2004 ISUZU TF SERIES ECU

6E-326 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered
Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go 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 By Priority" in "F0:
Diagnostic Trouble Code".
Is the DTC P1648 stored as "Present Failure"?
- Go to Step 3 Refer to
Diagnostic Aids
and Go to Step 3
3
1. Using the Tech2, ignition "On" and engine "Off".
2. Select "Clear DTC Information" with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the "F5: Failed
This Ignition" in "F2: DTC Information"
Was the DTC P1648 stored in this ignition cycle?
- Go to Step 4 Refer to
Diagnostic Aids
and Go to Step 4
4
1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "Immobilizer" in the system selection menu
"Body".
3. Select "Read DTC Info Ordered By Priority" in the
"Diagnositic Trouble Code".
Was the any DTC's B0002 or B0003 stored in this
ignition cycle?
- Refer to
"Immobilizer
Workshop
Manual" & Go to
DTC Chart
B0002 or B0003 Go to Step 5
5
Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the "SPS (Service Programming System)".
Was the problem solved?
- Verify repair Go to Step 6
6
Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual. Following
ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 “Immobilizer System-ECM replacement” for the
ECM/Immobilizer linking procedure.
- Verify repair -

6E-362 3.5L ENGINE DRIVEABILITY AND EMISSIONS
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM
DEFINITIONS: Vehicle fails an emission test. There is
excessive "rotten egg" smell. (Excessive odors do no
t
necessarily indicate excessive emissions.)



Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go to On Board
Diagnostic (OBD)
System Check
2
1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
- Verify repair Go to Step 3
3
Was a visually/physical check performed?
- Go to Step 4 Go to Visual /
physical Check.
4
Is the customer continual accelerated On/Off in cold
condition?
- System OK Go to Step 5
5
Is the customer used lead fuel?
- Replace to
Unlead fuel Go to Step 6
6
Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found?
- Verify repair &
Go to Step 17 Go to Step 7
7
1. Check fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 8
8
Check the fuel pressure. Refer to 6E-116 page Fuel
System Pressure Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 9
9
1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 10
10
Check the injector connectors, if any of the injectors
are connected an incorrect cylinder, correct as
necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 11
11
Perform the Injector Coil/Balance Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 12
12
Check for a problem with the engine cooling system.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 13
13
Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 14

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-377
FUEL PRESSURE REGULATOR

Removal Procedure
CAUTION: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fittings with a shop towel before disconnecting the
fittings. The towels will absorb any fuel that may
leak out. When the disconnect is completed, place
the towel in an approved container.
NOTE: Compressed air must never be used to test
or clean a fuel pressure regulator, as damage to the
fuel pressure regulator may result.
NOTE: To prevent damage to the fuel pressure
regulator, do not immerse the pressure regulator in
solvent.
1. Depressurize the fuel system. Refer to Fue
l
Pressure Relief Procedure.
2. Disconnect the negative battery cable.
3. Remove the fuel pump relay. Refer to Fuel Pump
Relay.
4. Remove the pressure regulator hose from the fuel
pressure regulator.
5. Remove the two bolts from the protector tha
t
secures the common chamber.



060RW066

6. Remove the fuel pressure regulator attaching
screw.




060RW116
7. Remove the fuel pressure regulator from the fuel
rail.

Disassembly Procedure
1. Remove the O-ring from the fuel pressure regulator.
2. Remove the fuel return line from the fuel pressure
regulator.
3. Remove the O-ring from the fuel return line.
 The O-ring may be left inside the fuel pressure
regulator instead of on the fuel return line.




060RW116

6E-378 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Assembly Procedure
1. Install a new O-ring on the fuel return line.
2. Install the fuel return line on the fuel pressure
regulator.
Do not over-tighten the swivel nut on the fuel pressure
regulator. The fuel pressure regulator can be damaged
and fuel may leak if the swivel nut is over-tightened.
3. Tighten the swivel nut.
4. Install a new O-ring on the fuel pressure regulator.

