2004 ISUZU TF SERIES technical data

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Page 2575 of 4264

ISUZU TF SERIES 2004 Workshop Manual STARTING AND CHARGING SYSTEM 6D3-21
Technical Data
(mm)
Brush wear - Minimum Length 3.8
Sliprings - Minimum Diameter 26.7
Sliprings - Trueness <0.06
Pole claws - Trueness <0.05(93.25
0

Page 2638 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–62 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought proc

6E–62 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Thought Process
As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:
Improves your understanding and definition of the
customer complaint
Saves time by avoiding testing and/or replacing good
parts
Allows you to look at the problem from different
perspectives
Guides you to determine what level of understanding
about system operation is needed:
–Owner’s manual level
–Service manual level
–In-depth (engineering) level
–Owner’s manual level
–Service manual level
–In-depth (engineering) level
1. Verify the Complaint
What you should do
To verify the customer complaint, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the
system.
The following information will help you verify the
complaint:
WHAT the vehicle model/options are
WHAT aftermarket and dealer-installed accessories
exist
WHAT related system(s) operate properly
WHEN the problem occurs
WHERE the problem occurs
HOW the problem occurs
HOW LONG the condition has ex isted (and if the
system ever worked correctly)
HOW OFTEN the problem occurs
Whether the severity of the problem has increased,
decreased or stayed the same
What resources you should use
Whenever possible, you should use the following
resources to assist you in verifying the complaint:
Service manual Theory or Circuit Description
sections
Service manual “System Performance Check”
Owner manual operational description
Technician ex perience
Identical vehicle for comparisonCircuit testing tools
Vehicle road tests
Complaint check sheet
Contact with the customer
2. Perform Preliminary Checks
NOTE: An estimated 10 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
You perform preliminary checks for several reasons:
To detect if the cause of the complaint is VISUALLY
OBVIOUS
To identify parts of the system that work correctly
To accumulate enough data to correctly and
accurately search for a ISUZU Service Bulletin on
ISUZU Web site.
The initial checks may vary depending on the
complex ity of the system and may include the following
actions:
Operate the suspect system
Make a visual inspection of harness routing and
accessible/visible power and ground circuits
Check for blown fuses
Make a visual inspection for separated connectors
Make a visual inspection of connectors (includes
checking terminals for damage and tightness)
Check for any DTCs stored by the on-board
computers
Sense unusual noises, smells, vibrations or
mov ements
Investigate the vehicle service history (call other
dealerships, if appropriate)
What resources you should use
Whenever appropriate, you should use the following
resources for assistance in performing preliminary
checks:
Tech II or other technical equipment for viewing DTCs
Service manual information:
–Component locations
–Harness routing
–Wiring schematics
–Procedures for viewing DTCs
Dealership service history file
Vehicle road test
Identical vehicle or system for comparison

Page 2639 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–63
3. Check Bulletins and
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
Yo

