oil ISUZU TF SERIES 2004 Workshop Manual

6E–240 ENGINE DRIVEABILITY AND EMISSIONS
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 Using Tech 2, monitor throttle position with the engine
idling.
Is the throttle position at the specified value and
steady?
0% Go to Step 10Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis
10 Check for proper ignition voltage output with the spark
tester.
Was a 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 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 14
14 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 15
15 Check the injector connectors, if any of the injectors
are connected any incorrect cylinder, correct as
necessary.
Was a problem found?—Verify repair Go to Step 16
16 1. Check for faulty engine mounts.
2. If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 17 Step Action Value(s) Yes No
Temperature (°C) Re sista nce (
) (Appro x imately)
-20 26740
09120
20 3500
40 1464
60 664
80 333
100 175
120 102

ENGINE DRIVEABILITY AND EMISSIONS 6E–243
9 Check the fuel pressure. Refer to 6E-108 page
Fuel
System Diagnosis
.
Was a problem found?—Verify repair Go to Step 10
10 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 11
11 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 12
12 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 13
13 Check for proper ignition voltage output with the spark
tester.
Was a problem found?—Verify repair Go to Step 14
14 Check for a loose ignition control module ground.
Was a problem found?—Verify repair Go to Step 15
15 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 16
16 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 17
17 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 18
18 1. Check the injector connectors.
2. If any of the connectors are connected at an
improper cylinder, connect as necessary.
Was a problem found?—Verify repair Go to Step 19
19 Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 20
20 Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.
Was a problem found?—Verify repair Go to Step 21 Step Action Value(s) Yes No

6E–246 ENGINE DRIVEABILITY AND EMISSIONS
10 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Go to Step 11Go to Step 12
11 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 12
12 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 13
13 Check for proper ignition voltage output with the spark
tester.
Was a problem found?—Verify repair Go to Step 14
14 Check for a loose ignition control module ground.
Was a problem found?—Verify repair Go to Step 15
15 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 16
16 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 17
17 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 18
18 Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 19
19 Visually/physically check the vacuum hose for splits,
kinks and proper connections and routing.
Was a problem found?—Verify repair Go to Step 20 Step Action Value(s) Yes No

6E–248 ENGINE DRIVEABILITY AND EMISSIONS
CUTS OUT, MISSES SYMPTOM
DEFINITIONS: Steady pulsation or jerking that follows
engine speed; usually more pronounced as engine load
increases.
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 visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Check the ECM grounds to verify that they are clean
and tight. Refer to the ECM wiring diagrams in
Electrical Diagnosis.
Was a problem found?—Verify repair Go to Step 5
5 Check for a loose or short circuit of ignition coil
module voltage feed.
Was a problem found?—Verify repair Go to Step 6
6 Check for a loose or short circuit of ignition coil
module ground.
Was a problem found?—Verify repair Go to Step 7
7 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 7
8 Check the CKP sensor wire, shield wire, or installation
condition.
Was a problem found?—Verify repair Go to Step 9
9 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Go to Step 10Go to Step 11

ENGINE DRIVEABILITY AND EMISSIONS 6E–249
10 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 11
11 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the lean
condition?—Go to Step 12Go to Step 13
12 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 13
13 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 14
14 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 15
15 Perform the “Injector Coil/Balance Test” (Refer to 6E-
98 page).
Was a problem found.—Verify repair Go to Step 16
16 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure
regulator assembly.
Was a problem found?—Verify repair Go to Step 17
17 Check for proper ignition voltage output with the spark
tester.
Was a problem found?—Verify repair Go to Step 18
18 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 19 Step Action Value(s) Yes No

