water pump ISUZU TF SERIES 2004 Owner's Guide

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–13
(1) Engine Control Module (ECM)
(1) Engine Coolant Temperature (ECT) Sensor
(2) Thermo Unit for Water Temperature Gauge
(1) Vehicle Speed Sensor (VSS)
21
(1) EGR EVRV
(2) To Vacuum Pump
(3) To EGR Valve
(1) Crankshaft Position (CKP) Sensor
(2) Clutch Housing
321
12

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–181
5 V i s u a l l y / p h y s i c a l l y i n s p e c t f o r t h e f o l l o w i n g c o n d i t i o n s .
Restrict fuel supply system. Check for a pinched
fuel ho se /pi pe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
f u e l.
If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 6
6 Replace the fuel fi lt er.
Was the problem solved? - Verify repair Go to Step 7
7 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.

Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
f u e l.
If a problem is found, repair as necessary.
Was the problem found?
-Replace the
eye bolt with
gauze filter and
verify repair Go to Step 8
8 Is the ECM programmed with the latest software
release? If
not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved? - Verify repair Go to Step 9
9 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobiliser system
(if equipped) must be linked to the ECM. Refer to
section 11 "Immobilizer System-ECM replacement" for
the ECM/Immobilizer linking procedure. - Go to Step 10Go to Step 11 Step Action Value(s) Yes No

6E–364 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
17 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 18
18 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
More than 2.1
Mpa (21.0 kg/
cm
2) Verify repair Go to Step 19
19 If the injection pump was replaced, are the timing
gears or injection pump correctly installed?
—Go to Step 20Repair as
necessary Step Action Value(s) Yes No

6E–368 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
15 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 16
16 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 17
17 Check the engine compression pressure for each
cylinders.
If a problem is found, repair as necessary.
Was the problem found?
More than 2.1
Mpa Verify repair Go to Step 18 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

6E–374 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
26 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or ex cessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 27
27 Check the ex haust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 28
28 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 29
29 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 30 Step Action Value(s) Yes No

Vacuum Pump Small Window

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–375
30 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 32
31 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 32
32 Check the engine compression pressure for each
cylinders. Each cylinder must be evenly.
If a problem is found, repair as necessary.
Was the problem found?
More than 2.1
Mpa Verify repair Go to Step 33 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

6E–380 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
24 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or ex cessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 25
25 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 26
26 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 27 Step Action Value(s) Yes No

Vacuum Pump Small Window

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–381
27 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 28
28 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Tech 2 data
All electrical connections within a suspected circuit
and/or system
Was a problem found?—Verify repair Go to Step 29
29 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 30
30 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. —Go to Step 31Go to Step 32
31 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step Action Value(s) Yes No

6E–386 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
24 Using the Tech 2 or the vacuum pump and check the
EGR valve operation for the following condition
through the small window.
ÅERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or ex cessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 25
25 Check the ex haust system for a possible restriction.
Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 26
26 Visually/physically inspect for the following conditions.
Restrict fuel supply system. Check for a pinched
fuel hose/pipe.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 27
27 Replace the fuel filter.
Was the problem solved?—Verify repair Go to Step 28 Step Action Value(s) Yes No

Vacuum Pump Small Window

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–387
28 Remove the eye bolt with gauze filter from the
injection pump and check for the following conditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
ex tended maintenance interval.
Check for a condition that causes fuel wax ing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mix ed with the
fuel.
If a problem is found, repair as necessary.
Was the problem found?
—Replace the
eye bolt with
gauze filter and
verify repair Go to Step 29
29 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Tech 2 data
All electrical connections within a suspected circuit
and/or system
Was a problem found?—Verify repair Go to Step 30
30 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 31
31 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. —Go to Step 32Go to Step 33
32 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step Action Value(s) Yes No