ENGINE DRIVEABILITY AND EMISSIONS 6E–63
3. Check Bulletins and
Troubleshooting Hints
NOTE: As estimated 30 percent of successful vehicle
repairs are diagnosed with this step!
What you should do
You should have enough information gained from
preliminary checks to accurately search for a bulletin
and other related service information. Some service
manual sections provide troubleshooting hints that
match symptoms with specific complaints.
What resources you should use
You should use the following resources for assistance in
checking for bulletins and troubleshooting hints:
Printed bulletins
Access ISUZU Bulletin Web site.
Videotapes
Service manual
4. Perform Service Manual
Diagnostic Checks
What you should do
The “System Checks” in most service manual sections
and in most cells of section 8A (electrical) provide you
with:
A systematic approach to narrowing down the
possible causes of a system fault
Direction to specific diagnostic procedures in the
service manual
Assistance to identify what systems work correctly
What resources you should use
Whenever possible, you should use the following
resources to perform service manual checks:
Service manual
Technical equipment (for viewing DTCs and
analyzing data)
Digital multimeter and circuit testing tools
Other tools as needed
5a and 5b. Perform Service Manual
Diagnostic Procedures
NOTE: An estimated 40 percent of successful vehicle
repairs are diagnosed with these steps!
What you should do
When directed by service manual diagnostic checks,
you must then carefully and accurately perform the
steps of diagnostic procedures to locate the fault relatedto the customer complaint.
What resources you should use
Whenever appropriate, you should use the following
resources to perform service manual diagnostic
procedures:
Service manual
Technical equipment (for analyzing diagnostic data)
Digital multimeter and circuit testing tools
Essential and special tools
5c. Technician Self Diagnoses
When there is no DTC stored and no matching
symptom for the condition identified in the service
manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
service manual combined with you ex perience and a
good process of elimination will result in accurate
diagnosis of the condition.
What you should do
Step 1: Identify and understand the suspect
circuit(s)
Having completed steps 1 through 4 of the Strategy
Based Diagnostics chart, you should have enough
information to identify the system(s) or sub-system(s)
involved. Using the service manual, you should
determine and investigate the following circuit
characteristics:
Electrical:
–How is the circuit powered (power distribution
charts and/or fuse block details)?
–How is the circuit grounded (ground distribution
charts)?
–How is the circuit controlled or sensed (theory of
operation):
–If it is a switched circuit, is it normally open or
normally closed?
–Is the power switched or is the ground
switched?
–Is it a variable resistance circuit (ECT sensor
or TP sensor, for ex ample)?
–Is it a signal generating device (MAF sensor of
VSS, for example)?
–Does it rely on some mechanical/vacuum
device to operate?
Physical:
–Where are the circuit components (component
locators and wire harness routing diagrams):
–Are there areas where wires could be chafed
or pinched (brackets or frames)?
–Are there areas subjected to ex treme
temperatures?

Page 2640 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–64 ENGINE DRIVEABILITY AND EMISSIONS
–Are there areas subjected to vibration or
movement (engine, transmission or
suspension)?
–Are there areas ex posed to moisture, road salt
or other corros

6E–64 ENGINE DRIVEABILITY AND EMISSIONS
–Are there areas subjected to vibration or
movement (engine, transmission or
suspension)?
–Are there areas ex posed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
–Are there common mounting areas with other
systems/components?
–Have previous repairs been performed to wiring,
connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
–Does the vehicle have aftermarket or dealer-
installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem
At this point, you should have a good idea of what could
cause the present condition, as well as could not cause
the condition. Actions to take include the following:
Divide (and separate, where possible) the system or
circuit into smaller sections
Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
For two or more circuits that do not share a common
power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
Loose connections:
–Open/high resistance in terminals, splices,
connectors or grounds
Incorrect connector/harness routing (usually in new
vehicles or after a repair has been made):
–Open/high resistance in terminals, splices,
connectors of grounds
Corrosion and wire damage:
–Open/high resistance in terminals, splices,
connectors of grounds
Component failure:
–Opens/short and high resistance in relays,
modules, switches or loads
Aftermarket equipment affecting normal operation of
other systems
You may isolate circuits by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another part
Operating shared circuits and eliminating those that
function normally from the suspect circuit
If only one component fails to operate, begin testingat the component
If a number of components do no operate, begin tests
at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Technical equipment (for data analysis)
Ex perience
Technical Assistance
Circuit testing tools
5d. Intermittent Diagnosis
By definition, an intermittent problem is one that does
not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
Faulty electrical connections and wiring
Malfunctioning components (such as sticking relays,
solenoids, etc.)
EMI/RFI (Electromagnetic/radio frequency
interference)
Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
ex ternal and internal system conditions to duplicate the
problem.
What you should do
Step 1: A cquire information
A thorough and comprehensive customer check sheet
is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
Step 2: A nalyze the intermittent problem
Analyze the customer check sheet and service history
file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.

Page 2975 of 4264

ISUZU TF SERIES 2004 Workshop Manual GENERAL INFORMATION 0A-3

NOTES ON THE FORMAT OF THIS MANUAL
1. Find the applicable Section by referring to the index at the front of the Workshop Manual binder.
2. The following technical servi

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