2004 ISUZU TF SERIES switch

6D – 24 ENGINE ELECTRICAL


RTW46DSH002601
Important Operations
1. Lead Wire
Disconnect the lead wire at the magnetic switch.



RTW46DSH002701
3. Magnetic Switch Assembly
Remove the magnetic switch bolts, then remove the
switch from the shift lever.



RTW46DSH002801
Remove the torsion spring from the magnetic switch.




RTW46DSH002901
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.



RTW46DSH003001
11. Motor Assembly
Remove the four brushes from the brush holders.

ENGINE ELECTRICAL 6D – 29
REASSEMBLY



RTW46DLF000601


Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring

6D – 30 ENGINE ELECTRICAL


RTW46DSH005601
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.




RTW46DSH005701











7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.

Dust Cover Bolt Torque Nm (kgm/lbft)
8 (0.8/5.4)



10. Pinion Assembly
Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041



RTW46DSH004501
21. Brush Holders
1. Install the brushes into the brush holder with raising
the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of
the yoke and the brush holder.

ENGINE ELECTRICAL 6D – 31






24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque Nm (kgm/lbft)
8.1 (0.83/6.00)

065RY00044


RTW46DSH002601






25. Lead Wire
Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque Nm (kgm/lbft)
8.6 (0.88/6.40)







RTW46DSH005801












Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)

6D – 32 ENGINE ELECTRICAL


MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).





RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.




RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.




RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–5
DIAGNOSTIC TROUBLE CODE (DTC) P0400
(SYMPTOM CODE 8) (FLASH CODE 32)
EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO BATTERY ............................ 6E-227
Circuit Description ..................................... 6E-228
Diagnostic Aids .......................................... 6E-228
Diagnostic Trouble Code (DTC) P0400
(Symptom Code 3) (Flash Code 32) Ex haust
Gas Recirculation Flow Ex cessive Detected 6E-228
Diagnostic Trouble Code (DTC) P0400
(Symptom Code 4) (Flash Code 32) Ex haust
Gas Recirculation Circuit Short to Ground or
Open Circuit ............................................. 6E-232
Diagnostic Trouble Code (DTC) P0400
(Symptom Code 5) (Flash Code 32) Ex haust
Gas Recirculation Flow Insufficient Detected 6E-235
Diagnostic Trouble Code (DTC) P0400
(Symptom Code 8) (Flash Code 32) Ex haust
Gas Recirculation Circuit Short to Battery 6E-238
DIAGNOSTIC TROUBLE CODE (DTC) P0500
(SYMPTOM CODE 1) (FLASH CODE 24)
VEHICLE SPEED SENSOR CIRCUIT HIGH
INPUT ...................................................... 6E-240
DIAGNOSTIC TROUBLE CODE (DTC) P0500
(SYMPTOM CODE A) (FLASH CODE 24)
VEHICLE SPEED SENSOR INPUT SIGNAL
FREQUENCY TOO HIGH ....................... 6E-240
DIAGNOSTIC TROUBLE CODE (DTC) P0500
(SYMPTOM CODE B) (FLASH CODE 24)
VEHICLE SPEED SENSOR INCORRECT
SIGNAL ................................................... 6E-240
Circuit Description ..................................... 6E-241
Diagnostic Aids .......................................... 6E-241
Diagnostic Trouble Code (DTC) P0500
(Symptom Code 1) (Flash Code 24) Vehicle
Speed Sensor Circuit High Input ............. 6E-241
Diagnostic Trouble Code (DTC) P0500
(Symptom Code A) (Flash Code 24)
Vehicle Speed Sensor Input Signal
Frequency Too High ................................ 6E-245
Diagnostic Trouble Code (DTC) P0500
(Symptom Code B) (Flash Code 24)
VehicleSpeed Sensor Incorrect Signal .... 6E-248
DIAGNOSTIC TROUBLE CODE (DTC) P0560
(SYMPTOM CODE 1) (FLASH CODE 35)
SYSTEM VOLTAGE TOO HIGH ............. 6E-253
DIAGNOSTIC TROUBLE CODE (DTC) P0560
(SYMPTOM CODE 2) (FLASH CODE 35)
SYSTEM VOLTAGE TOO LOW .............. 6E-253
DIAGNOSTIC TROUBLE CODE (DTC) P0560
(SYMPTOM CODE A) (FLASH CODE 35)
SYSTEM VOLTAGE MALFUNCTION ..... 6E-253
Circuit Description ..................................... 6E-253Diagnostic Aids .......................................... 6E-254
Diagnostic Trouble Code (DTC) P0560
(Symptom Code 1) (Flash Code 35)
System Voltage Too High ........................ 6E-254
Diagnostic Trouble Code (DTC) P0560
(Symptom Code 2) (Flash Code 35)
System Voltage Too Low ......................... 6E-256
Diagnostic Trouble Code (DTC) P0560
(Symptom Code A) (Flash Code 35)
System Voltage Malfunction .................... 6E-258
DIAGNOSTIC TROUBLE CODE (DTC) P0561
(SYMPTOM CODE A) (FLASH CODE 18)
IGNITION SWITCH CIRCUIT
MALFUNCTION ....................................... 6E-260
DIAGNOSTIC TROUBLE CODE (DTC) P0561
(SYMPTOM CODE B) (FLASH CODE 18)
IGNITION SWITCH CIRCUIT
MALFUNCTION ....................................... 6E-260
Circuit Description ...................................... 6E-261
Diagnostic Aids .......................................... 6E-261
Diagnostic Trouble Code (DTC) P0561
(Symptom Code A) (Flash Code 18)
Ignition Switch Circuit Malfunction ........... 6E-261
Diagnostic Trouble Code (DTC) P0561
(Symptom Code B) (Flash Code 18)
Ignition Switch Circuit Malfunction ........... 6E-261
DIAGNOSTIC TROUBLE CODE (DTC) P0602
CONTROL MODULE PROGRAMMING
ERROR .................................................... 6E-264
Circuit Description & Diagnostic Aids ........ 6E-264
Diagnostic Trouble Code (DTC) P0602
Control Module Programming Error ......... 6E-264
DIAGNOSTIC TROUBLE CODE (DTC) P0606
(SYMPTOM CODE A) (FLASH CODE 28)
ECU MALFUNCTION .............................. 6E-265
DIAGNOSTIC TROUBLE CODE (DTC) P0606
(SYMPTOM CODE B) (FLASH CODE 28)
ECU MALFUNCTION .............................. 6E-265
Circuit Description & Diagnostic Aids ........ 6E-265
Diagnostic Trouble Code (DTC) P0606
(Symptom Code A) (Flash Code 28)
ECU Malfunction ...................................... 6E-265
Diagnostic Trouble Code (DTC) P0606
(Symptom Code B) (Flash Code 28)
ECU Malfunction ...................................... 6E-267
DIAGNOSTIC TROUBLE CODE (DTC) P0645
(SYMPTOM CODE 4) (FLASH CODE 46)
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE LOW ...................................... 6E-268
DIAGNOSTIC TROUBLE CODE (DTC) P0645
(SYMPTOM CODE 8) (FLASH CODE 46)
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE HIGH ...................................... 6E-268

