2004 ISUZU TF SERIES seat adjustment

6E–64 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR ECM AND
SENSORS
Engine Control Module (ECM)
The engine control module (ECM) is located flower
panel just under the passenger's seat.
The fuel quantity and injection timing related functions
are controlled by the pump control unit (PSG).
The engine control module (ECM) performs the
following functions.
Control of the ex haust gas re-circulation (EGR)
Control of the quick on start (QOS) glow control
system
Control of the A/C compressor
Ex ecution of the immobilizer function
Pump Control Unit (PSG) & Data Exchange
Between Control Module
The radial plunger distributor type injection pump uses
two control modules to ex ecute full control of the enginemanagement system.
Engine Control Module (ECM)
Pump Control Unit (PSG) = Pumpen Steuer Great
(German)
The pump control unit (PSG) receives signals from the
sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from ex ternal sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
module (ECM) and the pump control unit (PSG) is
perfumed via a CAN-bus system. The abbreviation CAN
stands for Controller Area Network. By having two
separate control modules, the high pressure solenoid
valve. This prevents the discharge of any disturbing
signals.
The information ex change between the two control
modules takes place via two means.
Via analogue signal leads
Via the CAN-bus
The analogue signal leads are used to ex change the
following information.
Engine speed signal (ECM terminal 91)
Pump Speed (ECM terminal 105)
Fuel Cutoff solenoid valve signal (MAB signal) (ECM
terminal 105)
The engine speed signal is sent from the ECM to PSG
based on the input from the crank shaft position (CKP)
sensor.
The analogue CKP sensor signal is converted by the
ECM into a square wave signal.
The fuel cutoff solenoid valve signal is also referred to
as MAB signal.
MAB in this case, refers to the German abbreviation
Magnet ventil ABschaltung that stands for high pressure
solenoid v alv e cut off.
The MAB signal wire is used for two purposes.
-As a reference for the engine control module (ECM) for
the pump speed (back up for the CKP sensor).
-To turn Off the engine.
Sel f Dia gn osis / Interfa ce / Si gn al
To High Pressure Solenoid
Engine Speed
Injection Timing
Accelerator Pedal
Injection Quantity
In ta ke Air Temperat ure
Response Signal
Ma ss Air Flow
Additional Signal
Others

Additional Operations To Timing Control Valve (TCV)
Engin e
Con trol
Modu le
(ECM) Cam Rin g Rota tiona l Angle
Fuel Temper atu re
High Pressure
Solenoid Valve
Pump
Con tr ol Fuel Inject ion
Unit (Mechanical)
(PSG)

Ti m i n
g Devi ce

6A-62 ENGINE MECHANICAL (6VE1 3.5L)
5. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using the 5
8840
2446
0 valve
spring compresor and 5
8840
2547
0 valve
spring compressor adapter to install the spli
t
collars.



014RW042
6. Install tappet with shim.
7. Install camshaft assembly.
 Refer to installation procedure for Camshaft in
this manual.
Valve Clearance Adjustments
NOTE: To adjust valve clearance, apply engine oil to
the cam as well as to the adjusting shim (2) with the
cylinder head built on the cylinder block, give a fe
w
turns to the camshaft by means of timing pulley
tightening bolt, and measure valve clearance when the
nose of cam is just opposite to maximum cam lift (1) as
shown in illustration below.







014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet

Valve Clearance Standard Value (cold)
Intake: 0.23 mm




0.33 mm
(0.0091 in




0.0130 in)
Exhaust: 0.25 mm




0.35 mm
(0.0098 in




0.0138 in)
Selection of Adjusting Shim
Shim to be selected = (Thickness of removed
shim) + (Valve clearance measurement
Standard
value) Based on the above formula, the best suited
shim should be selected from 41 sorts of shim
(differently thick at 0.02mm (0.0008 in) intervals from
2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.

ENGINE DIAGNOSIS (C24SE) 6-11
Abnormal Combustion
Condition Possible cause Correction
Trouble in fuel injection system Fuel pressure control valve
defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump
loosely connected or defective Reconnect, correct or replace
Manifold Absolute Pressure
Sensor circuit open or shorted Correct or replace
Manifold Absolute Pressure
Sensor defective Replace
Engine Coolant Temperature
(ECT) Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Throttle Position Sensor
adjustment incorrect Reconnect
Throttle Position Sensor defective Replace
Throttle Position Sensor
connector loosely connected Reconnect
Vehicle Speed Sensor cable
loosely connected or defective Correct or replace
Vehicle Speed Sensor loosely
fixed Fix tightly
Vehicle Speed Sensor in wrong
contact or defective Replace
Engine Control Module cable
loosely connected or defective Correct or replace
Trouble in emission control
system Heated Oxygen Sensor circuit
open (If applicable) Correct or replace
Heated Oxygen Sensor defective
(If applicable) Replace
Signal vacuum hose loosely fitted
or defective Correct or replace
ECT Sensor circuit open or
shorted Correct or replace
ECT Sensor defective Replace
Evaporative Emission Control
system (If applicable) Refer to Section 6E
Trouble in ignition system - Refer to "Engine Lacks Power"
Trouble in cylinder head parts Carbon deposits in combustion
chamber Remove carbon
Carbon deposit on valve, valve
seat and valve guide Remove carbon

