2004 ISUZU TF SERIES Workshop Manual

coolant level engine overheat transmission battery service schedule door lock

Page 2625 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–49
Throttle Position Sensor (TPS)
The TPS is a potentiometer connected to throttle shaft
on the throttle body.
The engine control module (ECM) monitors the volt

ENGINE DRIVEABILITY AND EMISSIONS 6E–49
Throttle Position Sensor (TPS)
The TPS is a potentiometer connected to throttle shaft
on the throttle body.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The throttle body has a throttle plate to control the
amount of the air delivered to the engine.
Engine coolant is directed through a coolant cavity in
the throttle body to warm the throttle valve and to
prevent icing.
Idle Air Control (IAC) Valve
The idle air control valve (IAC) valve is two directional
and gives 2-way control. With power supply to the coils
controlled steps by the engine control module (ECM),
the IAC valve's pintle is moved to adjust idle speed,
raising it for fast idle when cold or there is ex tra load
from the air conditioning or power steering.
By moving the pintle in (to decrease air flow) or out (to
increase air flow), a controlled amount of the air can
move around the throttle plate. If the engine speed is
too low, the engine control module (ECM) will retract the
IAC pintle, resulting in more air moving past the throttle
plate to increase the engine speed.
If the engine speed is too high, the engine control
module (ECM) will ex tend the IAC pintle, allowing less
air to move past the throttle plate, decreasing the
engine speed.
The IAC pintle valve moves in small step called counts.
During idle, the proper position of the IAC pintle is
calculated by the engine control module (ECM) based
on battery voltage, coolant temperature, engine load,
and engine speed.
If the engine speed drops below a specified value, and
the throttle plate is closed, the engine control module
(ECM) senses a near-stall condition. The engine control
module (ECM) will then calculate a new IAC pintle valve
position to prevent stalls.
If the IAC valve is disconnected and reconnected with
the engine running, the idle speed will be wrong. In this
case, the IAC must be reset. The IAC resets when the
key is cycled “On” then “Off”. When servicing the IAC, it
should only be disconnected or connected with the
ignition “Off”.
The position of the IAC pintle valve affects engine start-
up and the idle characteristic of the vehicle.
If the IAC pintle is fully open, too much air will be
allowed into the manifold. This results in high idle
speed, along with possible hard starting and lean air/
fuel ratio. (1) Throttle Position Sensor
(2) Idle Air Control (IAC) Valve
1
2
C haract erist ic of TPS -R ef erenc e-
0 0. 51 1. 52 2. 53 3. 54 4. 55
0 102030405060708090100
Th rot t le An gle ( % ) ( Tec h 2 R ea di n g)
Output Voltage (V)
StepCoilAB CDCoil A High
(EC M J1-28)On On
Coil A Low
(EC M J1-30)On On
Coil B High
(EC M J1-13)On On
Coil B Low
(EC M J1-29)On On

(IAC Valve Close Direction)
(IAC Valve Open Direction)

Page 2626 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–50 ENGINE DRIVEABILITY AND EMISSIONS
Crankshaft Position (CKP) Sensor
The crankshaft position (CKP) sensor, which sends a
signal necessary for deciding on injection timing to the
ECM, is mounted

Page 2627 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–51
Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other
words it meas

ENGINE DRIVEABILITY AND EMISSIONS 6E–51
Intake Air Temperature (IAT) Sensor
The IAT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other
words it measures a temperature value. Low air
temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is
hot.
Vehicle Speed Sensor (VSS)
The VSS is a magnet rotated by the transmission output
shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
Heated Oxygen (O2) Sensor
The heated ox ygen sensor consists of a 4-wire low
temperature activated zirconia ox ygen analyzer element
with heater for operating temperature of 315°C, and
there is one mounted on each ex haust pipe.
A constant 450millivolt is supplied by the ECM between
the two supply terminals, and oxygen concentration in
the ex haust gas is reported to the ECM as returned
signal voltage.
The ox ygen present in the ex haust gas reacts with the
sensor to produce a voltage output. This voltage should
constantly fluctuate from approx imately 100mV to
1000mV and the ECM calculates the pulse width
commanded for the injectors to produce the proper
combustion chamber mix ture.
Low ox ygen sensor output voltage is a lean mix ture
which will result in a rich commanded to compensate.
High ox ygen sensor output voltage is a rich mix ture
which result in a lean commanded to compensate.
When the engine is first started the system is in “Open
Loop” operation. In “Open Loop”, the ECM ignores the
signal from the ox ygen sensors. When various
conditions (ECT, time from start, engine speed &
ox ygen sensor output) are met, the system enters
“Closed Loop” operation. In “Closed Loop”, the ECM
calculates the air fuel ratio based on the signal from the
ox ygen sensors.
Heated ox ygen sensors are used to minimize the
amount of time required for closed loop fuel control to
begin operation and allow accurate catalyst monitoring.
The ox ygen sensor heater greatly decreases the
amount of time required for fuel control sensors to
become active.
Oxygen sensor heaters are required by catalyst monitor
and sensors to maintain a sufficiently high temperature
which allows accurate ex haust ox ygen content readings
further away from the engine.
C haract erist ic of I A T Sen sor -Ref erence-
10 100 1000 10000 100000
- 20 - 10 0 10 20 30 40 50 60 70 80 90 100 110 120
I nt ake A i r T emp. ( deg . C ) ( Tec h2 R eadi ng )
Resistance (ohm) (Solid Line)

