Throttle Position Sensor ISUZU TF SERIES 2004 Workshop Manual

8A-430 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
E-54
(6VE1)
Ignition coil E-62
(6VE1)
Cam position sensor
E-54
(4JH1-TC)
Black A/T term ASM E-64
(C24SE)
(6VE1)
Oil pressure switch (P/STRG)
E-55
(6VE1)
Ignition coil E-65
(C24SE)
(6VE1)
Thermo unit
E-56
(6VE1)
Ignition coil E-66
(C24SE)
(6VE1)
Duty solenoid
E-57
(6VE1)
Ignition coil E-67
NOT USED
E-58
(6VE1)
Ignition coil E-68
(C24SE)
Throttle position sensor
E-59
(C24SE)
(6VE1)
(6VE1) Crank position sensor (C24SE) E-68
(6VE1)
Throttle position sensor
E-60
(C24SE)
ECM E-69
(6VE1)
Temperature sensor
E-60
(6VE1)
ECM-A E-70
(C24SE)
IACV
E-61
(6VE1)
ECM-B E-70
(6VE1)
IACV

ENGINE COOLING 6B – 7
DIAGNOSIS
Engine Cooling Trouble
Symptom Possible Cause Action
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace

6C – 20 FUEL SYSTEM

7. Power Steering Pump Bracket


6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.

11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold
1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)

FUEL SYSTEM 6C – 25







13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket

15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.


Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)

17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump
(4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–1
ENGINE
CONTENTS
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATION CHARTS ........................ 6E-9
4JA1-TC .................................................... 6E-10
4JH1-TC .................................................... 6E-11
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-14
ECM CIRCUIT DIAGRAM (4JA1-TC) ........ 6E-15
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-16
ECM CIRCUIT DIAGRAM (4JH1-TC) ........ 6E-17
GROUND POINT CHART GENERAL EXPORT
(LHD) (1/4) ............................................... 6E-18
LOCATION ................................................ 6E-34
PARTS LOCATION ................................... 6E-39
CONNECTOR LIST ................................... 6E-40
RELAY AND FUSE .................................... 6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ........................................... 6E-44
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45
ECM WIRING DIAGRAM (1/7) .................. 6E-46
ECM WIRING DIAGRAM (2/7) .................. 6E-47
ECM WIRING DIAGRAM (3/7) .................. 6E-48
ECM WIRING DIAGRAM (4/7) .................. 6E-49
ECM WIRING DIAGRAM (5/7) .................. 6E-50
ECM WIRING DIAGRAM (6/7) .................. 6E-51
ECM WIRING DIAGRAM (7/7) .................. 6E-52
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL .................................... 6E-53
GENERAL DESCRIPTION FOR ECM AND
SENSORS ............................................... 6E-64
Engine Control Module (ECM) ................... 6E-64
Pump Control Unit (PSG) & Data Ex change
Between Control Module ......................... 6E-64
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor ....................... 6E-65
Throttle Position Sensor (TPS) .................. 6E-66
Crankshaft Position (CKP) Sensor ............ 6E-66
Engine Coolant Temperature (ECT) Sensor 6E-67
Vehicle Speed Sensor (VSS) .................... 6E-67
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION) ..... 6E-68
GENERAL DESCRIPTION FOR
INJECTION PUMP .................................. 6E-70Outline ....................................................... 6E-70
Cross-section View .................................... 6E-70
Low Pressure Fuel Circuit .......................... 6E-71
High Pressure Fuel Circuit ......................... 6E-72
Pump Camshaft Speed Sensor ................. 6E-72
High Pressure Solenoid Valve ................... 6E-73
Timing Control Valve (TCV) ....................... 6E-74
ISUZU Strategy Based Diagnostics .............. 6E-76
Overview .................................................... 6E-76
STRATEGY BASED DIAGNOSTICS CHART 6E-76
Diagnostic Thought Process ...................... 6E-77
1. Verify the Complaint .............................. 6E-77
2. Perform Preliminary Checks .................. 6E-77
3. Check Bulletins and Troubleshooting Hints 6E-78
4. Perform Service Manual Diagnostic Checks 6E-78
5a and 5b. Perform Service Manual Diagnostic
Procedures .............................................. 6E-78
5c. Technician Self Diagnoses .................. 6E-78
5d. Intermittent Diagnosis .......................... 6E-79
5e. Vehicle Operates as Designed ............ 6E-80
6. Re-examine the complaint ..................... 6E-81
7. Repair and Verify Fix ............................. 6E-81
GENERAL SERVICE INFORMATION ....... 6E-82
ON-BOARD DIAGNOSTIC (OBD) ............. 6E-82
TECH 2 OPERATING FLOW CART
(START UP) ............................................. 6E-86
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ................................... 6E-88
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ................................... 6E-90
MISCELLANEOUS TEST .......................... 6E-92
Plotting Snapshot Graph ............................ 6E-93
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) .......... 6E-94
Flow Chart for Snapshot Replay
(Plotting Graph) ....................................... 6E-95
SNAPSHOT DISPLAY WITH TIS2000 ...... 6E-96
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK .................................................... 6E-105
Circuit Description ...................................... 6E-105
Diagnostic Aids .......................................... 6E-105
Test Description ......................................... 6E-105