6E–252 ENGINE DRIVEABILITY AND EMISSIONS
12 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 13
13 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 14
14 Check items that can cause the engine to run lean.
Refer to DTC P1171 “Fuel Supply System Lean
During Power Enrichment”.
Was a problem found?—Verify repair Go to Step 15
15 Check for proper ignition voltage output with a spark
tester.
Was the problem found?—Verify repair Go to Step 16
16 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 17
17 Drain sample fuel, visual inspection.
Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspencion of alcohol contamination,
completely drain the fuel, replace by fuel from known
vehicle source.—Verify repair Go to Step 18
18 Check the ex haust system for a possible restriction:
Damaged or collapsed pipes
Internal muffler failure
Was a problem found?—Verify repair Go to Step 19
19 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Leaking cylinder head gaskets
Worn camshaft
Loose timing belt
Was a problem found?—Verify repair Go to Step 20
20 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
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 21 Step Action Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–257
14 Monitor “B1S1 (Bank 1 Sensor 1) Status” on the Tech
2.
Is the “B1S1 (Bank 1 Sensor 1) Status” in the rich
condition?—Verify repair Go to Step 15
15 Check items that can cause the engine to run rich.
Refer to DTC P1167 “Fuel Supply System Rich During
Deceleration Fuel Cut Off”.
Was a problem found?—Verify repair Go to Step 16
16 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 17
17 Check for proper calibration of the speedometer.
Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?—Go to Step 19Go to Step 18
18 Diagnose and repair the inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.—Verify Repair—
19 Check for proper calibration of the fuel gauge.
Was a problem found?—Verify repair Go to Step 20
20 Check for the following engine mechanical problems
(refer to Engine Mechanical):
Low compression
Worn camshaft
Sticking or leaking valves
Valve timing
Was a problem found?—Verify repair Go to Step 21
21 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
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 22
22 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 23
23 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.—Verify Repair— Step Action Value(s) Yes No

6E–258 ENGINE DRIVEABILITY AND EMISSIONS
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM
DEFINITIONS: Vehicle fails an emission test. There is ex cessive “rotten egg” smell. (Ex cessive odors do not
necessarily indicate ex cessive emissions.)
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 visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Does the customer continual accelerate On/Off during
cold condition?—System OK Go to Step 5
5 Is the customer using the incorrect fuel type?
—Replace with
unleaded fuel Go to Step 6
6 Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found?—Go to Step 17Go to Step 7
7 1. Check fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was a problem found?—Go to Step 17Go to Step 8
8 Check the fuel pressure. Refer to 6E-108 page “Fuel
System Diagnosis” .
Was a problem found?—Go to Step 17Go 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? —Go to Step 17Go to Step 10
10 Check the injector connectors, if any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Was a problem found?—Go to Step 17Go to Step 11
11 Perform the
Injector Coil/Balance Test
(Refer to 6E-
98 page).
Was a problem found.—Go to Step 17Go to Step 12
12 Check for a problem with the engine cooling system.
Was a problem found?—Go to Step 17Go to Step 13
13 Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
Was a problem found?—Go to Step 17Go to Step 14
14 Check the EVAP purge solenoid valve operation.
Is the valve operated normally?—Go to Step 17Veri fy repai r &
Go to Step 15
15 Check the ex haust system for a possible restriction:
Damaged or collapsed pipes
Internal catalytic converter failure
Was a problem found?—Verify repair &
Go to Step 16Go to Step 17

6E–262 ENGINE DRIVEABILITY AND EMISSIONS
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in the ex haust system, making a loud popping noise.
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 visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Check for proper ignition voltage output with the spark
tester.
Was a problem found?—Verify repair Go to Step 5
5 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 6
6 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 7
7 Check the fuel pressure. Refer to 6E-108 page “Fuel
System Diagnosis” .
Was a problem found?—Verify repair Go to Step 8
8 Check for an intermittent ignition system malfunction:
Intermittent CKP 58X signal
Intermittent ignition feed circuit or sensor ground
circuit to the crankshaft position sensor.
Was a problem found?—Verify repair Go to Step 9
9 Refer to 6E-108 page
Fuel System Diagnosis to
determine if there is a problem with fuel delivery.
Was a problem found?—Verify repair Go to Step 10

6E–264 ENGINE DRIVEABILITY AND EMISSIONS
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE (ECM)
Location
On the intake manifold.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the two connectors from the ECM.
3. Remove four bolts.
4. Remove the ECM from bracket.
Installation Procedure
1. Put on the ECM to the bracket.
2. Tighten the ECM by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
3. Connect the two connectors to the ECM.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
CRANKSHAFT POSITION (CKP) SENSOR
Location
Left-hand side of the cylinder block. (Back of the A/C
compressor)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive belt. Refer to Engine Mechanical
Section.
3. Remove the A/C compressor from engine. Refer to
Engine Mechanical Section.
4. Disconnect connector from the CKP sensor.
5. Loosen a bolt and remove the CKP sensor from the
cylinder block.
NOTE: Use caution to avoid any hot oil that might drip
out.
Installation Procedure
1. Install the CKP sensor to the cylinder block.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolt: 6N·m (0.6kgf·m)
3. Reinstall the A/C compressor to the engine.
4. Reinstall the accessory drive belt.
5. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.