equipped H2OS)
Compression Ratio (with Tolerance) 9.6:10.25
Cylinder Head Material Aluminum Alloy (gravity cast)
Cylinder Block Material Cast Iron
No. of Mounting Points (including trans.) 3
Engine Installation Angles
-Longitudinal4 60'
-Lateral 7 50' (towards exhaust side)
Overall Dimensions (L




W




H):
- TF (2.4Litre/2WD) 610
564
708mm
- TF (2.4Litre/4WD) 610
564
746mm
Engine Weight
Engine Weight
- TF (2.4Liter/Man)140kg
Camshaft Type SOHC
No. of Valves per Cylinder
- Inlet1
- Exhaust 1
Spark Plug Location Side
Port Arrangement Cross Flow
Working Principle Spark Ignition 4-stroke

ENGINE FUEL (C24SE) 6C-1
ENGINE
ENGINE FUEL (C24SE)
CONTENTS

General Description............................................. 6C-2
Service Precaution............................................... 6C-3
Fuel Metering........................................................ 6C-4
Fuel Filter............................................................... 6C-5
Removal.............................................................. 6C-5
Inspection........................................................... 6C-6
Installation.......................................................... 6C-6
Inspection........................................................... 6C-6
In-Tank Fuel Filter............................................. 6C-6
Fuel Pump Flow Test....................................... 6C-7
Fuel Pump.............................................................. 6C-8
Fuel Pump and Associated Parts................. 6C-8
Removal.............................................................. 6C-8
Installation.......................................................... 6C-9
Fuel Tube / Quick - Connector Fittings.......... 6C-10
Precautions........................................................ 6C-10
Cautions During Work..................................... 6C-10

Removal............................................................... 6C-10
Reuse of Quick-Connector............................. 6C-11
Assembling Advice........................................... 6C-11
Fuel Pump Relay................................................... 6C-12
General Description.......................................... 6C-12
Fuel Tank................................................................ 6C-13
Fuel Tank and Associated Parts.................... 6C-13
Removal............................................................... 6C-14
Installation.......................................................... 6C-14
Filler Neck............................................................... 6C-15
Removal............................................................... 6C-15
Installation.......................................................... 6C-15
Fuel Gauge Unit.................................................... 6C-15
Removal and Installation................................. 6C-15
Fuel Filler Cap........................................................ 6C-16
General Description.......................................... 6C-16
Inspection............................................................ 6C-16
Main Data and Specifications............................ 6C-17
Special Tool........................................................ 6C-18

ENGINE FUEL (C24SE) 6C-3


When working on the fuel system, there are several things to
keep in mind:


Any time the fuel system is being worked on, disconnect the
negative battery cable except for those tests where battery
voltage is required.


Always keep a dry chemical (Class B) fire extinguisher near
the work area.

Replace all pipes with the same pipe and fittings that were
removed.

Clean and inspect "O" rings. Replace if required.


Always relieve the line pressure before servicing any fuel
system components.

Do not attempt repairs on the fuel system until you have
read the instructions and checked the pictures relating to
that repair.

Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper emission
control system operation.
Its use will also minimize spark plug fouling and extend engine
oil life. Using leaded gasoline can damage the emission control
system and could result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission Control
System. The purpose of the system is to minimize the escape
of fuel vapors to the atmosphere.



Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or othe
r
corrosion inhibitors) on threaded fasteners or fastene
r
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.

6C-6 ENGINE FUEL (C24SE)
Fuel Filter
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt o
r
sediment.
Installation
1. Install the filter to holder from side member side.
NOTE: Attend direction of fuel filter. (1) to engine side
(2) to fuel tank side.
NOTE: Verify to hang holder hook to fuel filter.


NOTE: Verify to hang holder hook to fuel filter.




RTW36CSH000301
2. Connect the quick connector from the fuel tube to
the fuel filter.
NOTE: Pull of the left checker into the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in
this section when performing any repairs.
3. Tighten fuel filler cap until at least one click are
heard.
4. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel
leakage.
In–Tank Fuel Filter
The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, no
t
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.