6E–6 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Circuit Description ..................................... 6E-268
Diagnostic Aids .......................................... 6E-268
Diagnostic Trouble Code (DTC) P0645
(Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low ... 6E-269
Diagnostic Trouble Code (DTC) P0645
(Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High .. 6E-272
DIAGNOSTIC TROUBLE CODE (DTC) P0703
(SYMPTOM CODE A) (FLASH CODE 25)
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
DIAGNOSTIC TROUBLE CODE (DTC) P0703
(SYMPTOM CODE B) (FLASH CODE 25)
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
Circuit Description ..................................... 6E-274
Diagnostic Aids .......................................... 6E-274
Diagnostic Trouble Code (DTC) P0703
(Symptom Code A) (Flash Code 25) Brake
Switch Circuit Malfunction ....................... 6E-274
Diagnostic Trouble Code (DTC) P0703
(Symptom Code B) (Flash Code 25)
Brake Switch Circuit Malfunction ............. 6E-278
DIAGNOSTIC TROUBLE CODE (DTC) P0704
(SYMPTOM CODE 6) (FLASH CODE 57)
CLUTCH SWITCH INPUT CIRCUIT
MALFUNCTION ....................................... 6E-281
Circuit Description ..................................... 6E-281
Diagnostic Aids .......................................... 6E-281
Diagnostic Trouble Code (DTC) P0704
(Symptom Code 6) (Flash Code 57)
Clutch Switch Input Circuit Malfunction ... 6E-282
DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE 1) (FLASH CODE 86)
BAROMETRIC PRESSURE SENSOR
CIRCUIT HIGH INPUT ............................ 6E-285
DIAGNOSTIC TROUBLE CODE (DTC) P1105
(SYMPTOM CODE 2) (FLASH CODE 86)
BAROMETRIC PRESSURE SENSOR
CIRCUIT LOW INPUT ............................. 6E-285
Circuit Description ..................................... 6E-285
Diagnostic Aids .......................................... 6E-285
Diagnostic Trouble Code (DTC) P1105
(Symptom Code 1) (Flash Code 86) Barometric
Pressure Sensor Circuit High Input ......... 6E-285
Diagnostic Trouble Code (DTC) P1105
(Symptom Code 2) (Flash Code 86) Barometric
Pressure Sensor Circuit Low Input .......... 6E-285
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 1) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
CIRCUIT HIGH INPUT ............................ 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 7) (FLASH CODE 21)PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE 9) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE D) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
BRAKE SWITCH ERROR ....................... 6E-287
DIAGNOSTIC TROUBLE CODE (DTC) P1120
(SYMPTOM CODE E) (FLASH CODE 21)
PEDAL/THROTTLE POSITION SENSOR
IDLE POSITION SWITCH ERROR ......... 6E-287
Circuit Description ...................................... 6E-288
Diagnostic Aids .......................................... 6E-288
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 1) (Flash Code 21)
Pedal/Throttle Position Sensor
Circuit High Input ..................................... 6E-288
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 7) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage
Supply Circuit High Input ......................... 6E-293
Diagnostic Trouble Code (DTC) P1120
(Symptom Code 9) (Flash Code 21)
Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input .......................... 6E-295
Diagnostic Trouble Code (DTC) P1120
(Symptom Code D) (Flash Code 21)
Pedal/Throttle Position Sensor Brake
Switch Error ............................................. 6E-298
Diagnostic Trouble Code (DTC) P1120
(Symptom Code E) (Flash Code 21)
Pedal/Throttle Position Sensor Idle
Position Switch Error ............................... 6E-300
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ...................................... 6E-302
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ...................................... 6E-302
DIAGNOSTIC TROUBLE CODE (DTC) P1173
(SYMPTOM CODE A) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY LOW FUEL
TEMPERATURE ...................................... 6E-302
Circuit Description ...................................... 6E-302
Diagnostic Aids .......................................... 6E-302
Diagnostic Trouble Code (DTC) P1173
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant

