2004 ISUZU TF SERIES check engine

6E-362 3.5L ENGINE DRIVEABILITY AND EMISSIONS
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM
DEFINITIONS: Vehicle fails an emission test. There is
excessive "rotten egg" smell. (Excessive odors do no
t
necessarily indicate excessive emissions.)



Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go 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 4 Go to Visual /
physical Check.
4
Is the customer continual accelerated On/Off in cold
condition?
- System OK Go to Step 5
5
Is the customer used lead fuel?
- Replace to
Unlead fuel Go to Step 6
6
Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found?
- Verify repair &
Go to Step 17 Go to Step 7
7
1. Check fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 8
8
Check the fuel pressure. Refer to 6E-116 page Fuel
System Pressure Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 9
9
1. Check for faulty, plugged or incorrectly installed
PCV valve.
2. Verify that the PCV system is not plugged.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 10
10
Check the injector connectors, if any of the injectors
are connected an incorrect cylinder, correct as
necessary.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 11
11
Perform the Injector Coil/Balance Test.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 12
12
Check for a problem with the engine cooling system.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 13
13
Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 14

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-363
Step Action Value (s) Yes No
14
Check the EVAP purge solenoid valve operation.
Is the valve operated normally?
- Verify repair &
Go to Step 17 Verify repair &
Go to Step 15
15
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.

Internal catalytic converter failure.
Was a problem found?
- Verify repair &
Go to Step 17 Go to Step 16
16
1. Remove excessive carbon buildup with a top
engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test?
- System OK Go to Step 18
17
Perform the exhaust emission test.
Does the vehicle pass the test?
- System OK Go to Step 18
18
Check the fuel control Heated Oxygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn't check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may have
a white powdery coating. Silicon contamination sends
a rich exhaust signal which causes the ECM to
command and excessively lean air/fuel mixture.
Was a problem found?
- Verify repair Go to Step 19
19
Monitor "B1S1 (Bank 1 Sensor 1) Status" and "B2S1
(Bank 2 Sensor 1) Status" on the Tech 2.
Is the "B1S1 (Bank 1 Sensor 1) Status" or "B2S1
(Bank 2 Sensor 1) Status" in the rich condition?
- Go to Step 20 Go to Step 21
20
Check items that can cause the engine to run rich.
Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
Was a problem found?
- Verify repair Go to Step 22
21
Check items that can cause the engine to run lean.
Refer to DTC P0171 "O2 Sensor System Too Lean
(Bank 1)" or DTC P0174 "O2 Sensor System Tool
Lean (Bank 2)".
Was a problem found?
- Verify repair Go to Step 22
22
Check for the following engine mechanical problems
(refer to Engine Mechanical):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft. -Sticking or leaking valves.

Valve timing. -Broken valve springs.
Was a problem found?
- Verify repair Go to Step 23

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-365
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
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go 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 4 Go to Visual /
physical Check.
4
Check for a short between voltage circuit and the
ignition feed circuit.
Was a problem found?
- Verify repair Go to Step 5
5
Check the fuel leaking from injector. Perform the
Injector Coil/Balance Test.
Refer to 6E-106 page.
Was a 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
following:

Visual/physical inspection.

Tech 2 data.

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.
- Verify repair -

6E-366 3.5L ENGINE DRIVEABILITY AND EMISSIONS
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in
the exhaust system, making a loud popping noise.



Step Action Value (s) Yes No
1
Was the "On-Board Diagnostic (OBD) System Check"
performed?
- Go to Step 2 Go 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 4 Go to Visual /
physical Check.
4
Check for proper ignition voltage output with the spark
tester.
Was a problem found?
- Verify repair Go to Step 5
5
Check the ignition coils for cracks or carbon tracking.
If a problem is found, repair as necessary.
Was a problem found?
- Verify repair Go to Step 6
6
1. Remove the spark plugs and check for gas or oil
fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
Was a problem found?
- Verify repair Go to Step 7
7
Check the fuel pressure. Refer to Fuel System
Pressure Test.
Was a problem found?
- Verify repair Go to Step 8
8
Refer to 6E-116 page Fuel System Diagnosis to
determine if there is a problem with fuel delivery.
Was a problem found?
- Verify repair Go to Step 9
9
Check the CKP sensor signal, shield wire, or
installation condition. Refer to DTC P0336 "Crankshaft
Position Sensor Circuit Range/Performance" and DTC
P0337 "Crankshaft Position Sensor Circuit No Signal".
Was a problem found?
- Verify repair Go to Step 10

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-367
Step Action Value (s) Yes No
10
Check for the following engine mechanical problems
(refer to Engine Mechanical):

Low compression.

