oil ISUZU TF SERIES 2004 Workshop Manual

6E–188 ENGINE DRIVEABILITY AND EMISSIONS
6 Using the DVM and check the ignition coil module
signal circuit for the affected coil.
1. Ignition “On”, engine “Off”.
2. Disconnect the ignition coil module connector.
3. Check the circuit for short to battery voltage circuit
for the affected coil.
Was the DVM indicated battery voltage?
—Repair faulty
harness and
verify repair Go to Step 7 Step A ction Value(s) Yes No
E-18




Co il 2
V
E-18




Coil 1
V

ENGINE DRIVEABILITY AND EMISSIONS 6E–189
7 Using the DVM and check the ignition coil signal
circuit for the affected coil.
Breaker box is available:
1. Ignition “Off”, engine “Off”.
2. Install the breaker box as type A. (ECM
disconnected) Refer to 6E-88 page.
3. Disconnect the ignition coil module connector.
4. Check the circuit for open or short to ground circuit
for the affected coil.
Was the problem found?
Breaker box is not available:
1. Ignition “Off”, engine “Off”.
2. Disconnect the ignition coil module connector and
ECM connector.
3. Check the circuit for open or short to ground circuit
for the affected coil.
Was the problem found?
—Repair faulty
harness and
verify repair Go to Step 8 Step A ction Value(s) Yes No
J1-18Breaker BoxE-1 8
Coil 2



J1-19Breaker BoxE-18
Coil 1



E- 18

Co i l 2



E- 60( J1)

E- 18

Coi l 1



E-60(J1)

6E–190 ENGINE DRIVEABILITY AND EMISSIONS
8 Using the DVM and check the ignition coil module
power supply circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the ignition coil module connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 10Go to Step 9
9 Repair the open or short to ground circuit between the
“IGN. Coil” fuse (15A) and ignition coil module.
Is the action complete?—Veri fy repai r—
10 Replace the ignition coil module.
Was the problem solved?—Verify repair Go to Step 11
11 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 12
12 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 A ction Value(s) Yes No
V
E-18
2

6E–192 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0443
EVAP Emission Control System Purge Control Circuit
Step A ction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go 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 P0443 stored as “Present Failure”?—Go to Step 3Refer 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 P0443 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Check for poor/faulty connection at the purge solenoid
valve or ECM connector. If a poor/faulty connection is
found, repair as necessary.
Was the problem found?
—Verify repair Go to Step 5
5 Using the DVM and check the purge solenoid valve.
1. Ignition “Off”, engine “Off”.
2. Disconnect purge solenoid valve connector.
3. Measure the resistance of purge solenoid valve
coil.
Does the tester indicate standard resistance?
25 - 30
at
20°CGo to Step 6Go to Step 9
5 E-60(J1) E-66


EVAP Purg e So le no id




ENGINE DRIVEABILITY AND EMISSIONS 6E–213
8 1. Using the Tech 2, ignition “On” and engine “On”.
2. Select the “Miscellaneous Test” and perform the
“IAC Control” in the “IAC System”.
3. Operate the Tech 2 in accordance with procedure.
Was the engine speed changed, when the IAC valve
is operating step by step?—Go to Step 10Go to Step 9
9 Check for the following conditions.
Objects blocking the IAC valve.
Objects blocking the throttle valve.
Vacuum leaking at throttle body.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 14
10 Check for injector for the affected bank.
Refer to “Injector Coil Test & Injector Balance Test
Procedure” 6E-98 page.
Was the injector operation correct?
—Go to Step 11Refer to Injector
Coil Test &
Injector
Balance Test
Procedure
11 Check for fuel pressure.
Refer to “Fuel System Diagnosis” 6E-108 page.
Was the fuel pressure correct? —Go to Step 15Refer to Fuel
System
Diagnosis
12 Replace the TPS.
Is the action complete?—Veri fy repai r—
13 Replace the MAP sensor.
Is the action complete?—Veri fy repai r—
14 Replace the IAC valve.
Is the action complete?—Veri fy repai r—
15 Replace the O
2 sensor.
Was the problem solved?—Verify repair Go to Step 16
16 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 17
17 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 A ction Value(s) Yes No