6E–8 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
(SYMPTOM CODE B) (FLASH CODE 76) ECM
MAIN RELAY SWITCHED OFF TOO LATE 6E-337
Circuit Description ..................................... 6E-337
Diagnostic Aids .......................................... 6E-337
Diagnostic Trouble Code (DTC) P1625
(Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early ......... 6E-338
Diagnostic Trouble Code (DTC) P1625
(Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late .......... 6E-339
DIAGNOSTIC TROUBLE CODE (DTC) P1630
(SYMPTOM CODE A) (FLASH CODE 51)
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION ....................................... 6E-340
DIAGNOSTIC TROUBLE CODE (DTC) P1630
(SYMPTOM CODE B) (FLASH CODE 51)
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION ....................................... 6E-340
Circuit Description ..................................... 6E-340
Diagnostic Aids .......................................... 6E-341
Diagnostic Trouble Code (DTC) P1630
(Symptom Code A) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction ...... 6E-341
Diagnostic Trouble Code (DTC) P1630
(Symptom Code B) (Flash Code 51) Fuel
Injection Quantity Circuit Malfunction ...... 6E-341
DIAGNOSTIC TROUBLE CODE (DTC) P1650
(SYMPTOM CODE A)
(FLASH CODE 44) CAN DEVICE OFFLINE 6E-342
DIAGNOSTIC TROUBLE CODE (DTC) P1650
(SYMPTOM CODE B) (FLASH CODE 44)
CAN DEVICE HANG-UP ......................... 6E-342
Circuit Description ..................................... 6E-342
Diagnostic Aids .......................................... 6E-342
Diagnostic Trouble Code (DTC) P1650
(Symptom Code A) (Flash Code 44)
CAN Device Offline .................................. 6E-343
Diagnostic Trouble Code (DTC) P1650
(Symptom Code B) (Flash Code 44)
CAN Device Hang-up .............................. 6E-348
DIAGNOSTIC TROUBLE CODE (DTC) P1651
(SYMPTOM CODE A) (FLASH CODE 45)
CAN MALFUNCTION .............................. 6E-349
DIAGNOSTIC TROUBLE CODE (DTC) P1651
(SYMPTOM CODE B) (FLASH CODE 45)
CAN RECEIVES ERROR ........................ 6E-349
Circuit Description ..................................... 6E-349
Diagnostic Aids .......................................... 6E-349
Diagnostic Trouble Code (DTC) P1651
(Symptom Code A) (Flash Code 45)
CAN Malfunction ...................................... 6E-350
Diagnostic Trouble Code (DTC) P1651
(Symptom Code B) (Flash Code 45) CAN Receives Error ................................ 6E-351
DIAGNOSTIC TROUBLE CODE (DTC) P1690
(SYMPTOM CODE 4) (FLASH CODE 77)
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE LOW ...................................... 6E-356
DIAGNOSTIC TROUBLE CODE (DTC) P1690
(SYMPTOM CODE 8) (FLASH CODE 77)
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE HIGH ...................................... 6E-356
Circuit Description ...................................... 6E-356
Diagnostic Aids .......................................... 6E-356
Diagnostic Trouble Code (DTC) P1690
(Symptom Code 4) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage Low .. 6E-357
Diagnostic Trouble Code (DTC) P1690
(Symptom Code 8) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage High . 6E-360
SYMPTOM DIAGNOSIS ............................ 6E-361
PRELIMINARY CHECKS .......................... 6E-361
VISUAL/PHYSICAL CHECK ...................... 6E-361
INTERMITTENT ........................................ 6E-361
ENGINE CRANKS BUT WILL NOT RUN .. 6E-362
HARD START SYMPTOM ......................... 6E-366
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM .................. 6E-370
SURGES AND/OR CHUGS SYMPTOM ... 6E-377
HESITATION, SAG, STUMBLE SYMPTOM 6E-383
CUTS OUT, MISSES SYMPTOM .............. 6E-389
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM .............................. 6E-396
POOR FUEL ECONOMY SYMPTOM ....... 6E-402
EXCESSIVE WHITE SMOKE .................... 6E-407
EXCESSIVE BLACK SMOKE .................... 6E-413
ON-VEHICLE SERVICE PROCEDURE .... 6E-418
ENGINE CONTROL MODULE (ECM) ... 6E-418
CRANKSHAFT POSITION (CKP) SENSOR 6E-419
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR ....................................... 6E-419
MASS AIR FLOW (MAF) & INTAKE AIR
TEMPERATURE (IAT) SENSOR ............ 6E-420
THROTTLE POSITION SENSOR (TPS) ... 6E-420
EGR EVRV
(Electrical Vacuum Regulating Valve) ..... 6E-421

