fuse box ISUZU TF SERIES 2004 Service Manual

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–59
3737No Connection---------
38 38 Throttle Po sitio n
Se nso r (TPS) Out-
put Signa lGRN/
ORGLe ss
tha n 1VLess than 1V Approx.
0.5VCo nnect DC V 38 49
39 39 Ke y Switch Input Sig-
nal Via Engine FuseWH T L e s s
tha n 1V10-14V Co nnect DC V 39 GND
4040No Connection---------
41 41 A/C Compressor
RelayWH T/
GRNLe ss
tha n 1V10-14V A/C comp. is o pe r-
ated: Less than 1V
A/C comp. is no t o pe r-
ate d: 10 - 14VCo nnect DC V 41 GND
42 42 Check Engine La mp GRN/
YELLe ss
tha n 1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 42 GND
43 43 Glo w Lamp ORG/
BLULe ss
tha n 1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 43 GND
4444No Connection---------
45 45 To Data Link Co n-
necto r No . 6BLU Less
tha n 1V10-14V Co nnect DC V 45 GND
4646No Connection---------
4747No Connection---------
4848No Connection---------
49 49 Throttle Po sitio n
Se nso r (TPS)
GroundBLK/
GRNIdle:
Appro x.
0.4K
ohm /
WO T:
Appro x.
4.0K
ohm---Discon-
ne ctOh m 3 8 4 9
5050No Connection---------
5151No Connection---------
5252No Connection---------
5353No Connection---------
5454No Connection---------
5555No Connection---------
5656No Connection---------
57 57 Throttle Po sitio n
Senso r (TPS) Po wer
SupplyRED/
GRNLe ss
tha n 1VApprox. 5V Connect DC V 57 49
58 58 ECM Re la y BLU/
BLK10-14V Less than 1V Connect DC V 58 GND
5959No Connection---------
6060No Connection---------
6161No Connection---------
6262No Connection---------Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–77
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:
Improves your understanding and definition of the
customer complaint
Saves time by avoiding testing and/or replacing good
parts
Allows you to look at the problem from different
perspectives
Guides you to determine what level of understanding
about system operation is needed:
–Owner’s manual level
–Service manual level
–In-depth (engineering) level
–Owner’s manual level
–Service manual level
–In-depth (engineering) level
1. Verify the Complaint
What you should do
To verify the customer complaint, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the
system.
The following information will help you verify the
complaint:
WHAT the vehicle model/options are
WHAT aftermarket and dealer-installed accessories
exist
WHAT related system(s) operate properly
WHEN the problem occurs
WHERE the problem occurs
HOW the problem occurs
HOW LONG the condition has ex isted (and if the
system ever worked correctly)
HOW OFTEN the problem occurs
Whether the severity of the problem has increased,
decreased or stayed the same
What resources you should use
Whenever possible, you should use the following
resources to assist you in verifying the complaint:
Service manual Theory or Circuit Description
sections
Service manual “System Performance Check”
Owner manual operational description
Technician ex perience
Identical vehicle for comparisonCircuit testing tools
Vehicle road tests
Complaint check sheet
Contact with the customer
2. Perform Preliminary Checks
NOTE: An estimated 10 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
You perform preliminary checks for several reasons:
To detect if the cause of the complaint is VISUALLY
OBVIOUS
To identify parts of the system that work correctly
To accumulate enough data to correctly and
accurately search for a ISUZU Service Bulletin on
ISUZU Web site.
The initial checks may vary depending on the
complex ity of the system and may include the following
actions:
Operate the suspect system
Make a visual inspection of harness routing and
accessible/visible power and ground circuits
Check for blown fuses
Make a visual inspection for separated connectors
Make a visual inspection of connectors (includes
checking terminals for damage and tightness)
Check for any DTCs stored by the on-board
computers
Sense unusual noises, smells, vibrations or
mov ements
Investigate the vehicle service history (call other
dealerships, if appropriate)
What resources you should use
Whenever appropriate, you should use the following
resources for assistance in performing preliminary
checks:
Tech II or other technical equipment for viewing DTCs
Service manual information:
–Component locations
–Harness routing
–Wiring schematics
–Procedures for viewing DTCs
Dealership service history file
Vehicle road test
Identical vehicle or system for comparison

