2004 ISUZU TF SERIES ESP

6E–92 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
mechanical trouble and an electrical trouble.
Connect Tech 2 and select "Powertrain", "4JA1-TC
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
F0: Lamps
F0: Glow Time Telltale Test
When the Tech 2 is operated, "Glow Time Indicator
Lamp" is turned on or off.
The circuit is correct if the "Glow Time Indicator Lamp"
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
Press "Active" key.
Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is correct if engine speed is changed in
accordance with this operation.
Press "Increase" key.
Then, Desired Idle speed is increases
50rpm-by-50rpm up to 1200rpm. Engine speed is
also
EGR Solenoid Test
Desired Mass Air Flow 470 mg/strk
Mass Air Flow 450 mg/strk
Engine Speed 700 rpm
Exhaust Gas Recirculation 95%
Engine Speed (RPM) Control
Engine Speed 850 rpm
Desired Idle Speed 850 rpm
Injection Quantity 7.5 mg/ strk

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–97
After recording the snapshot in Tech2, transfer the data
from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot, data
parameter list is displayed on the screen.3. Snapshot data is displayed with TIS2000
[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
4. Select the transferred snapshot.
5. Open the snapshot, to display the data parameter
list on the screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter]
window opens.
2. Click the first graph icon of the window upper part,
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max .
3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the
parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter. For
displaying the graph display screen in full size,
move the cursor upward on the screen. When thecursor is changed to the magnifying glass form, click
the screen. Graph screen is displayed on the whole
screen.

6E–126 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
55 P1605 E ON EEPROM Defect EEPROM checksum does
not match with the read
check sum during
initialization of the ECM.EEPROM checksum match
with the read check sum
during initialization of the
ECM.ECM malfunction.
——
56 P1610 A - Security Key and Security
Code not ProgrammedImmobilizer functions are not
programmed in the ECM.1 . E n g i n e d o e s n o t s t a r t .
2. Check engine lamp flash. No recovery. ECM malfunction.
— B****
56 P1611 A - Wrong Security Code
EnteredReceived security code is not
correct.1 . E n g i n e d o e s n o t s t a r t .
2. Check engine lamp flash. N o r e c o v e r y . 1 . E C M m a l f u n c t i o n .
2. Immobilizer control unit
m a l f u n c t i o n .
3. Transponder key
malfunction.— B****
56 P1612 A - Immobilizer No or Wrong
SignalReceived challenge signal is
not correct or not received.1 . E n g i n e d o e s n o t s t a r t .
2. Check engine lamp flash. No recovery. 1. ECM and immobilizer
control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit.
2 . E C M m a l f u n c t i o n .
3. Immobilizer control unit
m a l f u n c t i o n .
4. Transponder key
malfunction.2 7 /
35B****
56 P1613 A - Immobilizer No or Wrong
SignalReceived response signal is
not correct or not received.1 . E n g i n e d o e s n o t s t a r t .
2. Check engine lamp flash. No recovery. 1. ECM and immobilizer
control unit
communication circuit
open circuit, short to
ground circuit or short to
voltage circuit.
2 . E C M m a l f u n c t i o n .
3. Immobilizer control unit
m a l f u n c t i o n .
4. Transponder key
malfunction.2 7 /
35B****
56 P1614 A - Wrong Transponder Key Received response signal is
not correct from the
transponder key.1 . E n g i n e d o e s n o t s t a r t .
2. Check engine lamp flash. N o r e c o v e r y . 1 . E C M m a l f u n c t i o n .
2. Immobilizer control unit
m a l f u n c t i o n .
3. Transponder key
malfunction.— B****
76 P1625 A OFF ECM Main Relay Switched
Off Too EarlyWhen ignition switch was
turned off, timing of the ECM
main relay turning off is too
early.No fail-safe function. No recovery. ECM malfunction.
3 /
58—
B OFF ECM Main Relay Switched
Off Too LateWhen ignition switch was
turned off, timing of the ECM
main relay turning off is too
late or does not off.No recovery. 1. ECM main relay
m a l f u n c t i o n .
2. ECM malfunction.3 /
58— Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

6E–330 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P1613 (SYMPTOM CODE A)
(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM decides whether that is an abnormality in the
immobilizer control system. DTC P1613 (Symptom
Code A) is recorded when received immobilizer
response signal was not correct.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM and immobilizer control unit-
Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P1613 display on the Tech2 while moving
connectors and wiring harnesses.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
56 P1613 A - Immobilizer No or Wrong Sig-
na lReceived response signal is
no t co rrect or not re ce iv ed.1. Engine does not start.
2. Check e ngine lamp fla sh.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–335
DIAGNOSTIC TROUBLE CODE (DTC) P1614 (SYMPTOM CODE A)
(FLASH CODE 56) WRONG TRANSPONDER KEY
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM decides whether that is an abnormality in the
immobilizer control system. DTC P1614 (Symptom
Code A) is recorded when received immobilizer
response signal was not correct from the transponder
key.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM and immobilizer control unit-
Inspect harness connectors for backed out terminals,
improper mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P1614 display on the Tech2 while moving
connectors and wiring harnesses.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
56 P1614 A - Wrong Transponder Key Received response signal is
not correct from the transpon-
der key.1. Engine does not start.
2. Check e ngine lamp fla sh.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–383
HESITATION, SAG, STUMBLE SYMPTOM
DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
time rpm
Sug
Hesitation Stumble
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(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 Is the customer using the incorrect fuel type? Diesel fuel
onlyReplace with
diesel fuel Go to Step 5
5 Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
Was a problem found?—Verify repair Go to Step 6
6 Visually/physically inspect for the following conditions.
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or ex cessive 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.
Restrict air intake system at the turbocharger.
Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
If a problem is found, repair as necessary.
Was a problem found?—Verify repair Go to Step 7
7 Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Was a problem found?—Verify repair Go to Step 8

6A-44 ENGINE MECHANICAL (6VE1 3.5L)
1. Remove engine assembly.

Refer to removal procedure for Engine
Assembly in this manual.
2. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
3. Remove oil pan and crankcase.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6. Remove oil pump assembly.

Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.

Refer to removal procedure for Rear Oil Seal in
this manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.

Install main bearing in the cylinder block and
main bearing cap respectively.

Apply new engine oil to upper and lower main
bearings.
NOTE:

Do not apply engine oil to the bearing back faces.

Make sure that main bearings are in correc
t
position.

Install crankshaft with care.

Apply engine oil to the thrust washer.

Install thrust washer on No.3 journal.

Oil grooves in thrust washer must face the
crankshaft.





015RS012



015RS013
2. Install crankshaft main bearing caps.


Apply engine oil to the thread and seating
surface of each bearing cap fixing bolt.
NOTE:

Do not apply engine oil to the bearing back faces.

Install bearing caps in the order of numbers,
starting with cylinder block front side.

Tighten main bearing fixing bolts to the specified
torque.
Torque: 39 N




m (4.0 kg




m/29 lb ft)


After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.

The cap number must be same as connecting
rod number.


Apply engine oil to the thread and seating
surface of each nut.

ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:

During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaf
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).



014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.


Inspection and Repair
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
Insufficient torque on head bolts
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:

  Do not attempt to weld the cylinder head.
Replace it.

  Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. I
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)



011RW019