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–9
ABBREVIATION CHARTS
A bbreviations A ppellation
A/C Air conditioner
A/T Automatic transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CAN Controller Area Network
CEL Check engine lamp
CKP Crankshaft position sensor
DLC Data link connector
DTC Diagnosis trouble code
DVM Digital voltage meter
ECM Engine control module
ECT Engine coolant temperature
EEPROM Electrically erasable & programmable read only memory
EGR Ex haust gas recirculation
EVRV Electric vacuum regulating valve
GND Ground
GRY Gray
IAT Intake air temperature
IG Ignition
M/T Manual transmission
MAB High pressure solenoid valve cutoff (German abbreviation)
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
RED Red
PSG Pump control unit (German abbreviation)
SW Switch
TCM Transmission control module
TCV Timing control valve
TDC Top dead center
TPS Throttle position sensor
VCC Voltage constunt control
VIO Violet
VSS Vehicle speed sensor
WHT Whi te
YEL Yellow

6E–12 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
324
1
(1) Throttle Position Sensor (TPS)
(2) Pump Control Unit (PSG)(3) Injection Pump Assembly
(4) Fuel Filter (Ex cept Euro 3)
213
(1) Mass Air Flow (MAF) & Intake Air Temperature
(IAT) Sensor Assembly
(2) EGR EVRV(3) Air Cleaner Case

6E–66 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Throttle Position Sensor (TPS)
The TPS is a potentiometer connected to throttle shaft
on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
delivery based on throttle valve angle.
Crankshaft Position (CKP) Sensor
The CKP sensor is located on top of the flywheel
housing of the flywheel and fix ed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
ex citer ring and is used to determine the engine speed
and engine cylinder top dead center (TDC). (1) Throttle Position Sensor (TPS)
(2) Idle Switch

1 2
Characteristic of TPS -Reference-
0 0.51 1.52 2.53 3.54 4.5
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pedal Position (%) (Tech2 Readin
g
Output Voltage (V)
(1) Crankshaft Position (CKP) Sensor
(2) Fly wheel with sensor slot

1 2