6E–276 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
8 Repair the open circuit between the “Stop Lamp fuse
(15A)” and brake switch 1.
Is the action complete?—Verify repair—
9 Using the DVM and check the brake switch 1 circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM
connected) Ref. Page 6E-103
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage
circuit.
Was the DVM indicated specified value?
Breaker box is not available:
1. Ignition “On”, engine “Off”.
2. Back probe the DVM to the brake switch 1 and
check the circuit for open or short to voltage
circuit.
Was the problem found?
Pedal is not
stepped on:
Less than 1V
Pedal stepped
on: 10-14.5V Go to Step 12Fix ed at 10-
14.5V: Go to
Step 10
Fix ed at less
than 1V: Go to
Step 11
10 Repair the short to voltage circuit between the brake
switch 1 connector and ECM.
Is the action complete?
—Verify repair—
11 Repair the open circuit between the brake switch 1
connector and ECM.
Is the action complete?
—Verify repair— Step Action Value(s) Yes No
105Breaker Box
V
V
2 C-44
230C-56
C-44
230C-56
C-44

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–279
6 Using the DVM and check the brake switch 2 power
supply circuit.
1. Ignition “On”, engine “Off”.
2. Remove the brake switch connector from the
brake switch.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10-14.5V Go to Step 8Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)”
and brake switch 2.
Is the action complete?—Verify repair—
8 Using the DVM and check the brake switch 2 circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM
connected)
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage
circuit.
Was the DVM indicated specified value?
Breaker box is not available:
1. Ignition “On”, engine “Off”.
2. Back probe the DVM to the brake switch 2 and
check the circuit for open or short to voltage
circuit.
Was the problem found?
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V Go to Step 11Fix ed at 10-
14.5V: Go to
Step 9
Fix ed at less
than 1V: Go to
Step 10 Step Action Value(s) Yes No
V
3C-44
65Breaker Box
V
V
4 C-44

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–283
6 Using the DVM and check the clutch switch power supply circuit.
1. Ignition “On”, engine “Off”.
2. Remove the clutch switch connector from the clutch switch.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10-14.5V Go to Step 8Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)” and clutch switch.
Is the action complete? — Verify repair —
8 Using the DVM and check the clutch switch circuit. Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM connected) Ref. Page 6E-104
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage circuit.
Was the DVM indicated specified value?
Breaker box is not available: 1. Ignition “On”, engine “Off”.
2. Back probe the DVM to the clutch switch and check the circuit for open or short to voltage
circuit.
Was the problem found?
Pedal is not
stepped on: 10-14.5V
Pedal stepped on: Less than 1V Go to Step 11 Fix ed at 10-
14.5V: Go to Step 9
Fix ed at less
than 1V: Go to Step 10
Step Action Value(s) Yes No
V
1
2
C-77
31Breaker Box
V
V
2
C-77

6E–316 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6 Using the DVM and check the neutral switch (inhibitor switch) power supply circuit.
1. Ignition “On”, engine “Off”.
2. Remove the neutral switch (inhibitor switch) connector from the switch.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10-14.5V Go to Step 8Go to Step 7
7 Repair the open circuit between the “ECM fuse (10A)” and neutral switch (between the “Back Up fuse (15A)”
and inhibitor switch).
Is the action complete? — Verify repair —
8 Using the DVM and check the neutral switch (inhibitor switch) circuit.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type B. (ECM connected) Ref. Page 6E-104
3. Ignition “On”, engine “Off”.
4. Check the circuit for open or short to voltage circuit.
Was the DVM indicated specified value?
Breaker box is not available: 1. Ignition “On”, engine “Off”.
2. Back probe the DVM to the neutral switch (inhibitor switch) and check the circuit for open or
short to voltage circuit.
Was the DVM indicated specified value?
Neutral (P or
N): 10-14.5V Other than
neutral (P or
N): Less than
1V Go to Step 11 Fix ed at 10-
14.5V: Go to Step 9
Fix ed at less
than 1V: Go to
Step 10
Step Action Value(s) Yes No
V
E-12
M/T
V
3
E-51
A/T
E-687Br eak er Box




V
8
2
VV
E-11
E-51
M/T
A/T

ENGINE MECHANICAL (6VE1 3.5L) 6A-5
3. Trouble In Fuel System
Symptom Possible Cause Action
Starting motor turns over and spark
occurs but engine does not start. Fuel tank empty Fill
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control System
circuit clogged Correct or replace
Multiport Fuel Injection System faultyRefer to “Electronic Fuel Injection"
section

4. Engine Lacks Compression
Symptom Possible Cause Action
Engine lacks compression Spark plug loosely fitted Tighten to specified torque
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.