Page 2628 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–52 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR FUEL
METERING
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps

6E–52 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR FUEL
METERING
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an in-line fuel filter.
The pump is designed to provide fuel at a pressure
above the pressure needed by the injectors.
A fuel pressure regulator in the fuel rail keeps fuel
available to the fuel injectors at a constant pressure.
A return line delivers unused fuel back to the fuel tank.
The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is
delivered to the engine by individual fuel injectors
mounted in the intake manifold.
The main control sensor is the heated ox ygen sensor
located in the ex haust system. The heated ox ygen
sensor reports to the ECM how much oxygen is in the
ex haust gas. The ECM changes the air/fuel ratio to the
engine by controlling the amount of time that fuel
injector is “On”.
The best mix ture to minimize exhaust emissions is 14.7
parts of air to 1 part of gasoline by weight, which allows
the catalytic converter to operate most efficiently.
Because of the constant measuring and adjusting of the
air/fuel ratio, the fuel injection system is called a “closed
loop” system.
The ECM monitors signals from several sensors in
order to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called “mode”.
All modes are controlled by the ECM.
Battery Voltage Correction Mode
When battery voltage is low, the ECM will compensate
for the weak spark by increasing the following:
The amount of fuel delivered.
The idle RPM.
Clear Flood Mode
Clear a flooded engine by pushing the accelerator pedal
down all the way. The ECM then de-energizes the fuel
injectors. The ECM holds the fuel injectors de-energized
as long as the throttle remains above 75% and the
engine speed is below 800 RPM. If the throttle position
becomes less than 75%, the ECM again begins to pulse
the injectors ON and OFF, allowing fuel into the
cylinders.
Deceleration Fuel Cutoff (DFCO) Mode
The ECM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air
flow. When deceleration is very fast, the ECM may cut
off fuel completely. Until enable conditions meet the
engine revolution less 1000 rpm or manifold absolute
pressure less than 10 kPa.
Engine Speed/ Vehicle Speed/ Fuel Disable
Mode
The ECM monitors engine speed. It turns off the fuel
injectors when the engine speed increases above 6000
RPM. The fuel injectors are turned back on when
engine speed decreases below 3500 RPM.
Acceleration Mode
The ECM provides ex tra fuel when it detects a rapid
increase in the throttle position and the air flow.
Fuel Cutoff Mode
No fuel is delivered by the fuel injectors when the
ignition is OFF. This prevents engine run-on. In addition,
the ECM suspends fuel delivery if no reference pulses
are detected (engine not running) to prevent engine
flooding.
Starting Mode
When the ignition is first turned ON, the ECM energizes
the fuel pump relay for two seconds to allow the fuel
pump to build up pressure. The ECM then checks the
engine coolant temperature (ECT) sensor and the
throttle position sensor to determine the proper air/fuel
ratio for starting.
The ECM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors
are energized by pulsing the injectors for very short
times.
Run Mode
The run mode has the following two conditions:
Open loop
Closed loop
When the engine is first started, the system is in “open
loop” operation. In “Open Loop,” the ECM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAP sensors.
The system remains in “Open Loop” until the following
conditions are met:
The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since starting
the engine.
Engine speed has been greater than a specified RPM
since start-up.
The specific values for the above conditions vary with
different engines and are stored in the programmable
read only memory (PROM). When these conditions are
met, the system enters “closed loop” operation. In
“closed loop,” the ECM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.