6E–216 ENGINE DRIVEABILITY AND EMISSIONS
7 Remove the MAP sensor and check for the following
conditions.
Objects blocking the air cleaner.
Objects blocking the MAP sensor.
Objects blocking the throttle valve.
Vacuum leaking at intake duct.
Vacuum leaking at throttle body.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 13
8 1. Using the Tech 2, ignition “On” and engine “On”.
2. Select the “Miscellaneous Test” and perform the
“IAC Control” in the “IAC System”.
3. Operate the Tech 2 in accordance with procedure.
Was the engine speed changed, when the IAC valve
is operating step by step?—Go to Step 10Go to Step 9
9 Check for the following conditions.
Objects blocking the IAC valve.
Objects blocking the throttle valve.
Vacuum leaking at throttle body.
If a problem is found, repair as necessary.
Was the problem found?—Verify repair Go to Step 14
10 Check for injector for the affected bank.
Refer to “Injector Coil Test & Injector Balance Test
Procedure” 6E-98 page.
Was the injector operation correct?
—Go to Step 11Refer to Injector
Coil Test &
Injector
Balance Test
Procedure
11 Check for fuel pressure.
Refer to “Fuel System Diagnosis” 6E-108 page.
Was the fuel pressure correct? —Go to Step 15Refer to Fuel
System
Diagnosis
12 Replace the TPS.
Is the action complete?—Veri fy repai r—
13 Replace the MAP sensor.
Is the action complete?—Veri fy repai r—
14 Replace the IAC valve.
Is the action complete?—Veri fy repai r—
15 Replace the O
2 sensor.
Was the problem solved?—Verify repair Go to Step 16
16 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 17
17 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 A ction Value(s) Yes No

6E–232 ENGINE DRIVEABILITY AND EMISSIONS
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the “On-Board
Diagnostic (OBD) System Check” and verify all of the
following items:
The engine control module (ECM) and malfunction
indicator lamp (MIL = Check Engine Lamp) are
operating correctly.
There are no Diagnostic Trouble Code(s) stored.
Tech 2 data is within normal operating range. Refer to
Typical Scan Data Values.
Verify the customer complaint and locate the correct
symptom in the table of contents. Perform the
procedure included in the symptom chart.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time. This check should include the following items:
ECM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper
connection, shown on the “Emission Control System
Schematics”. Check thoroughly for any type of leak or
restriction.
Air intake ducts for collapsed or damaged areas.
Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
Ignition wires for cracking, harness, and carbon
tracking.
Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn
on the malfunction indicator lamp (MIL) or store a
Diagnostic Trouble Code. Do NOT use the Diagnostic
Trouble Code (DTC) charts for intermittent problems.
The fault must be present to locate the problem.
Most intermittent problems are cased by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions.
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal form the connector body to
check.
Ignition coils shorted to ground and arcing at ignition
wires or plugs.MIL (Check Engine Lamp) wire to ECM shorted to
ground.
Poor ECM grounds. Refer to the ECM wiring
diagrams.
Road test the vehicle with a Digital Multimeter
connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Using Tech 2 to help detect intermittent conditions. The
Tech 2 has several features that can be used to located
an intermittent condition.
An intermittent MIL (Check Engine Lamp) with no stored
Diagnostic Trouble Code may be caused by the
follow ing:
Ignition coil shorted to ground and arcing at ignition
wires or plugs.
MIL (Check Engine Lamp) wire to ECM short to
ground.
Poor ECM grounds. Refer to the ECM wiring
diagrams.
Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
to the ignition control module for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
If problem has not been found, refer to ECM connector
symptom tables.
Check the “Broadcast Code” of the ECM, and
compare it with the latest Isuzu service bulletins and/
or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECM’s reprogrammable
memory has been released.
To check the “Broadcast Code”, connect the Tech 2,
then look for “ID info.” then select “Broadcast Code”.
This should display a 4 character code, such as “XBYA”
(ex ample only).
This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
If the “Broadcast Code” is not the most current
available, it is advisable to reprogram the ECM’s
EEPROM memory, which may either help identify a
hard-to find problem or may fix the problem.
The Service Programming System (SPS) will not allow
incorrect software programming or incorrect calibration
changes.