Installation Procedure
1. Install the fuel pressure regulator attaching screw.
Tighten
 Tighten the fuel pressure regulator attaching scre
w
to 3 Nm (0.3 kgm/26 lb in.).




060RW116
2. Install the fuel pressure regulator on the fuel rail.

3. Install the two bolts to the protector that secures
the common chamber.



060RW066
4. Install the pressure regulator hose to the fuel
pressure regulator.
5. Install the fuel pump relay. Refer to Fuel Pump
Relay.
6. Connect the negative battery cable.
7. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel lines.

ENGINE MECHANICAL (C24SE) 6A-69
FUEL INJECTION SYSTEM
MAP SENSOR


Removal
1. Disconnect the battery cable.
2. Disconnect the electrical connector from the sensor.
3. Remove the mounting bolts securing the sensor to the manifold.
4. Remove the sensor from the intake manifold.


Installation
1. Push MAP sensor into the manifold.
2. Install the mounting bolts and tighten them.
3. Connect electrical connector.
4. Connect the battery cable.









Pressure Regulator
Removal
1. Remove vacuum hose.
2. Remove fuel hoses.
3. Remove pressure regulator.

Installation
1. Install pressure regulator.
2. Install fuel hoses.
3. Install vacuum hoses.


ECM (Engine Control Module)
Removal

(2.4L)
1. Disconnect the ECM connector.
2. Remove the four hex bolts and nuts.
3. Remove the ECM from the ECM bracket on engine.

ENGINE MECHANICAL (C24SE) 6A-75









Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).

Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)

Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N

m (2.5
kgf
m) - use.

ENGINE FUEL (C24SE) 6C-11




140R100028
Reuse of Quick–Connector
 Replace the port and connector if scratch, dent or
crack is found.
 Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.

After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling a
t
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.




140R100036

Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dus
t
from sticking to the pipe surface –which may
decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON" position and listen
for pump start-up sound. Inspect for leaks, the
fuel pressure will increase as the fuel pump is
actuated.
3. Perform leak inspection (step 2) several times.
4. Start the engine and observe the engine idle speed.
The presence of dirt in the fuel system may affec
t
the fuel injection system.

STARTING AND CHARGING SYSTEM 6D3-13

5. During current output tests please make sure that the
ammeter is securely connceted into the charge circuit.
6. Some battery powered timing lights can produce high
transient voltages when connected or disconnected. Onl
y
disconnect or connect timing lights when the engine is
switched off.
7. Make sure the warning lamp circuit is functioning normall
y
before commencing tests.
8. Battery isolation switches must only be operated when the
engine is stopped.
9. To protect the charging system when using 240 vol
t
chargers it is recommeneded that the battery is
disconnected whilst charging.
10. Due to the very low resistance value of the stator winding i
t
may not be possible to obtain accurate readings withou
t
special equipment.
11. 12 volts must never be connected to the "L" terminal of the
regulator as this will damage the lamp driver circuit.
12. No loads apart from the warning lamp can be connected to
the "L" termainal. The "W" terminal is provided for this
purpose.

Disassembly
1. Mark the relative positions of the end housings in relation to
the stator assembly to aid reassembly. Use a permanen
t
marking pen do not use centre punched as this can cause
misalignmnet of the housings.
2. Remove the EP regulator from the slipring end housing b
y
removing the two screws. Tilt the regulator slightly from the
plug connection until the regulator clears the housing, then
lift clear.
3. Remove the four through bolts.
4. Carefully remove the stator assembly along with the slipring
end housing taking care not to put strain on the stator wires.
5. To disconnect the stator from the rectifier assembly, grasp
the stator wires close to the wire loop with a pair of long
nosed pliers, heat the joint with a soldering iron, when the
point becomes plastic apply a slight twisting motion to the
wires, then pull upwards to release the wires. Remove the
stator.
This procedure opens the wire loop to release the stato
r
connections easily.
6. To remove the rectifier remove the three retaining scre
w
and the B+ terminal nut and washers.

Note: the B+ bolt and the positive heatsink retaining screw are
fitted with mica insulating washers.
These must be discarded and replaced with new washers and
heatsink compound.