Glow plug ISUZU TF SERIES 2004 Workshop Manual

ELECTRICAL-BODY AND CHASSIS 8A-429


No. Connector face No. Connector face
E-23
(4JH1-TC)
Gray TPS 2 main E-44
Gray Vehicle speed sensor
E-24
~
E-29 NOT USED E-45
(4JH1-TC)
Gray 2WD-4WD switch
E-30
(4JH1-TC)
Gray A/T speed sensor E-46
(4JH1-TC)
BrownH-L neutral switch
E-31
(4JH1-TC)
Gray Turbine sensor E-47
~
E-48 NOT USED
E-32
~
E-34 NOT USED E-49
(4JH1-TC)
Glow plug
E-35
(4JH1-TC)
(C24SE)
Black Motor actuator E-50

NOT USED
E-36
~
E-40 NOT USED E-51
(6VE1)
Fuel injector
E-41
(4JH1-TC)
Black Coolant temp sensor E-51
(4JH1-TC)
BlackInhibiter switch
E-42
Natural
green
Backup lamp switch E-52
(6VE1)
Fuel injector
E-43
Natural
green
Backup lamp switch E-53
(6VE1)
Ignition coil

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several
times and check for fuel leakage.
5. Check the water separator indicator light. It should be
off.



Except EURO III model
RTW46ASH002901




For EURO III model
RTW46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is
felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait until
the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and
crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

ENGINE ELECTRICAL 6D – 1


SECTION 6D
ENGINE ELECTRICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description......................................................................................................... 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator.......................................................................................................................... 6D - 7
Removal and Installation ............................................................................................ 6D - 7
Disassembly................................................................................................................. 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly.................................................................................................................. 6D - 18
Starter Motor .................................................................................................................... 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly................................................................................................................. 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly.................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug ..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33

ENGINE ELECTRICAL 6D – 33
PRE-HEATING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.

VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.



825R300046




Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94  114

GLOW PLUG


LNW21KSH001401
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9

EGR SYSTEM 4JA1T (L)
Refer to 6F-9. (EGR system diagram)

6E–4 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
MALFUNCTION ....................................... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE 7) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE 9) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE A) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE B) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE D) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
DIAGNOSTIC TROUBLE CODE (DTC) P0251
(SYMPTOM CODE E) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION ....... 6E-196
Circuit Description ..................................... 6E-197
Diagnostic Aids .......................................... 6E-197
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 6) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-197
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 7) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-199
Diagnostic Trouble Code (DTC) P0251
(Symptom Code 9) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-203
Diagnostic Trouble Code (DTC) P0251
(Symptom Code A) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-204
Diagnostic Trouble Code (DTC) P0251
(Symptom Code B) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-205
Diagnostic Trouble Code (DTC) P0251
(Symptom Code D) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-206
Diagnostic Trouble Code (DTC) P0251
(Symptom Code E) (Flash Code 53)
Injection Pump Malfunction ..................... 6E-207
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE B) (FLASH CODE 43)
CRANKSHAFT POSITION SENSOR
CIRCUIT MALFUNCTION ....................... 6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE D) (FLASH CODE 43)
CRANKSHAFT POSITION SENSOR
MALFUNCTION ....................................... 6E-208
DIAGNOSTIC TROUBLE CODE (DTC) P0335
(SYMPTOM CODE E) (FLASH CODE 43)
ENGINE SPEED INPUT CIRCUITRANGE/PERFORMANCE ....................... 6E-208
Circuit Description ...................................... 6E-209
Diagnostic Aids .......................................... 6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit
Malfunction .............................................. 6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction .. 6E-209
Diagnostic Trouble Code (DTC) P0335
(Symptom Code E) (Flash Code 43) Engine
Speed Input Circuit Range/Performance . 6E-214
DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE 4) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE LOW 6E-217
DIAGNOSTIC TROUBLE CODE (DTC) P0380
(SYMPTOM CODE 8) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
Circuit Description ...................................... 6E-217
Diagnostic Aids .......................................... 6E-217
Diagnostic Trouble Code (DTC) P0380
(Symptom Code 4) (Flash Code 66)
Glow Relay Circuit Voltage Low .............. 6E-218
Diagnostic Trouble Code (DTC) P0380
(Symptom Code 8) (Flash Code 66) Glow
Relay Circuit Voltage High ....................... 6E-221
DIAGNOSTIC TROUBLE CODE (DTC) P0381
(SUB CODE 4) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE LOW .. 6E-222
DIAGNOSTIC TROUBLE CODE (DTC) P0381
(SUB CODE 8) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE HIGH . 6E-222
Circuit Description ...................................... 6E-222
Diagnostic Aids .......................................... 6E-222
Diagnostic Trouble Code (DTC) P0381
(Symptom Code 4) (Flash Code 67) Glow
Plug Indicator Circuit Voltage Low ........... 6E-222
Diagnostic Trouble Code (DTC) P0381
(Symptom Code 8) (Flash Code 67) Glow
Plug Indicator Circuit Voltage High .......... 6E-226
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 3) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION FLOW
EXCESSIVE DETECTED ........................ 6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 4) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO GROUND OR OPEN CIRCUIT 6E-227
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 5) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION FLOW
INSUFFICIENT DETECTED .................... 6E-227

