ignition ISUZU TF SERIES 2004 Workshop Manual

IGNITION SYSTEM 6D2-5
Main Data and Specifications
General Specifications
Ignition System
Ignition Form Electronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug

Type
No. of Coils and Type
Coil Location
Torque Electronic Spark Control
2 Solid State
Engine-mounted
20 Nm (2.0 kgfm)

6D2-6 IGNITION SYSTEM
MEMO

6D3-8 STARTING AND CHARGING SYSTEM

General On-Vehicle Inspection
The operating condition of charging system is indicated by the
charge warning lamp. The warning lamp comes on when the
starter switch is turned to "ON" position. The charging system
operates normally if the lamp goes off when the engine starts.
If the warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform diagnosis
by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to "ON"
position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and ground
the terminal "L" on connector side.
If lamp comes on:
Repair or replace the generator.




Generator
Removal
1. Disconnect battery ground cable.
2. Move drive belt tensioner to loose side using wrench then
remove drive belt.
3. Disconnect terminal "B" wiring connector and connector.
4. Remove generator assembly.

Generator Power and Circuit Diagram



Inspection
Legend
1 Load resistor, set parallel to battery
2 Battery
3 Voltmeter
4 Ammeter
5 Ignition Lock
6 Charge Telltale
7 Generator

1. Disconnect battery.
2. Close off connecting cable from alternator terminal "B+".
3. Set ammeter (measuring range 100A) in disconnected line.
4. Connect controllable load resistor to battery terminal.
5. Set resistor in front of connection to "O"; connect first to
battery, then to resistor.
6. Connect tachometer.
7. Connect oscilloscope according to manufacturer's
instructions.
8. Connect battery.
9. Start engine and read off resulting current at various engine
speeds.

STARTING AND CHARGING SYSTEM 6D3-9



Generator Power
1. Adjust load resistor, if the required load currents are not
attained.
2. The shape of the voltage curves on oscilloscope curve
should be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not attained, o
r
if the oscilloscope picture shows variations, the alternator
should be overhauled.

Regulated Voltage Circuit Diagram


Legend
1 Battery
2 Ignition Lock
3 Charge Telltale
4 Resistor, for attainment of load current with the battery set in
series
5 Voltmeter
6 Ammeter
7 Generator




Installation
1. Install generator assembly and bring generator assembly to
the position to be installed.
2. Install generator assembly and tighten to the specified
torque.
Torque:
Long bolt: 35 N




m (3.6 kgf




m)
Short bolt: 20 N





m (2.0 kgf





m)
3. Connect wiring harness connector.
4. Move drive belt tensioner to loose side using a wrench, then
install drive belt to normal position.
5. Reconnect battery ground cable.

6D3-10 STARTING AND CHARGING SYSTEM
The generator has four external connections; the "B+" lead to
battery positive, "L" lead to the warning lamp circuit(max. 2
watts), "S" lead to battery positive terminal for battery sensing
and an earth connection.

Explanation of type inscripiton
Example:KC-A--> 14V 50-90A.

K = Code for Stator OD(126mm OD).
C = Compact Generator.
A = Ausland (countries other than Germany)
> = Direction of rotation(clockwise).
14V = Generator Operating Voltage.
50A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.
90A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.

Generator Connetions.
B+ : Battery Main Connection (battery positive)
S : Battery Sense Connection(battery positive)
L : Waring lamp(via warning lamp to Ignition switch)


BATT.SENSE
REGULATOR ASSEMBLYHYBR10ALTERNATOR ASSEMBLY
12V BATT.1GN.SW.
300a* WARN.LAMP
1.2 WATT
L S8+SUPPRESSOR
CAPACITOR
0.5

f
NOTE: * RESISTOR IS RECOMMENDED TO
ENSURE THAT THE GENERATOR
REMAINS FUNCTIONAL IN CASE OF
WARNING LAMP FAILURE

STARTING AND CHARGING SYSTEM 6D3-21
Technical Data
(mm)
Brush wear - Minimum Length 3.8
Sliprings - Minimum Diameter 26.7
Sliprings - Trueness <0.06
Pole claws - Trueness <0.05(93.25

0.05)

Torque
N.m(kgf
m)
Pulley retaining nut 54-68(5.5-6.9)
Capacitor retaining screw 2.7-3.8(0.3-0.4)
Capacitor whiz nut 1.5-2.2(0.1-0.2)
B+ terminal nut M8 7.5-8.5(0.8-0.9)
B+ terminal rectifier nut 6.0-7.5(0.6-0.8)
Regulator retaining screw 1.6-2.3(0.1-0.2)
Rectifier retaining screw 1.6-2.3(0.1-0.2)
Bearing retaining plate screw 2.1-3.0(0.2-0.3)
Through bolt 3.8-5.5(0.4-0.6)

