2004 ISUZU TF SERIES glow

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–42 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
No. Connector face No. Connector face
H-33
Engine ~ Engine roomX-16
Black DIODE
P-1
Silver Battery (+)X-17
Black DIODE
P-2
Silver Relay & Fuse box
P-5
Silver Battery (-)
P-6
Silver Body earth (Ground)
P-10
Silver Engine ground
X-5
Black Relay ; Glow
X-13
Black Relay ; ECM MAIN
X-14
Black Relay; A/C Compressor
X-15
Black Relay; Thermo

6E–44 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
RELAY A ND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
No .RELAY
(4JA1-TC/4JH1-TC)
X -1 RELAY; TAIL LIGHT
X -2 RELAY; FRT F OG LI GHT
X -3 RELAY; HORN
X -4 RELAY; DIMMER
X -5 RELAY; GLOW
X -6 RELAY; COND, FAN
X -7 RELAY; RR FOG
X -8 RELAY; STARTER
X -9 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-RH (RHD)
X-10 SHORT CONNECTOR
(with Co oler) (LHD)
RELAY; HAZARD-LH (RHD)
X -11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE
SLOW BLOW FUSE
NO.FUSE
(4JA1-TC/4JH1-TC)
EB-1 10A ECM
EB-2 10A RR FOG
EB-3 15A FRT FOG
EB-4 —
EB-5 10A ILLUMI & TAIL-RH
EB-6 10A TAIL-LH
EB-7 10A H/LIGHT RH-LOW
EB-8 10A H/LIGHT LH-LOW
EB-9 10A TRA ILER
EB-10 10A AC G (S)
EB-11 10A H/LIGHT RH-HIGH
EB-12 10A H/LIGHT LH-HIGH
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD
NO.SLOW BLOW FUSE
4JA1-TC/4JH1-TC
SBF-1 80A MAIN
SBF-2 20A COND, FAN
SBF-3 50A GLOW
SBF-4 30A ECM
SBF-5 40A IG 1
SBF-6 40A ABS-1
SBF-7 30A ABS-2
SBF-8 30A BLOWER
SBF-9 50A IG 2

