bulb ISUZU TF SERIES 2004 Repair Manual

6E-72 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors
a vehicle system or component. Conversely, an active
test, actually takes some sort of action when performing
diagnostic functions, often in response to a failed
passive test.
Intrusive Diagnostic Tests
This is any on-board test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
Warm-Up Cycle
A warm-up cycle means that engine at temperature
must reach a minimum of 70

C (160
F) andrise at
least 22

C (40
F) over the course of a trip.
The Diagnostic Executive
The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:

Commanding the MIL (“Check Engine" lamp) on and
off

DTC logging and clearing

Freeze Frame data for the first emission related DTC
recorded

Current status information on each diagnostic
The Diagnostic Executive records DTCs and turns on
the MIL when emission-related faults occur. It can also
turn off the MIL if the conditions cease which caused
the DTC to set.
Diagnostic Information
The diagnostic charts and functional checks are
designed to locate a faulty circuit or component through
a process of logical decisions. The charts are prepared
with the requirement that the vehicle functioned
correctly at the time of assembly and that there are no
t
multiple faults present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented
by the diagnostic procedures contained in this manual.
The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
When a malfunction is detected by the control module,
a diagnostic trouble code is set and the MIL (“Check
Engine" lamp) is illuminated.

Check Engine Lamp (MIL)
The Check Engine Lamp (MIL) looks the same as the
MIL you are already familiar with (“Check Engine"
lamp).
Basically, the MIL is turned on when the ECM detects a
DTC that will impact the vehicle emissions.
The MIL is under the control of the Diagnostic
Executive. The MIL will be turned on if an
emissions-related diagnostic test indicates a
malfunction has occurred. It will stay on until the
system or component passes the same test, for three
consecutive trips, with no emissionsrelated faults.
Extinguishing the MIL
When the MIL is on, the Diagnostic Executive will turn
off the MIL after three consecutive trips that a “tes
t
passed" has been reported for the diagnostic test tha
t
originally caused the MIL to illuminate.
Although the MIL has been turned off, the DTC will
remain in the ECM memory (both Freeze Frame and
Failure Records) until forty(40) warm-up cycles after no
faults have been completed.
If the MIL was set by either a fuel trim or misfire-related
DTC, additional requirements must be met. In addition
to the requirements stated in the previous paragraph,
these requirements are as follows:

The diagnostic tests that are passed must occur with
375 RPM of the RPM data stored at the time the las
t
test failed.

Plus or minus ten (10) percent of the engine load tha
t
was stored at the time the last failed.

Similar engine temperature conditions (warmed up o
r
warming up ) as those stored at the time the last tes
t
failed.
Meeting these requirements ensures that the fault which
turned on the MIL has been corrected.
The MIL (“Check Engine" lamp) is on the instrumen
t
panel and has the following functions:

It informs the driver that a fault that affects vehicle
emission levels has occurred and that the vehicle
should be taken for service as soon as possible.


As a bulb and system check, the MIL will come “ON"
with the key “ON" and the engine not running. When
the engine is started, the MIL will turn “OFF."

When the MIL remains “ON" while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E -101

NO CHECK ENGINE LAMP (MIL)

RTW46EM F000401

CIRCUIT DESCRIPTION
The “Check Engine" lamp (MIL) should always be
illuminated and steady with the ignition “ON" and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The Engine Control
Module (ECM) turns the MIL “ON" by grounding the MIL
driver circuit.

DIAGNOSTIC AIDS
An intermittent MIL may be cased by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:

Inspect the ECM harness and connections fo
r
improper mating, broken locks, improperly formed o
r
damaged terminals, poor terminal-to-wire connection,
and damaged harness.

If the engine runs OK, check for a faulty light bulb, an
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
 If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.

6E-102 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Check Engine Lamp (MIL)

Step
Action Value (s) Yes No
1
Check the meter fuse (15A). If the fuse is burnt out,
repair as necessary.
Was the problem found?
- Verify repair Go to Step 2

2
Using the DVM and check the "CHECK ENGINE"
lamp circuit.
1. Ignition "Off", engine "Off".
2. Disconnect the ECM connector.
3. Ignition "On".
4. Check the circuit for open circuit.
Was the DVM indicated specified value?
V
E-61(B)



10 – 14.5V
Go to Step 5

Go to Step 3

3
Check the "CHECK ENGINE" lamp bulb. If the bulb is
burnt out, repair as necessary.
Was the problem found?
- Verify repair Go to Step 4

4
Using the DVM and check the "CHECK ENGINE"
lamp circuit.
1. Ignition "Off", engine "Off".
2. Disconnect the meter connector and ECM
connector.
3. Check the circuit for open circuit.
Was the problem found?




E-61(B)
B-24


-
Verify repair
Go to Step 5

5
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 6

6-14 ENGINE DIAGNOSIS (C24SE)
Malfunction Indicator Lamp
The instrument panel "CHECK ENGINE" Malfunction
Indicator lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of
engine, or senses malfunctions.

