2004 ISUZU TF SERIES injector

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-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-374 3.5L ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance o
f
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.

1. Remove the fuel filler cap.
2. Remove the fuel pump relay.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.



FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
 Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
 Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
 Fittings should be capped and holes plugged
during servicing to prevent dirt and othe
r
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.

5. Disconnect the connectors from, solenoid valve,
sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do no
t
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retaine
r
clip must be replaced.
3. Drain residual fuel into an approved container.




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8. If removal of the fuel pressure regulator is
necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.

Installation Procedure
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

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

6E-376 3.5L ENGINE DRIVEABILITY AND EMISSIONS
4. Remove the injector retainer clip.






F06RW017
5. Remove the fuel injector assembly.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .

Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.

Installation Procedure
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.






F06RW017

4. Use new fuel injector retainer clips to retain the fuel
injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to Fuel Rail.




060RW044
7. Install the upper intake manifold. Refer to Common
Chamber in Engine Mechanical.
8. Install the engine cover.
9. Connect the negative battery cable.

6E-382 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME
5–8840–0285–0
(J 39200)
High Impedance
Multimeter (Digital
Voltmeter – DVM) Breaker Box
(1) PCMCIA Card
(2) RS232 Loop Back
Connector
(3) SAE 16/19 Adapter
(4) DLC Cable
(5) TECH 2 5–8840–2618–0
Fuel Injector Tester
5–8840–0385–0
(J 35616-A/BT-8637)
Connector Test Adapter
Kit
5–8840–0378–0
(J 34730-E)
Port Fuel Injection
Diagnostic Kit
5–8840–2635–0
(J 39021-90)
Injector Switch Box
5–8840–0383–0
(J 26792/BT-7220-1)
Spark Tester

6-2 ENGINE DIAGNOSIS (C24SE)
Engine Diagnosis
Hard Starting
1.Starting Motor Does Not Turn Over
Trouble Shooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim
considerably Battery run down or under
charged Recharge or replace battery
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect a high tension cable from any spark plug.
Connect the spark plug tester (use commercially
available tool), crank the engine, and check if a spark is
generated in the spark plug tester. Before cranking the
engine, make sure that the spark plug tester is properly
grounded. To avoid electrical shock, do not touch the
high tension cable while the engine is running.

Condition Possible cause Correction
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Spark plug wire in correct Connect properly or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s)
or engine Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or
broken Connect properly or replace
Electronic Ignition System with
module Replace
Poor connections in engine
harness Correct
Engine Control Module cable
disconnected or defective Correct or replace

6-4 ENGINE DIAGNOSIS (C24SE)
Rough Engine Idling or Engine Stalling
Condition Possible cause Correction
Trouble in fuel injection system Idle air control valve defective Replace
Throttle shutting off incomplete Correct or replace
Throttle position sensor circuit
open or shorted Correct or replace
Fuel injector circuits open or
shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Manifold Absolute Pressure
Sensor cable disconnected or
broken Correct or replace
Manifold Absolute Pressure
Sensor defective Replace
Engine Coolant Temperature
Sensor cable disconnected or
broken Correct or replace
Engine Coolant Temperature
Sensor defective Replace
Intake Air Temperature sensor
cable disconnected or broken Correct or replace
Intake Air Temperature sensor
defective Replace
Knock Sensor (KS) circuits open
or shorted Correct or replace
KS defective Replace
KS Module circuits open or
ground Correct or replace
KS Module defective Replace
Vehicle Speed Sensor circuit open
or shorted Correct or replace
Vehicle Speed Sensor defective Replace
Trouble in emission control
system Engine Control Module defective Replace
Canister purge solenoid circuit
open Correct
Canister purge solenoid defective Replace
Evaporative Emission Canister
Purge control valve defective Replace
Trouble in ignition system Refer to Hard Start
Troubleshooting Guide
Others Engine lacks compression Refer to Hard Start
Troubleshooting Guide
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace