2004 ISUZU TF SERIES ad blue

ENGINE ELECTRICAL (6VE1 3.5L) 6D1-3
4. Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
2.
Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE –The
battery is good and should be returned to
service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.


ESTIMATED TEMPERATURE MINIMUM
VOLTAGE





F




C V
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 –1 9.1
20 –7 8.9
10 –12 8.7
0 –18 8.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas o
r
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue do
t
or ring, it may be necessary to jiggle or tilt the
battery.
4. Battery temperature can have a great effect on
battery charging capacity.
5. The sealed battery used on this vehicle may be
either quick charged or slow charged in the same
manner as other batteries.
Whichever method you decide to use, be sure tha
t
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booste
r
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW
THE JUMP STARTING PROCEDURE COULD
RESULT IN THE FOLLOWING:
1. Serous personal injury, particularly to you
r
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one o
r
both vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire o
r
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with you
r
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any othe
r
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-5
ABBREVIATION CHARTS

Abbreviations Appellation
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
CMP Camshaft position
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 Exhaust gas recalculation
GND Ground
GRY Gray
HO2S Heated Oxygen Sensor
IAT Intake air temperature
IAC Idle air control
IG Ignition
M/T Manual transmission
MAF Mass air flow
MIL Malfunction indicator lamp
OBD On-board diagnostic
ORN Orange
PNK Pink
PROM Programmable read only memory
RED Red
SW Switch
TPS Throttle position sensor
TCM Transmission control module
VCC Voltage Constant Control
VIO Violet
VSS Vehicle speed sensor
WHT White
WOT Wide open throttle
YEL Yellow

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-29

No. Connector face No. Connector face
E-78

O2 sensor LH-Front P-1
SilverBattery (+)
E-79


Neutral start switch P-2
SilverRelay & Fuse box
F-2
White
Fuel pump & sensor P-5
SilverBattery (-)
H-4

White Engine ~ Engine room P-8

WhiteACG (L)
H-6
White
Engine room ~ INST P-10
SilverEngine ground
H-7
White
Engine room ~ INST X-2

BlackRelay ; Fuel pump
H-9
Blue
Engine room ~ Chassis X-13

BlackRelay ; ECM MAIN
H-18
White
Engine room ~ INST X-14

BlackRelay ; A/C Compressor
H-22

White
Engine ~ Engine room C X-15
BlackRelay ; Thermo
H-23

White Engine ~ Engine room B X-17
BlackDIODE

ENGINE MECHANICAL (C24SE) 6A-83
Crankshaft, Cylinder Block (continued)

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
Normal size
Bearing journal and colour code from 57.9820 green
to 57.9885
> 57.9885 brown
to 57.9950
25.900
25.850
48.988
48.970
26.580
26.460
26.390
26.338

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown-662N
green-663N brown-655N
green-658N

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.25mm Undersize for Production and Customer Service
Bearing journal and colour code from 57.7320 green/
to 57.7385 blue
> 57.7385 brown/
to 57.7450 blue
26.100
26.050
48.738
48.720
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown/blue-664 A
green/blue-655 A brown/blue-657 A
green/blue-658 A

Crankshaft
jounal
I, II, IV, V Guide
bearing
III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.50mm Undersize Customer Service
Bearing journal and colour code from 57.4820 green/
to 57.4885 blue
> 57.4885 brown/
to 57.4950 blue
26.300
26.250
48.488
48.470
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark brown/white-666 B
green/white-667 B brown/blue-659 B
green/blue-660 B

6D1-4 ENGINE ELECTRICAL

Battery Charging
Observe the following safety precautions when charging the
battery:
1. Never attempt to charge the battery when the fluid level is
below the lower level line on the side of the battery. In this
case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate o
f
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate o
f
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot or ring,
it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on battery
charging capacity.
5. The sealed battery used on this vehicle may be either quick
charged or slow charged in the same manner as othe
r
batteries.
Whichever method you decide to use, be sure that you
completely charge the battery. Never partially charge the
battery.































Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an attempt to
start it. Serious damage to the emission system as well as
other vehicle parts will result.
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the jump starting procedure, being careful
at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP
STARTING PROCEDURE COULD RESULT IN THE
FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery acid, o
r
an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical spark.
Gas generated by the battery may catch fire or explode.
Remove any rings, watches, or other jewelry before working
around the battery. Protect your eyes by wearing an approved
set of goggles.
Never allow battery fluid to come in contact with your eyes or
skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.

