2004 ISUZU TF SERIES battery

ENGINE DRIVEABILITY AND EMISSIONS 6E–203
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 P0562 stored as “Present Failure”?—Go to Step 3Refer 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 P0562 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14.5V Go to Step 6Go to Step 5
5 Using the DVM and check the battery voltage at the
battery terminal.
Does the tester indicate enough battery voltage?
10 - 14.5V Go to Step 6Check the
charging
system, charge
or replace the
battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
—Verify repair Go to Step 7
7 Check for poor/faulty connection of the ECM ground
at the inlet manifold. If a poor/faulty connection is
found, repair as necessary.
Was the problem found?
—Verify repair Go to Step 8
8 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 9
9 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.—Veri fy repai r— Step A ction Value(s) Yes No
16
2
17
12 C-56(J2)E-60(J1)
E-72

6E–204 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The engine control module (ECM) monitors the system
voltage on the ignition feed terminals to the ECM. A
system voltage Diagnostic Trouble Code will setwhenever the voltage is above a calibrated value.Diagnostic Aids
Check for a faulty charging system components.
Diagnostic Trouble Code (DTC) P0563 Sy stem Voltage High
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P0563 A System Voltage High Battery voltage is above 16V. No fail-safe function.
Step A ction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check

ENGINE DRIVEABILITY AND EMISSIONS 6E–205
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 P0563 stored as “Present Failure”?—Go to Step 3Refer 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 P0563 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage? Less than 16V Go to Step 5Check the
charging
system and Go
to Step 5
5 Is the battery jamp start cable incorrectly connecting?
—Verify
procedure Go to Step 6
6 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 7
7 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.—Veri fy repai r— Step A ction Value(s) Yes No

ENGINE DRIVEABILITY AND EMISSIONS 6E–233
ENGINE CRANKS BUT WILL NOT RUN
DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: 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.
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagosis.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to 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 4Go to Visual /
physical Check.
4 Check the “Ignition coil” fuse (15A) and “ECM” fuse
(15A).
Was a fuse blown?—Verify repair Go to Step 5
5 1. Ignition ON
2. Use a DVM to verify that battery voltage at the
ignition coil fuse, and the ECM fuse.
Was battery voltage presented at the fuses?—Go to Step 6Verify & repair
6 1. Visually/physically inspect for the following
conditions:
Restriction of air intake system. Check for a
restricted air filter element, or foreign objects
blocking the air intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
Was a problem found?—Verify repair Go to Step 7
7 1. Using a Tech 2, display the IAC value.
2. Check for a faulty, plugged, or sticking IAC
operation.
Was the problem found?—Verify repair Go to Step 8
8 1. Using a Tech 2, display the MAP sensor value.
2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Was the problem found?—Verify repair Go to Step 9
9 If oscilloscope is available, check the wave form of the
CKP signal.
Was the correct wave form found?—Go to Step 12Go to Step 10
10 Check the CKP sensor wire for open or short circuit.
Was a problem found?—Verify repair Go to Step 11
11 Replace CKP sensor.
Is there still problem?—Replace pulsar
ring. Verify repair

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

ENGINE DRIVEABILITY AND EMISSIONS 6E–261
DIESELING, RUN-ON SYMPTOM
DEFINITIONS: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check
the ignition switch and adjustment.
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to 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 visual/physical check performed?
—Go to Step 4Go to Visual /
physical Check.
4 Check for a short between battery voltage and the
ignition feed circuit.
Was a problem found?—Verify repair Go to Step 5
5 Check the fuel leaking from injector. Refer to Fuel
System Diagnostic.
Was the problem found?—Verify repair Go to Step 6
6 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
followi ng:
Visual/physical inspection
Te c h 2 d a t a
All electrical connections within a suspected
circuit and/or system
Was a problem found?—Verify repair Go to Step 7
7 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 8
8 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.—Veri fy repai r—

6E–264 ENGINE DRIVEABILITY AND EMISSIONS
ON-VEHICLE SERVICE PROCEDURE
ENGINE CONTROL MODULE (ECM)
Location
On the intake manifold.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the two connectors from the ECM.
3. Remove four bolts.
4. Remove the ECM from bracket.
Installation Procedure
1. Put on the ECM to the bracket.
2. Tighten the ECM by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 N·m (0.8 - 1.2 kgf·m)
3. Connect the two connectors to the ECM.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
CRANKSHAFT POSITION (CKP) SENSOR
Location
Left-hand side of the cylinder block. (Back of the A/C
compressor)
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the drive belt. Refer to Engine Mechanical
Section.
3. Remove the A/C compressor from engine. Refer to
Engine Mechanical Section.
4. Disconnect connector from the CKP sensor.
5. Loosen a bolt and remove the CKP sensor from the
cylinder block.
NOTE: Use caution to avoid any hot oil that might drip
out.
Installation Procedure
1. Install the CKP sensor to the cylinder block.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolt: 6N·m (0.6kgf·m)
3. Reinstall the A/C compressor to the engine.
4. Reinstall the accessory drive belt.
5. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.

ENGINE DRIVEABILITY AND EMISSIONS 6E–265
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
Location
Installed to the thermostat housing.
Removal Procedure
1. Disconnect the negative battery cable.
2. Drain enough engine coolant so that the coolant
level will be below the ECT sensor.
3. Disconnect connector from the ECT sensor.
4. Loosen and remove the ECT sensor from the
thermostat housing.
NOTE: Cool down the engine before above procedures
are carried out.
Installation Procedure
1. Apply sealer to threads of screw at the ECT sensor.
2. Tighten the ECT sensor with specified tightening
torque.
Tightening Torque
Bolt: 13N·m (1.3kgf·m)
3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.
5. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify no engine coolant leaking from the sensor
threads after replacement.
INTAKE AIR TEMPERATURE (IAT) SENSOR
Location
Installed to the intake duct housing.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect a IAT sensor connector from the IAT
sensor.
3. Remove the IAT sensor from the intake duct.
Installation Procedure
1. Install the IAT sensor into intake air duct.
2. Connect a IAT sensor connector to the IAT sensor.
3. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.