6E–54 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
41 41 A/C Compresso r
Re la yWH T/
GRNLess than
1V10-14V A/C comp. is operated:
L e s s t h a n 1 V
A/C comp. is not oper-
ated: 10 - 14VCo nnect DC V 41 GND
42 42 Che ck Engine La mp GRN/
YELLess than
1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 42 GND
43 43 Glow La mp ORG/
BLULess than
1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 43 GND
44 44 No Conne ctio n - - - - - - - - -
45 45 To Da ta Link Co nnec-
to r No . 6BLU Less than
1V10-14V Co nnect DC V 45 GND
46 46 No Conne ctio n - - - - - - - - -
47 47 No Conne ctio n - - - - - - - - -
48 48 No Conne ctio n - - - - - - - - -
49 49 Throttle Po sitio n Sen-
so r (TPS) Gro undBLK/
GRNIdle :
Approx.
0.4K ohm /
WOT:
Approx.
4.0K ohm---Discon-
ne ctOhm 38 49
50 50 No Conne ctio n - - - - - - - - -
51 51 No Conne ctio n - - - - - - - - -
52 52 No Conne ctio n - - - - - - - - -
53 53 No Conne ctio n - - - - - - - - -
54 54 No Conne ctio n - - - - - - - - -
55 55 No Conne ctio n - - - - - - - - -
56 56 No Conne ctio n - - - - - - - - -
57 57 Throttle Po sitio n Sen-
sor (TPS) Po wer Sup-
plyRED/
GRNLess than
1VAppro x . 5V Co nnect DC V 57 49
58 58 ECM Re lay BLU/
BLK10-14V Less than 1V Connect DC V 58 GND
59 59 No Conne ctio n - - - - - - - - -
60 60 No Conne ctio n - - - - - - - - -
61 61 No Conne ctio n - - - - - - - - -
62 62 No Conne ctio n - - - - - - - - -
63 63 ECM Power Supply Less than
1V10-14V - DC V 63 GND
64 64 No Conne ctio n - - - - - - - - -
65 65 Bra ke Switch 2 Signa l WHT/
BLKLess than
1VPedal is not stepped on: 10-14V
Pedal is stepped on: Less than 1VCo nnect DC V 65 GND
66 66 No Conne ctio n - - - - - - - - -
67 67 No Conne ctio n - - - - - - - - -
68 68 Vehicle Spe ed Se n-
so r (VSS)YEL/
GRN- Approx . 14.5Hz by wav e fo rm or
approx. 6.0V at vehicle speed 20km/hCo nnect AC V 68 GND
69 69 Idle Switch GRN/
BLKLess than
1VPedal is not stepped on: Less than 1V
Pedal is stepped on: Approx. 5VCo nnect DC V 69 GND
70 70 No Conne ctio n - - - - - - - - -
71 71 No Conne ctio n - - - - - - - - -
72 72 No Conne ctio n - - - - - - - - -
73 73 No Conne ctio n - - - - - - - - -
74 74 No Conne ctio n - - - - - - - - -Signal or Continuity Tester Position
Pin
No. B/Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRange (+) (-)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–55
75 75 No Conne ctio n - - - - - - - - -
76 76 No Conne ctio n - - - - - - - - -
77 77 No Conne ctio n - - - - - - - - -
78 78 No Conne ctio n - - - - - - - - -
79 79 No Conne ctio n - - - - - - - - -
80 80 No Conne ctio n - - - - - - - - -
81 81 No Conne ctio n - - - - - - - - -
82 82 No Conne ctio n - - - - - - - - -
83 83 Ma ss Air Flo w (MAF)
Se nso r Po wer SupplyWH T/
REDLess than
1VAppro x . 5V Co nnect DC V 83 92
84 84 Intake Air Tempera-
ture (IAT) Sensor Sig-
na lBLK/
BLULess than
1V0 deg. C: Approx. 3.6V / 20 deg. C:
Approx. 2.6V / 40 deg. C: Approx.
1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7VCo nnect DC V 84 92
85 85 No Conne ctio n - - - - - - - - -
86 86 No Conne ctio n - - - - - - - - -
87 87 Neutral Switch BLK/
WH TLess than
1VIn neutral: Less than 1V
Other than neutral: 10-14VCo nnect DC V 87 GND
88 88 Ma ss Air Flo w (MAF)
Se nso r SignalGRN/
REDLess than
1VAppro x . 1V Appro x .
1.8VApprox.
2.5VCo nnect DC V 88 92
89 89 Engine Coolant Tem-
perature (ECT) Sen-
so r S ig na lGRY Less than
1V0 deg. C: Approx. 4.4V / 20 deg. C:
Approx. 3.8V / 40 deg. C: Approx.
2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4VCo nnect DC V 89 93
90 90 CKP Se nso r Signal RED - - Appro x .
47Hz by
w a v e fo rm Approx.
134Hz by
wave form
or approx.
1.1VCo nnect AC V 90 98
91 91 CKP Senso r Output
To Pump Co ntrol Unit
(PSG) No.8PNK - - Appro x .
47Hz by
w a v e fo rm Approx.
134Hz by
wave form
or approx.
0.7VCo nnect AC V 91 GND
92 92 Ma ss Air Flo w (MAF)
Se nsor GroundBLK/
REDContinuity
with
gro und- - - Connect Ohm 92 GND
93 93 Engine Coolant Tem-
perature (ECT) Sen-
so r Gro undBLK/
PNKContinuity
with
gro und- - - Connect Ohm 93 GND
94 94 Glo w Relay BLK/
REDLess than
1VGlow system is operated: Less than
1 V
Glow system is not operated: 10 - 14VCo nnect DC V 94 GND
95 95 No Conne ctio n - - - - - - - - -
96 96 No Conne ctio n - - - - - - - - -
97 97 EGR EVRV BLK/
ORG- - Approx. 140Hz by wave
fo rm whe n EVRV is
operated----
98 98 CKP Se nsor Ground WHT Continuity
with
gro und- - - Connect Ohm 98 GND
99 99 CAN (Contro ller Are a
Ne two rk) to PSG No .1BLU--------
100 100 CAN (Contro ller Are a
Ne two rk) to PSG No .2YEL--------Signal or Continuity Tester Position
Pin
No. B/Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRange (+) (-)