Winding resistance(between phases)
(
)
Stator Rotor
70 Amp generator 0.086+10% 2.6

0.13
85 Amp generator 0.058+10% 2.6

0.13
90 Amp generator 0.056+10% 2.6

0.13

Warning lamp fault indication

Fault running Generator not
running Ignition ONGenerator
Iginiton ON
Generator out cable
O/CON ON
Battery "S" cable O/C ON ON
Battery overcharged ON ON
Positive diode short OFF ON
Negative diode short ON ON
Positive diode open ON OFF
Negative diode open ON OFF
Phase voltage sensing ON ON
cable open circuit
Power transistor
shortedON ON
Warnign lamp driver
O/COFF OFF

ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
CONTENTS
C24SE ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATIONS CHARTS ......................... 6E-6
ECM Circuit Diagram (1/2) ............................ 6E-11
ECM Circuit Diagram (2/2) ............................ 6E-12
GROUND POINT CHART - LHD G.EXP (1/4) 6E-13
GROUND POINT CHART - RHD G.EXP (1/4) 6E-17
LOCATION ................................................... 6E-21
CABLE HARNESS & CONNECTOR
LOCATION .............................................. 6E-23
CABLE HARNESS & CONNECTOR
LOCATION
LHD ................................... 6E-24
CABLE HARNESS & CONNECTOR
LOCATION
RHD ................................... 6E-25
CONNECTOR LIST ...................................... 6E-28
RELAY AND FUSE ....................................... 6E-30
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-30
FUSE AND RELAY LOCATION (LHD & RHD) 6E-32
ECM WIRING DIAGRAM (1/9) ..................... 6E-33
ECM WIRING DIAGRAM (2/9) ..................... 6E-34
ECM WIRING DIAGRAM (3/9) ..................... 6E-35
ECM WIRING DIAGRAM (4/9) ..................... 6E-36
ECM WIRING DIAGRAM (5/9) ..................... 6E-37
ECM WIRING DIAGRAM (6/9) ..................... 6E-38
ECM WIRING DIAGRAM (7/9) ..................... 6E-39
ECM WIRING DIAGRAM (8/9) ..................... 6E-40
ECM WIRING DIAGRAM (9/9) ..................... 6E-41
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-42
GENERAL DESCRIPTION FOR ECM AND
SENSORS ............................................... 6E-48
Engine Control Module (ECM) ................... 6E-48
Manifold Absolute Pressure (MAP) Sensor 6E-48
Throttle Position Sensor (TPS) .................. 6E-49
Idle Air Control (IAC) Valve ....................... 6E-49
Crankshaft Position (CKP) Sensor ............ 6E-50
Knock Sensor (KS) .................................... 6E-50
Engine Coolant Temperature (ECT) Sensor 6E-50
Intake Air Temperature (IAT) Sensor ........ 6E-51
Vehicle Speed Sensor (VSS) .................... 6E-51
Heated Ox ygen (O
2) Sensor ..................... 6E-51
GENERAL DESCRIPTION FOR FUEL
METERING .............................................. 6E-52Battery Voltage Correction Mode ............... 6E-52
Clear Flood Mode ...................................... 6E-52
Deceleration Fuel Cutoff (DFCO) Mode .... 6E-52
Engine Speed/ Vehicle Speed/ Fuel Disable
Mode ........................................................ 6E-52
Acceleration Mode ..................................... 6E-52
Fuel Cutoff Mode ....................................... 6E-52
Starting Mode ............................................ 6E-52
Run Mode .................................................. 6E-52
Fuel Metering System Components .......... 6E-53
Fuel Injector ............................................... 6E-53
Fuel Pressure Regulator ............................ 6E-53
Fuel Rail ..................................................... 6E-53
Fuel Pump Electrical Circuit ....................... 6E-53
Thottle Body Unit ....................................... 6E-53
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM ................................. 6E-54
Spark Plug ................................................. 6E-54
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ............................... 6E-57
EVAP Emission Control System Purpose .. 6E-57
EVAP Emission Control System Operation 6E-57
System Fault Detection .............................. 6E-57
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM .................................................. 6E-59
Crankcase Ventilation System Purpose .... 6E-59
A/C CLUTCH DIAGNOSIS ........................ 6E-60
A/C Clutch Circuit Operation ...................... 6E-60
A/C Clutch Circuit Purpose ........................ 6E-60
A/C Request Signal ................................... 6E-60
ISUZU STRATEGY BASED DIAGNOSTICS 6E-61
Overview .................................................... 6E-61
STRATEGY BASED DIAGNOSTICS CHART 6E-61
Diagnostic Thought Process ...................... 6E-62
1. Verify the Complaint .............................. 6E-62
2. Perform Preliminary Checks .................. 6E-62
3. Check Bulletins and Troubleshooting Hints 6E-63
4. Perform Service Manual Diagnostic Checks 6E-63
5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-63
5c. Technician Self Diagnoses .................. 6E-63
5d. Intermittent Diagnosis .......................... 6E-64

ENGINE DRIVEABILITY AND EMISSIONS 6E–3
Diagnostic Aids .......................................... 6E-139
Diagnostic Trouble Code (DTC) P0118
Engine Coolant Temperature Sensor High
Input ......................................................... 6E-140
DIAGNOSTIC TROUBLE CODE (DTC) P0122
THROTTLE POSITION SENSOR LOW
INPUT ......................................................... 6E-143
Circuit Description ..................................... 6E-143
Diagnostic Aids .......................................... 6E-143
Diagnostic Trouble Code (DTC) P0122 Throttle
Position Sensor Low Input ....................... 6E-144
DIAGNOSTIC TROUBLE CODE (DTC) P0123
THROTTLE POSITION SENSOR HIGH
INPUT ...................................................... 6E-147
Circuit Description ..................................... 6E-147
Diagnostic Aids .......................................... 6E-147
Diagnostic Trouble Code (DTC) P0123 Throttle
Position Sensor High Input ...................... 6E-148
DIAGNOSTIC TROUBLE CODE (DTC) P0131
O
2 SENSOR CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) ................................. 6E-150
Circuit Description ..................................... 6E-150
Diagnostic Aids .......................................... 6E-150
Diagnostic Trouble Code (DTC) P0131
O
2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
6E-160
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O
2
SENSOR CIRCUIT HIGH VOLTAGE (BANK 1
SENSOR 1) ................................................ 6E-155
Circuit Description ..................................... 6E-155
Diagnostic Aids .......................................... 6E-155
Diagnostic Trouble Code (DTC) P0132
O
2 Sensor Circuit High Voltage
(Bank 1 Sensor 1) .................................... 6E-156
DIAGNOSTIC TROUBLE CODE (DTC) P0134
O
2 SENSOR NO ACTIVITY DEFECTED
(BANK 1 SENSOR 1) ................................. 6E-159
Circuit Description ..................................... 6E-159
Diagnostic Aids .......................................... 6E-160
Diagnostic Trouble Code (DTC) P0134
O
2 Sensor Circuit No Activity Detected
(Bank 1 Sensor 1) .................................... 6E-160
DIAGNOSTIC TROUBLE CODE (DTC) P0135
O
2 SENSOR HEATER CIRCUIT
(BANK 1 SENSOR 1) ................................. 6E-163
Circuit Description ..................................... 6E-163
Diagnostic Aids .......................................... 6E-164
Diagnostic Trouble Code (DTC) P0135
O
2 Sensor Heater Circuit (Bank 1 Sensor 1) 6E-164
DIAGNOSTIC TROUBLE CODE (DTC) P0201
INJECTOR 1 CONTROL CIRCUIT ............. 6E-167
DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR 2 CONTROL CIRCUIT ............. 6E-167
DIAGNOSTIC TROUBLE CODE (DTC) P0203
INJECTOR 3 CONTROL CIRCUIT ............. 6E-167
DIAGNOSTIC TROUBLE CODE (DTC) P0204
INJECTOR 4 CONTROL CIRCUIT ............. 6E-167
Circuit Description ...................................... 6E-167
Diagnostic Aids .......................................... 6E-168
Diagnostic Trouble Code (DTC) P0201
Injector 1 Control Circuit .......................... 6E-168
Diagnostic Trouble Code (DTC) P0202
Injector 2 Control Circuit .......................... 6E-168
Diagnostic Trouble Code (DTC) P0203
Injector 3 Control Circuit .......................... 6E-168
Diagnostic Trouble Code (DTC) P0204
Injector 4 Control Circuit .......................... 6E-168
DIAGNOSTIC TROUBLE CODE (DTC) P0325
KNOCK SENSOR (KS) MODULE CIRCUIT 6E-174
Circuit Description ...................................... 6E-174
Diagnostic Aids .......................................... 6E-174
Diagnostic Trouble Code (DTC) P0325
Knock
Sensor Module Circuit ............................. 6E-174
DIAGNOSTIC TROUBLE CODE (DTC) P0327
KNOCK SENSOR (KS) CIRCUIT ............... 6E-177
Circuit Description ...................................... 6E-177
Diagnostic Aids .......................................... 6E-177
Diagnostic Trouble Code (DTC) P0327
Knock Sensor Circuit ............................... 6E-178
DIAGNOSTIC TROUBLE CODE (DTC) P0336
CRANKSHAFT POSITION (CKP) SENSOR
CIRCUIT RANGE/PERFORMANCE (58X) . 6E-180
DIAGNOSTIC TROUBLE CODE (DTC) P0337
CRANKSHAFT POSITION (CKP) SENSOR
CIRCUIT LOW INPUT (58X) ...................... 6E-180
Circuit Description ...................................... 6E-180
Diagnostic Aids .......................................... 6E-181
Diagnostic Trouble Code (DTC) P0336
Crankshaft Position Sensor Circuit
Range/performance (58x) ........................ 6E-181
Diagnostic Trouble Code (DTC) P0337
Crankshaft Position Sensor Circuit Low
Input (58x) ............................................... 6E-181
DIAGNOSTIC TROUBLE CODE (DTC) P0351
IGNITION 1 CONTROL CIRCUIT ............... 6E-186
DIAGNOSTIC TROUBLE CODE (DTC) P0352
IGNITION 2 CONTROL CIRCUIT ............... 6E-186
Circuit Description ...................................... 6E-186
Diagnostic Aids .......................................... 6E-186
Diagnostic Trouble Code (DTC) P0351
Ignition 1 Control Circuit .......................... 6E-187
Diagnostic Trouble Code (DTC) P0352
Ignition 2 Control Circuit .......................... 6E-187