ENGINE DRIVEABILITY AND EMISSIONS 6E–233
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: 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.
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagosis.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to 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 4Go to Visual /
physical Check.
4 Check the “Ignition coil” fuse (15A) and “ECM” fuse
(15A).
Was a fuse blown?—Verify repair Go to Step 5
5 1. Ignition ON
2. Use a DVM to verify that battery voltage at the
ignition coil fuse, and the ECM fuse.
Was battery voltage presented at the fuses?—Go to Step 6Verify & repair
6 1. Visually/physically inspect for the following
conditions:
Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 7
7 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?—Verify repair Go to Step 8
8 1. Using a Tech 2, display the MAP sensor value.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 9
9 If oscilloscope is available, check the wave form of the
CKP signal.
Was the correct wave form found?—Go to Step 12Go to Step 10
10 Check the CKP sensor wire for open or short circuit.
Was a problem found?—Verify repair Go to Step 11
11 Replace CKP sensor.
Is there still problem?—Replace pulsar
ring. Verify repair

6E–234 ENGINE DRIVEABILITY AND EMISSIONS
12 Visually/physically inspect the secondary ignition
wires. Check for the following conditions:
Verify that all ignition wire resistance are less than
the specified value.
Verify that ignition wires are correctly routed to
eliminate cross-fitting.
Verify that ignition wires are not arcing to ground.
Spraying the secondary ignition wires with a light
mist of water may help locate an intermittent
problem.
Was a problem found?#1 cyl. 4.4k

#2 cyl. 3.6k

#3 cyl. 3.1k

#4 cyl. 2.8k
Verify repair Go to Step 13
13 1. Disconnect the spark plug high tension cable from
No.1 spark plug.
2. Install a spark tester at the end of the
disconnected ignition coil.
3. Clip the spark tester to a good ground.
4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same
as “No Spark”.)—Go to Step 21Go to Step 14
14 1. Disconnect the ignition coil harness connector.
2. Check for an open or short circuit between the
ignition coil and the ECM.
Was a problem found?—Verify repair Go to Step 15
15 1. Ignition “On”.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition coil harness connector.
Was the voltage equal to the specified value?Battery
voltage Go to Step 16Verify repair
16 1. Ignition “Off”.
2. With DVM, check for an open in the ground wire at
the ignition coil harness connector.
Was the ground wire OK?—Go to Step 17Verify repair
17 Replace the ignition coil, verify the repair.
Attempt to start the engine.
Is there still a problem?—Go to Step 18Verify repair
18 Use an ohmmeter to check the ignition coil primary
winding resistance.
Was the primary winding resistance approximately
equal to the specified value? 0.8-18k
Go to Step 19Go to Step 20
19 Use an ohmmeter to check the ignition coil secondary
winding resistance.
Was the primary winding resistance hear around the
to the specified value? 2.5k
Go to Step 21Go to Step 20
20 Replace the ignition coil.—Veri fy repai r—
21 1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
ex cessive fouling?—Correct the
fouling
condition Go to Step 22 Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–237
7 1. Using a Tech 2, display the engine coolant
temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?
—Go to Step 8Replace the
ECT sensor.
Verify repair
8 1. Using a Tech 2, display the MAP sensor value in
comparison with atmosphere temperature.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 9
9 Visually/physically inspect all spark plug high-tension
cables. Check for the following conditions:
Verify that the resistance of all spark plug high-
tension cables are less than the specified value.
Verify that the all spark plug high-tension cables are
correctly fitted to eliminate cross-fitting.
Verify that the all spark plug high-tension cables are
not arcing to ground.
Spraying the spark plug high-tension cables with a
light mist of water may help locate an intermittent
problem.
Was a problem found?#1 cyl. 4.4k

#2 cyl. 3.6k

#3 cyl. 3.1k

#4 cyl. 2.8k
Verify repair Go to Step 10
10 Check for proper ignition voltage output with a spark
tester.
Was the problem found?—Verify repair Go to Step 11
11 1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?—Verify repair Go to Step 12
12 Check for a loose ignition control module ground.
Was a problem found?—Verify repair Go to Step 13
13 1. Check the ignition coil secondary resistance.
2. Replace the coil if it is greater than the specified
resistance.
Did the coil require replacement? 2.5k
Verify repair Go to Step 14 Step Action Value(s) Yes No
Temperature (°C) Resistance (
) (Approximately)
-20 26740
09120
20 3500
40 1464
60 664
80 333
100 175
120 102