6E–6 ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATIONS CHARTS
A bbreviations A ppellation
A/C Air Conditioner
A/T Automatic Transmission
ACC Accessory
BLK Black
BLU Blue
BRN Brown
CEL Check Engine Lamp
CKP Crankshaft Position
DLC Data Link Connector
DTC Diagnostic Trouble Code
DVM Digital Volt Meter
ECM Engine Control Module
ECT Engine Coolant Temperature
EEPROM Electrically Erasable & Programmable Read Only Memory
EVAP Evaporative Emission
EVRV Electric Vacuum Regulating Valve
EXH Exhaust
FT Fuel Temperature
GND Ground
GRY Gray
HOS2 Heated Ox ygen Sensor
IAC Idel Air Control
IAT Intake Air Temperature
IG Ignition
ITP Intake Throttle Position
KS Knock Sensor
M/T Manual Transmission
MAP Manifold Absolute Pressure
MIL Malfunction Indicator Lamp
OBD On-Board Diagnostic
ORN Orange
OT Oil Temperature
PNK Pink
RED Red
SW Switch
TB Throttle Body
TEMP Temperature
TP Throttle Posi tion
VCC Voltage Constant Control
VSS Vehicle Speed Sensor
WHT Whi te
Y EL Yellow

ENGINE DRIVEABILITY AND EMISSIONS 6E–29
No. Connector face No. Connector face
E-84
Knock sensorP-1
Silver Battery (+)
E-85
MAP sensorP-2
Silver Relay & Fuse box
F-2
White Fuel pump & sensorP-5
Silver Battery (-)
H-4
White Engine room ~ MissionP-6
Silver Body earth (Ground)
H-6
White Engine room ~ INSTP-10
Silver Engine ground
H-7
White Engine room ~ INSTX-2
Black Relay; Fuel pump
H-9
Blue Engine room ~ ChassisX-11
Black Relay; Heater
H-18
White Engine room ~ INSTX-14
Black Relay; A/C Compressor
H-31
Engine room ~ Mission
H-34
Engine ~ Engine room

6E–234 ENGINE DRIVEABILITY AND EMISSIONS
12 Visually/physically inspect the secondary ignition
wires. Check for the following conditions:
Verify that all ignition wire resistance are less than
the specified value.
Verify that ignition wires are correctly routed to
eliminate cross-fitting.
Verify that ignition wires are not arcing to ground.
Spraying the secondary ignition wires with a light
mist of water may help locate an intermittent
problem.
Was a problem found?#1 cyl. 4.4k

#2 cyl. 3.6k

#3 cyl. 3.1k

#4 cyl. 2.8k
Verify repair Go to Step 13
13 1. Disconnect the spark plug high tension cable from
No.1 spark plug.
2. Install a spark tester at the end of the
disconnected ignition coil.
3. Clip the spark tester to a good ground.
4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same
as “No Spark”.)—Go to Step 21Go to Step 14
14 1. Disconnect the ignition coil harness connector.
2. Check for an open or short circuit between the
ignition coil and the ECM.
Was a problem found?—Verify repair Go to Step 15
15 1. Ignition “On”.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition coil harness connector.
Was the voltage equal to the specified value?Battery
voltage Go to Step 16Verify repair
16 1. Ignition “Off”.
2. With DVM, check for an open in the ground wire at
the ignition coil harness connector.
Was the ground wire OK?—Go to Step 17Verify repair
17 Replace the ignition coil, verify the repair.
Attempt to start the engine.
Is there still a problem?—Go to Step 18Verify repair
18 Use an ohmmeter to check the ignition coil primary
winding resistance.
Was the primary winding resistance approximately
equal to the specified value? 0.8-18k
Go to Step 19Go to Step 20
19 Use an ohmmeter to check the ignition coil secondary
winding resistance.
Was the primary winding resistance hear around the
to the specified value? 2.5k
Go to Step 21Go to Step 20
20 Replace the ignition coil.—Veri fy repai r—
21 1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
ex cessive fouling?—Correct the
fouling
condition Go to Step 22 Step Action Value(s) Yes No