ENGINE MECHANICAL (C24SE) 6A-13
Valve System C24SE
Actuation Type Direct-acting Inverted Bucked Tappet
Valve Clearance Adjustment Hydraulic
Valve Rotor Type None
Inlet-Valve Material Chromium Alloyed Steel
-Seat Insert Material Sintered Iron
Exhaust-Valve Material Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated
-Seat Insert Material Sintered Iron
Valve Spring Material GME 06 100-C1
Valve Guide Material QS 13 MR 00
Valve Seal Type Lip

Water Pump C24SE
Type Centrifugal
Drive-Material &Type HNBR Toothed-belt
Bearing Type Double Row Ball
Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C24SE
Type Bypass

Oil Pump & Filter C24SE
Type Gear Pump
Location Front of Engine
Drive Direct Crankshaft Driven
Filter Type Full Flow with Bypass for blocked filter

Oil & Oil Reservoir C24SE
Reservoir-Description & Location 1-piece below Engine
Reservoir Material Aluminum Alloy (pressure cast)
Replacement Oil Fill Volume
-With Filter change 4.25liters
-Without Filter change 4.00liters
Recommended Oil-Run-in 10W/30SG
-Service (above-18C) 10W/40SG
-Service (below-18C) 5W/30SG
Oil Classification API&CCMC

Ignition Components C24SE
Spark Plugs Conventional
Type Electronic Spark Control
No. of Coils &Type 2 Solid State
Coil Location Engine-mounted
Ignition Lead Type Inductive (hi-resistance)

6A-78 ENGINE MECHANICAL (C24SE)

Adjustment Values/Checking Values

Valve clearance
Inlet Hydraulic valve lash adjustment
Outlet No adjustment necessary

Spark plugs - electrode gap 1.0  1.1mm

Compression The difference in compression
between the individual cylinders
in the engine must not exceed
100 kPa (1 bar).

Pressure loss The pressure loss of an engine
in perfect condition per cylinder
is not more than max. 25%
























Cylinder Head
Cylinder Head Gasket
Thickness - installed mm 1.2

Valve seat width at cylinder head
inlet mm 1.0 to 1.5
outlet mm 1.7 to 2.2

Valve stem play inlet mm 0.018 to 0.052
outlet mm 0.038 to 0.072

Permissible valve stem to cone runout
inlet mm 0.03
outlet mm 0.33

Overall height of cylinder head
(Sealing surface to sealing surface) mm 95.5  0.25

Installation height
inlet and
outlet valves mm 17.85 to 18.25
dimension "A" Distance Gauge
5-8840-2596-0

Installation height valve guide mm 83.50 to 83.80

Sealing surface peak-to-valley height mm max. 0.025

ENGINE DRIVEABILITY AND EMISSIONS 6E–55
Low or high spark plug installation torque or improper
seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table.
Low torque may result in poor contact of the seats due
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poor
contact between the seats. In ex treme cases, ex haust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug re-
gapping, or heat shock to the insulator material. Upper
insulators can be broken when a poorly fitting tool is
used during installation or removal, when the spark plug
is hit from the outside, or is dropped on a hard surface.
Cracks in the upper insulator may be inside the shell
and not visible. Also, the breakage may not cause
problems until oil or moisture penetrates the crack later.A broken or cracked lower insulator tip (around the
center electrode) may result from damage during re-
gapping or from “heat shock” (spark plug suddenly
operating too hot).
Damage during re-gapping can happen if the gapping
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
“Heat shock” breakage in the lower insulator tip
generally occurs during several engine operating
conditions (high speeds or heavy loading) and may
be caused by over-advanced timing or low grade
fuels. Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped, then

3C-36 FRONT SUSPENSION


Rubber seat


2.
Apply grease to the portion that fits into the bracket
then install height control arm and align the setting
marks (2).





410RS005
3. Apply grease to the bolt portion of the end piece
(4). Apply grease to the portion of the seat (5) that
fits into the bracket.





410RS008

4. Apply grease to the serrated portions.
5. Install adjust bolt and seat, then turn the adjust bolt
to the setting mark (1) applied during disassembly.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.






410RS004