Condition Possible cause Correction
"CHECK ENGINE" MIL does not
illuminate at the starting of engine Bulb defective Replace
MIL circuit open Correct or replace
Command signal circuit to operate
self diagnostic system shorted Correct or replace
Engine Control Module (ECM)
cable loosely connected,
disconnected or defective Correct or replace
ECM defective Replace
“CHECK ENGINE” MIL
illuminates, and stays on Deterioration heated oxygen
sensor of internal element Replace
Heated oxygen sensor connector
terminal improper contact
(If applicable) Reconnect properly
Heated oxygen sensor lead wire
shorted (If applicable) Correct
Heated oxygen sensor circuit
open (If applicable) Correct or replace
Deterioration engine coolant
temperature sensor of internal
element Replace
Engine coolant temperature
sensor connector terminal
improper contact Reconnect properly
Engine coolant temperature
sensor lead wire shorted Correct
Engine coolant temperature
sensor circuit open Correct or replace
Throttle position sensor open or
shorted circuits Correct or replace
Deterioration of crankshaft
position sensor Replace
Crankshaft position sensor circuit
open or shorted Correct or replace
Vehicle speed sensor circuit open Correct or replace
Manifold absolute pressure sensor
circuit open or shorted Correct or replace
Intake air temperature sensor
circuit open or shorted Correct or replace
Fuel injector circuit open or shorted Correct or replace
ECM driver transistor defective Replace EPROM or ECM
Malfunctioning of ECM RAM
(Random Access Memory) or
Malfunctioning of ECM PROM
(Programmed Read Only Memory)Replace EPROM or ECM

6E–94 ENGINE DRIVEABILITY AND EMISSIONS
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and
steady for about five seconds with the ignition “ON” and
the engine stopped. Ignition feed voltage is supplied to
the check engine lamp bulb through the meter fuse.
The Engine Control Module (ECM) turns the check
engine lamp “ON” by grounding the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or awire broken inside the insulation. Check for the
following items:
Inspect the ECM harness and connections for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection,
and damaged harness.
If the engine runs OK, check for a faulty light bulb, an
open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.
No Check Engine Lamp (MIL)
Step Action Value(s) Yes No
1 Check the “Meter” fuse (15A).
If the fuse is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 2

ENGINE DRIVEABILITY AND EMISSIONS 6E–95
2 Using the DVM and check the “CHECK ENGINE”
lamp circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the ECM connector.
3. Ignition “On”.
4. Check the circuit for open circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 5Go to Step 3
3 Check the “CHECK ENGINE” lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 4
4 Using the DVM and check the “CHECK ENGINE”
lamp circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the meter connector and ECM
connector.
3. Check the circuit for open circuit.
Was the problem found?
—Verify repair Go to Step 5
5 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 6
6 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
V
32C56(J2)
3217C56(J2)B24

ENGINE DRIVEABILITY AND EMISSIONS 6E–209
Diagnostic Trouble Code (DTC) P0650
Malfunction Indicator Lamp (MIL) Control Circuit Malfunction
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 P0650 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 P0650 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Ignition “On”, engine “Off”.
2. Check the “Check Engine” lamp.
Does the lamp turn “On”?—Go to Step 5Go to Step 6
5 1. Ignition “On”, engine “Off”.
2. Check the “Check Engine” lamp.
Does the lamp turn “Off”?—Go to Step 9Go to Step 7
6 Check the “Check Engine” lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 7
7 Check for poor/faulty connection at the meter
connector and ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
—Verify repair Go to Step 8
32
17
C-56(J2) B-24

1-2 HEATER AND AIR CONDITIONING
PAGE
Duct (Without A/C) ........................................................................................................... 1- 63
Removal and Installation ............................................................................................ 1- 63
Disassembly and Reassembly ................................................................................... 1- 64
Blower Unit Assembly ..................................................................................................... 1- 65
Removal and Installation ............................................................................................ 1- 65
Disassembly and Reassembly ................................................................................... 1- 67
Defroster Nozzle and Vent Duct ..................................................................................... 1- 68
Removal and Installation ............................................................................................ 1- 68
Rear Heater Duct.............................................................................................................. 1- 69
Removal and Installation ............................................................................................ 1- 69
Control Lever Assembly .................................................................................................. 1- 70
Removal and Installation ............................................................................................ 1- 70
Control Panel Illumination Bulb ..................................................................................... 1- 74
Removal and Installation ............................................................................................ 1- 74
Inspection and Repair................................................................................................. 1- 76
Troubleshooting .............................................................................................................. 1- 79
Special Service Tool ........................................................................................................ 1-104

1-74 HEATER AND AIR CONDITIONING
CONTROL PANEL ILLUMINATION BULB
REMOVAL AND INSTALLATION

This illustration is based on RHD model
RTW410MF000601

Removal Steps

1. Control lever assembly

2. Illumination bulb

Installation Steps
2. Illumination bulb
1. Control lever assembly

HEATER AND AIR CONDITIONING 1-75
Important Operation - Removal
1. Control lever assembly
Refer to “CONTROL LEVER ASSEMBLY” in this section.

2. Illumination Bulb
To remove the illumination bulb, insert an ordinary screwdriver
into the slot (B) at the back of the bulb. Turn the bulb
counterclockwise and pull it free.