Page 2629 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–53
Fuel Metering System Components
The fuel metering system is made up of the following
parts.
Fuel injector
Throttle body
Fuel rail
Fuel pressure regulator

ENGINE DRIVEABILITY AND EMISSIONS 6E–53
Fuel Metering System Components
The fuel metering system is made up of the following
parts.
Fuel injector
Throttle body
Fuel rail
Fuel pressure regulator
ECM
Crankshaft position (CKP) sensor
Idle air control (IAC) valve
Fuel pump
Fuel Injector
The group fuel injection fuel injector is a solenoid
operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Ex cess fuel
not used by the injectors passes through the fuel
pressure regulator before being returned to the fuel
tank.
Fuel Pressure Regulator
The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the
other side. The fuel pressure regulator maintains the
fuel pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separately.
If the pressure is too low or poor performance, DTC
P0131 or P1171 will be the result. If the pressure is too
high, DTC P0132 or P1167 will be the result. Refer to
Fuel System Diagnosis for information on diagnosing
fuel pressure conditions.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator
maintains a constant fuel pressure at the injectors.
Remaining fuel is then returned to the fuel tank.
Fuel Pump Electrical Circuit
When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits
until the engine is cranked. When the engine is cranked
and the 58X crankshaft position signal has been
detected by the ECM, the ECM supplies 12 volts to the
fuel pump relay to energize the electric in-tank fuel
pump.
An inoperative fuel pump will cause a “no-start”
condition. A fuel pump which does not provide enoughpressure will result in poor performance.
Thottle Body Unit
The throttle body has a throttle plate to control the
amount of air delivered to the engine. The Thottle
position sensor and IAC valve are also mounted on the
throttle body.
Vacuum ports located behind the throttle plate provide
the vacuum signals needed by various components.
Engine coolant is directed through a coolant cavity in
the throttle body to warm the throttle valve and to
prevent icing.

Page 2630 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–54 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM
The engine use two ignition coils, one per two cylinders.
A two wire connector provides a battery voltage pr

6E–54 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM
The engine use two ignition coils, one per two cylinders.
A two wire connector provides a battery voltage primary
supply through the ignition fuse.
The ignition control spark timing is the ECM’s method of
controlling the spark advance and the ignition dwell.
The ignition control spark advance and the ignition dwell
are calculated by the ECM using the following inputs.
Engine speed
Crankshaft position (CKP) sensor
Engine coolant temperature (ECT) sensor
Throttle position sensor
Vehicle speed sensor
ECM and ignition system supply voltage
Ignition coil works to generate only the secondary
voltage be receiving the primary voltage from ECM.
The primary voltage is generated at the coil driver
located in the ECM. The coil driver generate the primary
voltage based on the crankshaft position signal. In
accordance with the crankshaft position signal, ignition
coil driver determines the adequate ignition timing and
also cylinder number to ignite.
Ignition timing is determined the coolant temperature,
intake air temperature, engine speed, engine load,
knock sensor signal, etc.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequently fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels
and lubricating oils with additives. Some electrode wear
will also occur. Engines which are not running properly
are often referred to as “misfiring.” This means the
ignition spark is not igniting the air/fuel mix ture at the
proper time. While other ignition and fuel system causes
must also be considered, possible causes include
ignition system conditions which allow the spark voltage
to reach ground in some other manner than by jumping
across the air gap at the tip of the spark plug, leaving
the air/fuel mix ture unburned. Misfiring may also occur
when the tip of the spark plug becomes overheated and
ignites the mixture before the spark jumps. This is
referred to as “pre-ignition.”
Spark plugs may also misfire due to fouling, ex cessive
gap, or a cracked or broken insulator. If misfiring occursbefore the recommended replacement interval, locate
and correct the cause.
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Ex cessive idling and slow speeds
under light engine loads can keep the spark plug
temperatures so low that these deposits are not burned
off. Very rich fuel mix tures or poor ignition system output
may also be the cause. Refer to DTC P1167.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of
combustion by-products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the center
electrode. If the fouling is found in only one or two
cylinders, valve stem clearances or intake valve seals
may be allowing ex cess lubricating oil to enter the
cylinder, particularly if the deposits are heavier on the
side of the spark plug facing the intake valve.
Ex cessive gap means that the air space between the
center and the side electrodes at the bottom of the
spark plug is too wide for consistent firing. This may be
due to improper gap adjustment or to ex cessive wear of
the electrode during use. A check of the gap size and
comparison to the gap specified for the vehicle in
Maintenance and Lubrication will tell if the gap is too
wide. A spark plug gap that is too small may cause an
unstable idle condition. Ex cessive gap wear can be an
indication of continuous operation at high speeds or
with engine loads, causing the spark to run too hot.
Another possible cause is an ex cessively lean fuel
mixture.

Page 2631 of 4264

ISUZU TF SERIES 2004 Workshop Manual 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

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

Page 2632 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–56 ENGINE DRIVEABILITY AND EMISSIONS
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should

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