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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–7
Temperature ............................................ 6E-302
Diagnostic Trouble Code (DTC) P1173
(Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel
Temperature ............................................ 6E-305
Diagnostic Trouble Code (DTC) P1173
(Symptom Code A) (Flash Code 22) Fuel
Reduction Caused By Low Fuel
Temperature ............................................ 6E-305
DIAGNOSTIC TROUBLE CODE (DTC) P1335
(SYMPTOM CODE A)
(FLASH CODE 43) ENGINE SPEED OUTPUT
CIRCUIT MALFUNCTION ....................... 6E-306
Circuit Description ..................................... 6E-306
Diagnostic Aids .......................................... 6E-306
Diagnostic Trouble Code (DTC) P1335
(Symptom Code A) (Flash Code 43)
Engine Speed Output Circuit Malfunction 6E-307
DIAGNOSTIC TROUBLE CODE (DTC) P1345
(SYMPTOM CODE A) (FLASH CODE 45)
CAMSHAFT SPEED MALFUNCTION ..... 6E-311
Circuit Description ..................................... 6E-311
Diagnostic Aids .......................................... 6E-311
Diagnostic Trouble Code (DTC) P1345
(Symptom Code A) (Flash Code 45)
Camshaft Speed Malfunction .................. 6E-312
DIAGNOSTIC TROUBLE CODE (DTC) P1520
(SYMPTOM CODE A) (FLASH CODE 47)
NEUTRAL SWITCH ON ERROR ............ 6E-313
DIAGNOSTIC TROUBLE CODE (DTC) P1520
(SYMPTOM CODE B) (FLASH CODE 47)
NEUTRAL SWITCH OFF ERROR .......... 6E-313
Circuit Description ..................................... 6E-313
Diagnostic Aids .......................................... 6E-313
Diagnostic Trouble Code (DTC) P1520
(Symptom Code A) (Flash Code 47)
Neutral Switch ON Error .......................... 6E-314
Diagnostic Trouble Code (DTC) P1520
(Symptom Code B) (Flash Code 47)
Neutral Switch OFF Error ........................ 6E-314
DIAGNOSTIC TROUBLE CODE (DTC) P1605
(SYMPTOM CODE C) (FLASH CODE 55)
SEED AND KEY FILE DESTROYED ...... 6E-318
DIAGNOSTIC TROUBLE CODE (DTC) P1605
(SYMPTOM CODE D) (FLASH CODE 55)
EEPROM DEFECT .................................. 6E-318
DIAGNOSTIC TROUBLE CODE (DTC) P1605
(SYMPTOM CODE E) (FLASH CODE 55)
EEPROM DEFECT .................................. 6E-318
Circuit Description & Diagnostic Aids ........ 6E-318
Diagnostic Trouble Code (DTC) P1605
(Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed .................. 6E-318Diagnostic Trouble Code (DTC) P1605
(Symptom Code D) (Flash Code 55)
EEPROM Defect ...................................... 6E-318
Diagnostic Trouble Code (DTC) P1605
(Symptom Code E) (Flash Code 55)
EEPROM Defect ...................................... 6E-318
DIAGNOSTIC TROUBLE CODE (DTC) P1610
(SYMPTOM CODE A) (FLASH CODE 56)
SECURITY KEY AND SECURITY CODE NOT
PROGRAMMED ...................................... 6E-320
Circuit Description ...................................... 6E-320
Diagnostic Aids .......................................... 6E-320
Diagnostic Trouble Code (DTC) P1610
(Symptom Code A) (Flash Code 56) Security
Key and Security Code Not Programmed 6E-320
DIAGNOSTIC TROUBLE CODE (DTC) P1611
(SYMPTOM CODE A) (FLASH CODE 56)
WRONG SECURITY CODE ENTERED .. 6E-322
Circuit Description ...................................... 6E-322
Diagnostic Aids .......................................... 6E-322
Diagnostic Trouble Code (DTC) P1611
(Symptom Code A) (Flash Code 56)
Wrong Security Code Entered ................. 6E-323
DIAGNOSTIC TROUBLE CODE (DTC) P1612
(SYMPTOM CODE A) (FLASH CODE 56)
IMMOBILIZER NO OR WRONG SIGNAL 6E-324
Circuit Description ...................................... 6E-324
Diagnostic Aids .......................................... 6E-324
Diagnostic Trouble Code (DTC) P1612
(Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal .............. 6E-325
DIAGNOSTIC TROUBLE CODE (DTC) P1613
(SYMPTOM CODE A) (FLASH CODE 56)
IMMOBILIZER NO OR WRONG SIGNAL 6E-330
Circuit Description ...................................... 6E-330
Diagnostic Aids .......................................... 6E-330
Diagnostic Trouble Code (DTC) P1613
(Symptom Code A) (Flash Code 56)
Immobilizer No or Wrong Signal .............. 6E-331
DIAGNOSTIC TROUBLE CODE (DTC) P1614
(SYMPTOM CODE A) (FLASH CODE 56)
WRONG TRANSPONDER KEY .............. 6E-335
Circuit Description ...................................... 6E-335
Diagnostic Aids .......................................... 6E-335
Diagnostic Trouble Code (DTC) P1614
(Symptom Code A) (Flash Code 56)
Wrong Transponder Key .......................... 6E-336
DIAGNOSTIC TROUBLE CODE (DTC) P1625
(SYMPTOM CODE A) (FLASH CODE 76) ECM
MAIN RELAY SWITCHED OFF
TOO EARLY ............................................ 6E-337
DIAGNOSTIC TROUBLE CODE (DTC) P1625