ENGINE DRIVEABILITY AND EMISSIONS 6E–5
ENGINE CRANKS BUT WILL NOT RUN ..... 6E-233
HARD START SYMPTOM ............................ 6E-236
ROUGH, UNSTABLE, OR INCORRECT IDLE,
STALLING SYMPTOM ............................... 6E-239
SURGES AND/OR CHUGS SYMPTOM ...... 6E-242
HESITATION, SAG, STUMBLE SYMPTOM 6E-245
CUTS OUT, MISSES SYMPTOM ................. 6E-248
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM ................................................. 6E-251
DETONATION/SPARK KNOCK SYMPTOM 6E-254
POOR FUEL ECONOMY SYMPTOM .......... 6E-256
EXCESSIVE EXHAUST EMISSIONS OR
ODORS SYMPTOM ................................... 6E-258
DIESELING, RUN-ON SYMPTOM ............... 6E-261
BACKFIRE SYMPTOM ................................. 6E-262
ON-VEHICLE SERVICE PROCEDURE ....... 6E-264
ENGINE CONTROL MODULE (ECM) .......... 6E-264
CRANKSHAFT POSITION (CKP) SENSOR 6E-264
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR .................................................... 6E-265
INTAKE AIR TEMPERATURE (IAT) SENSOR 6E-265
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR .................................................... 6E-266
THROTTLE POSITION SENSOR (TPS) ...... 6E-266
IDLE AIR CONTROL (IAC) VALVE .............. 6E-267
KNOCK SENSOR ......................................... 6E-268
POWER STEERING PRESSURE (PSP)
SWITCH ..................................................... 6E-268
HEATED OXYGEN SENSOR (HO2S) ......... 6E-269
EVAP CANISTER PURGE VALVE SOLENOID 6E-269
FUEL PRESSURE RELIEF .......................... 6E-270
FUEL RAIL ASSEMBLY ............................... 6E-270
FUEL INJECTOR .......................................... 6E-271
FUEL PRESSURE REGULATOR ................ 6E-273
IGNITION COIL ............................................ 6E-275
SPARK PLUGS ............................................ 6E-275
SPARK PLUG CABLES ................................ 6E-277
EMISSION CONTROL ; CO ADJUSTER (W/O
CATALYSTIC CONVERTER) .................. 6E-277
SPECIAL SERVICE TOOLS ......................... 6E-279

6E–6 ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATIONS CHARTS
A bbreviations A ppellation
A/C Air Conditioner
A/T Automatic Transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CEL Check Engine Lamp
CKP Crankshaft Position
DLC Data Link Connector
DTC Diagnostic Trouble Code
DVM Digital Volt Meter
ECM Engine Control Module
ECT Engine Coolant Temperature
EEPROM Electrically Erasable & Programmable Read Only Memory
EVAP Evaporative Emission
EVRV Electric Vacuum Regulating Valve
EXH Exhaust
FT Fuel Temperature
GND Ground
GRY Gray
HOS2 Heated Ox ygen Sensor
IAC Idel Air Control
IAT Intake Air Temperature
IG Ignition
ITP Intake Throttle Position
KS Knock Sensor
M/T Manual Transmission
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
OBD On-Board Diagnostic
ORN Orange
OT Oil Temperature
PNK Pink
RED Red
SW Switch
TB Throttle Body
TEMP Temperature
TP Throttle Posi tion
VCC Voltage Constant Control
VSS Vehicle Speed Sensor
WHT Whi te
Y EL Yellow