Leaking cylinder head gaskets.

Worn camshaft.

Sticking or leaking valves.

Valve timing.

Broken valve springs.

Camshaft drive belt slipped or stripped.
Was a problem found?
- Verify repair Go to Step 11
11
Check the intake and exhaust manifold for casting
flash. Refer to Engine Mechanical.
Was a problem found?
- Verify repair Go to Step 12
12
1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:

Visual/physical inspection.

Tech 2 data.

All electrical connections within a suspected circuit
and/or system.
Was a problem found?
- Verify repair Go to Step 13
13
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 14
14
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.
- Verify repair -

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-371
THROTTLE POSITION SENSOR
(TPS)

Location
Installed on the throttle body.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the TPS connector.
3. Loosen two screws and remove TPS from the
throttle body.




Installation Procedure
1. Temporary tighten the TPS by two screws.
2. Connect a TPS connectors to the TPS.
3. Connect the Tech2 to the vehicle.
4. Connect the negative battery cable.
5. Select "Data Display" with the Tech2.
6. Check the throttle position data and adjust the TPS
position.
7. Tighten two screws.

NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.



IDLE AIR CONTROL (IAC) VALVE

Location
Installed on the throttle body.

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the IAC valve connector.
3. Loosen two screws and remove IAC valve from
the throttle body.




Cleaning and Inspection
1. Clean the IAC valve O-ring sealing surface, pintle
valve seat and air passage.
2. Use carburetor cleaner and a parts cleaning brush
to remove carbon deposit.
Do not use a cleaner that contain methyl ethyl
ketone. This is an extremely strong solvent and no
t
necessary for this type of deposit.
3. Shiny spots on the pintle are normal and do no
t
indicate misalignment or a bent pintle shaft.
4. Inspect the IAC valve O-ring for cuts, cracks o
r
distortion.

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-375
3. Install the common chamber. Refer to common
chamber in engine Mechanical.




060RW044
4. Connect the vacuum hose on Canister Solenoid
and positive crankcase ventilation hose.
5. Connect the connectors to, solenoid valve.
6. Connect the accelerator pedal cable to throttle
body and cable bracket.
7. Install the engine cover.
8. Connect the negative battery cable.
9. Crank the engine until it starts. Cranking the
engine may take longer than usual due to trapped
air in the fuel rail and in the injectors.

FUEL INJECTORS

Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil fo
r
signs of contamination and change the oil and the
filter if necessary.
NOTE: Use care in removing the fuel injectors in
order to prevent damage to the fuel injecto
r
electrical connector pins or the fuel injector
nozzles. The fuel injector is an electrical component
and should not be immersed in any type of cleane
r
as this may damage the fuel injector.
Important: Fuel injectors are serviced as a complete
assembly only.
1. Disconnect the negative battery cable.
2. Remove the upper intake manifold. Refer to
Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail.




060RW044

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-379
IGNITION COIL

Removal Procedure
1. Disconnect battery ground cable.
2. Ignition coil connector and ignition coil.
 Disconnect three connector from ignition coil.
 Remove harness bracket bolt on cylinder head
cover.
 Remove fixing bolts on ignition coil.




060RW001
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assembly


Inspection Procedure
Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.


Terminal No. Limit
1 to 2 Without 0 ohm or infinity
maximum ohm.
1 to 3 Same as above
2 to 3 Same as above


Measure resistance of ignition coil assembly, and
replace the ignition coil assembly if its value exceeds
the standard.





060RW006

Installation Procedure
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
Torque: 4 N




m (0.4 kg




m/35 lb in)





060RW001
2. Connect battery ground cable.