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–41
No. Connector face No. Connector face
C-118
A/C Resister & Neutral switchE-23
Gray Idle SW
C-123 E-41
Black Coolant temp sensor
C-124 E-44
Gray Vehicle speed sensor
E-3
Black Magnetic clutch AC COMPE-49
Gray Glow plug
E-6 E-51
Black Inhibiter switch
E-9 H-4
White Engine room ~ Mission
E-10
Silver Engine groundH-6
White Engine room ~ INST
E-11
Natural
green Neutral switchH-7
White Engine room ~ INST
E-12
Natural
green Neutral switchH-18
White Engine room ~ INST
E-22
Brown TPS 1 mainH-22
White Engine ~ Engine room C

6E–120 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
67 P0381 4 ON Glow Plug Indicator Circuit
Voltage LowGlow plug indicator circuit
open or short to ground
circuit.No fail-safe function. Glow plug indicator circuit is
correct condition.1. Glow plug indicator
circuit open or short to
g r o u n d c i r c u i t .
2. Glow plug indicator lamp
m a l f u n c t i o n .
3. ECM malfunction.43 —
8 ON Glow Plug Indicator Circuit
Voltage HighGlow plug indicator circuit
short to voltage circuit.ECM malfunction.
——
32 P0400 3 ON Exhaust Gas Recirculation
Flow Excessive Detected1. Intake air temperature is
between 15 deg. C and
1 0 0 d e g . C .
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1-
T C ) .
3. Barometric pressure is
between 850hpa and
1 1 0 0 h p a .
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)Fuel injection quantity is
reduced. 1. Engine speed is between
1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and 3200rpm (4JH1-TC).



















2. Injection quantity is
below 32mg/strk (4JA1-
TC) or 40mg/stk (4JH1-
T C ) .
3. Correct amount of mass
air flow.1. EGR valve is stuck at
o p e n p o s i t i o n .
2. EGR EVRV malfunction.
3 . A i r i n t a k e i s o b s t r u c t e d .
4. Air intake is leaking.
5. MAF sensor malfunction.
6. ECM malfunction.
8 8 /
97—
4 ON Exhaust Gas Recirculation
Circuit Short to Ground or
Open CircuitEGR EVRV circuit open or
short to ground circuit.Fuel injection quantity is
reduced and EGR EVRV
10% conditions as substitute.EGR EVRV circuit is correct
condition.1. EGR EVRV circuit open
or short to ground circuit.
2. EGR EVRV malfunction.
3. ECM malfunction.97 —
5 ON Exhaust Gas Recirculation
Flow Insufficient Detected1. Intake air temperature is
between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1-
T C ) .
3. Barometric pressure is
between 850hpa and
1 1 0 0 h p a .
4. Large mount of mass air
flow. (Desired mass air
flow - mass air flow is
below -150 mg/strk)Fuel injection quantity is
reduced. 1. Engine speed is between
1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and 3200rpm (4JH1-TC).



















2. Injection quantity is
below 32mg/strk (4JA1-
TC) or 40mg/stk (4JH1-
T C ) .
3. Correct amount of mass
air flow.1. EGR valve is stuck at
c l o s e p o s i t i o n .
2. EGR valve operating
vacuum hose is clogged
or disconnected.
3. EGR EVRV malfunction.


4. MAF sensor signal circuit
short to voltage circuit.
5. MAF sensor malfunction.
6. ECM malfunction.8 8 /
97—
8 ON Exhaust Gas Recirculation
Circuit Short to BatteryEGR EVRV circuit short to
voltage circuit.Fuel injection quantity is
reduced & EGR EVRV 10%
conditions as substitute.EGR EVRV circuit is correct
condition.1. EGR EVRV circuit short
t o v o l t a g e c i r c u i t .
2. EGR EVRV malfunction.
3. ECM malfunction.97 — Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–217
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 4)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 8)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The voltage on the coil of the relay glow plug is supplied
by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
66 P0380 4 ON Glo w Re la y Circuit Volta ge
Lo wGlow relay circuit open or
sho rt to ground circuit.No fa il-sa fe fun ctio n.
8 ON Glo w Re la y Circuit Volta ge
HighGlo w re la y circuit short to vo lt-
age circuit.

6E–222 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer
activated.
In the after glow phase the lamp is not illuminated butthe glow plugs remain active for a certain period
depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
67 P0381 4 ON Glo w Plug Indica to r Circuit
Voltage LowGlo w plug indicator circuit
open or short to ground cir-
cuit.No fa il-sa fe fun ctio n.
8 ON Glo w Plug Indica to r Circuit
Vo lta ge HighGlo w plug indicator circuit
short to voltage circuit.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–223
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, andpoor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P0381 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0381 (Symptom Code 4) (Flash Code 67)
Glow Plug Indicator Circuit Voltage Low
Step Action Value(s) Yes No
1Was 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 As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0381 (Symptom Code 4) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0381 (Symptom Code 4) 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 glow plug indicator lamp.
Does the lamp turn “On”?—Go to Step 5Go to Step 6
5 1. Ignition “On”, engine “Off”.
2. Check the glow plug indicator lamp.
Does the lamp turn “Off”?—Go to Step 9Go to Step 7
6 Check the glow plug indicator lamp bulb.
If the bulb is burnt out, repair as necessary.
Was the problem found?—Verify repair Go to Step 7