2004 ISUZU TF SERIES lock

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-1
ENGINE
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
CONTENTS

Service Precaution................................................. 6D3-1
Starting System...................................................... 6D3-2
General Description............................................... 6D3-2
Diagnosis................................................................. 6D3-4
Starter...................................................................... 6D3-5
Removal............................................................... 6D3-5
Installation............................................................ 6D3-5
Disassembled View............................................ 6D3-6
Disassembly........................................................ 6D3-7
Inspection and Repair........................................ 6D3-9
Reassembly.........................................................6D3-12
Main Data and Specifications............................6D3-13
Charging System....................................................6D3-15
General Description................................................6D3-15
General On-Vehicle Inspection.............................6D3-15
Generator.................................................................6D3-16
Removal................................................................6D3-16
Inspection.............................................................6D3-16
Installation.............................................................6D3-16
Disassembled View.............................................6D3-17
Disassembly.........................................................6D3-17
Inspection and Repair.........................................6D3-20
Reassembly..........................................................6D3-22
Bench Test...........................................................6D3-22
Main Data and Specifications................................6D3-23


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

6D3-12 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
2. Check continuity between the lead wire of terminal
C and brush.
Replace the yoke assembly, if there is no continuity.





065RY00066
Overrunning Clutch
1. Visual check for excessive wear or damage.
2. Test the pinion rotation, it must rotate smoothly
when rotated clockwise and it shouldn't rotate when
turned counterclockwise.





065RY00067

Bearing
1. Inspect excessive wear or damage.
Replace the bearing if an abnormal noise is heard
under normal operating condition.





065RY00068
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
 Bearing in rear cover
 Gears in reduction gear
 Sliding portion of pinion

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-13
Main Data and Specifications
General Specifications

Model ADX4IH
Rating
Voltage 12 V
Output 1.4 Kw
Time 30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion) Clockwise
Weight(approx.) 3.8kg (8.4lb)
No–load characteristics
Voltage /Current 11.5V/90A or less
Speed 3000rpm or more
Load characteristics
Voltage/current 8.5V/350A or less
Torque 13.2Nm (1.35kgm/9.77lb in.) or more
Speed 1000rpm or more
Locking characteristics
Voltage/current 2.4V/500A or less
Torque 11.8N




m (1.2kg




m/8.68lb in) or more

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-23
Main Data and Specifications
General Specifications
Parts Number 102211-1740
Model ACJV74
Rated voltage 12 V
Rated output 90 A
Rotating direction (As viewed from pulled) Clockwise
Pulley effective diameter 57.5 mm (2.26 in)
Weight 5.1 kg (11 lb)

6E-54 3.5L 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 on the right-hand side of the cylinde
r
block.
The crankshaft has a 58 teeth press-fit timing disc, from
which the CKP sensor reads the position of the
crankshaft at all the times. It converts this to an
electrical signal, which it sends to the ECM.
Of the 58 teeth, 57 have a base with of 3°, and are
evenly spaced, but tooth No. 58 is 15° wide at its based
to serve as a timing mark, allowing the sensor to repor
t
the standard crankshaft position.
Using the 58 X signals per rotation and the timing-mark
signal sent by the CKP sensor, the ECM is able to
accurately calculate engine speed and crank position.
Also, the position of each cylinder is precisely known by
the ECM from signals sent by the camshaft position
(CMP) sensor, so the sequential multi-point fuel
injection can be controlled with accuracy.

The 58 X signals are converted by the ECM into a
retangle wave signal. This converted signal is sent from
the ECM terminal B12 to the tachometer and transfe
r
case control module (TCCM) terminal 15 (if 4WD
model).
Engine Coolant Temperature (ECT) Sensor




















The ECT sensor is a thermistor. A temperature
changes the resistance value. And it changes voltage.
In other words it measures a temperature value. It is
installed on the coolant stream. Low coolan
t
temperature produces a high resistance.
The ECM supplies 5 volts signal to the ECT senso
r
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.

Characteris tic of ECT Sens or
10 100 1000 10000 100000-3010 50 90130Temperature (

)
Resistance (Ω)

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-65
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 related
to 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 experience 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 o
r
normally closed?
 Is the power switched or is the ground
switched?
 Is it a variable resistance circuit (ECT senso
r
or TPS, for example)?
 Is it a signal generating device (MAF senso
r
of VSS, for example)?

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E -97

ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

RTW46EM F000401

CIRCUIT DESCRIPTION
The on-board diagnostic system check is the starting
point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical
check of the ECM and engine grounds for cleanliness
and tightness.
The on-board diagnostic system check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction.
DIAGNOSTIC AIDS
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness. Inspect the ECM harness and
connector for improper mating, broken locks, improperl
y
formed or damaged terminals, poor terminal-to-wire
connection, and damaged harness.

TEST DESCRIPTION
Number(s) below refer the step number(s) on the
Diagnostic Chart:
1. The Check Engine Lamp (MIL) should be ON
steady with the ignition "On", engine "Off". If not,
"No Check Engine Lamp (MIL)" chart should be
used to isolate the malfunction.
2. Checks the Class 2 data circuit and ensures that
the ECM is able to transmit serial data.
3. This test ensures that the ECM is capable o
f
controlling the Check Engine Lamp (MIL) and the
Check Engine Lamp (MIL) driver circuit is not
shorted to ground circuit.
4. If the engine will not start, "Engine Cranks But Will
Not Run" chart should be used to diagnose the
fault.
6. The Tech2 parameters which is not within the
typical range may help to isolate the area which is
causing the problem.
12. This vehicle is equipped with ECM which utilizes
an electrically erasable programmable read onl
y
memory (EEPROM).

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E -101

NO CHECK ENGINE LAMP (MIL)

RTW46EM F000401

CIRCUIT DESCRIPTION
The “Check Engine" lamp (MIL) should always be
illuminated and steady with the ignition “ON" and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The Engine Control
Module (ECM) turns the MIL “ON" by grounding the MIL
driver circuit.

DIAGNOSTIC AIDS
An intermittent MIL may be cased by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:

Inspect the ECM harness and connections fo
r
improper mating, broken locks, improperly formed o
r
damaged terminals, poor terminal-to-wire connection,
and damaged harness.

If the engine runs OK, check for a faulty light bulb, an
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
 If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.