Engine Compression Test Procedure
1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and
fuse box.
6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the
starter engaged until the compression gage needle
reaches the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls belo
w
the limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS


ABBREVIATION CHARTS ................................ 6E-5
COMPONENT LOCATOR ................................. 6E-6
ENGINE COMPONENT LOCATOR TABLE .. 6E-6
ECM CIRCUIT DIAGRAM ................................. 6E-10
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4). 6E-13
GROUND POINT CHART G.EXP (LHD) (2/4) .. 6E-14
GROUND POINT CHART G.EXP (LHD) (3/4) .. 6E-15
GROUND POINT CHART G.EXP (LHD) (4/4) .. 6E-16
GROUND POINT CHART G.EXP (RHD) (1/4) . 6E-17
GROUND POINT CHART G.EXP (RHD) (2/4) . 6E-18
GROUND POINT CHART G.EXP (RHD) (3/4) . 6E-19
GROUND POINT CHART G.EXP (RHD) (4/4) . 6E-20
LOCATION ........................................................ 6E-21
CABLE HARNESS & CONNECTOR
LOCATION ....................................................... 6E-22
CONNECTOR LIST ........................................... 6E-27
RELAY AND FUSE ............................................ 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD&RHD) ................................................... 6E-31
FUSE AND RELAY LOCATION
(LHD&RHD) ................................................... 6E-32
ECM WIRING DIAGRAM (1/10) ........................ 6E-33
ECM WIRING DIAGRAM (2/10) ........................ 6E-34
ECM WIRING DIAGRAM (3/10) ........................ 6E-35
ECM WIRING DIAGRAM (4/10) ........................ 6E-36
ECM WIRING DIAGRAM (5/10) ........................ 6E-37
ECM WIRING DIAGRAM (6/10) ........................ 6E-38
ECM WIRING DIAGRAM (7/10) ........................ 6E-39
ECM WIRING DIAGRAM (8/10) ........................ 6E-40
ECM WIRING DIAGRAM (9/10) ........................ 6E-41
ECM WIRING DIAGRAM (10/10) ...................... 6E-42
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL ......................................... 6E-43
GENERAL DESCRIPTION FOR ECM AND
SENSORS ........................................................ 6E-51

Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O
2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL ......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
5a and 5b. Perform Service Manual
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69

6E-6 3.5L ENGINE DRIVEABILITY AND EMISSIONS
COMPONENT LOCATOR
ENGINE COMPONENT LOCATOR TABLE



 



Legend
(1) Engine Control Module (ECM)
(2) Throttle Position Sensor (TPS)
(3) Idle Air Control (IAC) Valve
(4) Battery
(5) Relay & Fuse Box
(6) Auto Cruise Actuator
(7) Mass Air Flow (MAF) & Intake Air Temperature
(IAT) Sensor Assembly

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-29

No. Connector face No. Connector face
E-78

O2 sensor LH-Front P-1
SilverBattery (+)
E-79


Neutral start switch P-2
SilverRelay & Fuse box
F-2
White
Fuel pump & sensor P-5
SilverBattery (-)
H-4

White Engine ~ Engine room P-8

WhiteACG (L)
H-6
White
Engine room ~ INST P-10
SilverEngine ground
H-7
White
Engine room ~ INST X-2

BlackRelay ; Fuel pump
H-9
Blue
Engine room ~ Chassis X-13

BlackRelay ; ECM MAIN
H-18
White
Engine room ~ INST X-14

BlackRelay ; A/C Compressor
H-22

White
Engine ~ Engine room C X-15
BlackRelay ; Thermo
H-23

White Engine ~ Engine room B X-17
BlackDIODE