Isuzu 20LE Скачать руководство пользователя страница 1

Страница: 1 / 510

WORKSHOP MANUAL

TF SERIES

GASOLINE ENGINE

(C22NE, 22LE, 20LE)

SECTION

6, 6A, 6B, 6C, 6D, 6E, 6F, 6G, 6H & 6J

Содержание 20LE

Страница 1: ...WORKSHOP MANUAL TF SERIES GASOLINE ENGINE C22NE 22LE 20LE SECTION 6 6A 6B 6C 6D 6E 6F 6G 6H 6J...

Страница 2: ...Engine Diagnosis 6A Engine Mechanical 6B Engine Cooling 6C Engine Fuel 6D1 Engine Electrical 6D2 Ignition System 6D3 Starting and Charging System 6E Driveability and Emissions 6F Engine Exhaust 6G Eng...

Страница 3: ...efully read and thoroughly understand the information contained in Section OA under the headings GENERAL REPAIR INSTRUCTIONS and HOW TO USE THIS MANUAL All material contained in this Manual is based o...

Страница 4: ...ling or Engine Stalling 6 4 Rough Engine Running 6 5 Hesitation 6 6 Engine Lacks Power 6 7 Engine Noisy 6 8 Abnormal Noise Due to Hydraulic Lash Adjustor 6 9 Troubleshooting Procedure 6 9 Abnormal Com...

Страница 5: ...lly 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...

Страница 6: ...inder head gasket defective Replace gasket Valve incorrectly seated Lap valve Valve stem seized Replace valve and valve guide Valve spring weakened Replace Cylinder or piston rings worn Overhaul engin...

Страница 7: ...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 M...

Страница 8: ...s power Spark plugs fouled Clean Fuel injectors defective Replace Manifold Absolute Pressure MAP Sensor or Manifold Absolute Pressure Sensor circuit defective Correct or replace Engine Coolant Tempera...

Страница 9: ...Fuel Pressure Control Valve leaking Replace Hesitation at high speeds Fuel injector not working normally Power supply or ground circuit for Multiport Fuel Injection System shorted or open Check and c...

Страница 10: ...ule supplied poor voltage Correct circuit Throttle Position Sensor cable disconnected or broken Correct or replace Throttle Position Sensor defective Replace Manifold Absolute Pressure Sensor not work...

Страница 11: ...n at 92 C 197 6 F Engine lacks compression Refer to Hard Start Others Tire inflation pressure abnormal Adjust to recommend pressures Brake drag Adjust Clutch slipping Adjust or replace Level of oil in...

Страница 12: ...bearing noise which becomes more evident when engine is accelerated Bearing or crankshaft pin worn Replace connecting rod bearings and crankshaft or regrind crankshaft and install the under size bear...

Страница 13: ...e Replace Timing wheels defective Replace Timing belt comes in contact with timing cover Replace timing belt and timing cover Valve noise Valve and valve guide seized Replace valve and valve guide Val...

Страница 14: ...Throttle Position Sensor defective Replace Throttle Position Sensor connector loosely connected Reconnect Vehicle Speed Sensor cable loosely connected or defective Correct or replace Vehicle Speed Se...

Страница 15: ...stion chambers due to poor seal in valve system Valve stem oil seal defective Replace Valve stem or valve guide worn Replace valve and valve guide Oil leaking into combustion chambers due to poor seal...

Страница 16: ...ctive Correct or replace Crankshaft bearing or connecting rod bearing worn Replace Oil contamination Wrong oil in use Replace with new engine oil Oil filter clogged Replace oil filter Cylinder head ga...

Страница 17: ...e shorted If applicable Correct Heated oxygen sensor circuit open If applicable Correct or replace Deterioration engine coolant temperature sensor of internal element Replace Engine coolant temperatur...

Страница 18: ...A 26 OPERATIONS ON INSTALLED ENGINE 6A 28 Gasket Exhaust Manifold Cylinder Head 6A 28 Gasket Intake Manifold Clinder Head 6A 28 Seal Ring Camshaft Housing Timing Side 6A 29 Seal Ring Thermostat Housin...

Страница 19: ...CRANK DRIVE 6A 53 Con Rod Bearing 6A 53 Piston with Con Rod 6A 53 Con Rod 6A 54 Pistion Rings 6A 55 OPERATIONS ON REMOVED ENGINE 6A 57 Crankshaft 6A 57 Bearing Free Play Measurement 6A 59 Plastigage M...

Страница 20: ...6A 70 Map Sensor 6A 70 Pressure Regulator 6A 70 ECM Engine Control Module 6A 70 ECT 6A 71 Idle Air Control IAC Valve 6A 71 Ignition Coil 6A 71 Crank Position Sensor 6A 72 FUEL INJECTOR 6A 73 Knock Se...

Страница 21: ...d to all friction areas during assembly to protect and lubricate the surfaces on initial operation Whenever valve train components pistons piston rings connecting rods rod bearings and crankshaft jour...

Страница 22: ...ade of cast iron The crankshaft is supported by five bearings The bearing cap is made of nodular cast iron Cylinder Head The cylinder head is made of aluminum alloy casting with a spark plug in the ce...

Страница 23: ...6A 6 ENGINE MECHANICAL C22NE 22LE 20LE ENGINE PICTORIAL Front View 4WD OIL PAN...

Страница 24: ...ENGINE MECHANICAL C22NE 22LE 20LE 6A 7 Inlet Side View 4WD OIL PAN...

Страница 25: ...6A 8 ENGINE MECHANICAL C22NE 22LE 20LE Rear View 4WD OIL PAN...

Страница 26: ...ENGINE MECHANICAL C22NE 22LE 20LE 6A 9 Exhaust Side View 4WD OIL PAN...

Страница 27: ...6A 10 ENGINE MECHANICAL C22NE 22LE 20LE Top View...

Страница 28: ...0 0 Intake valves Open at BTDC deg 29 Close at ABDC deg 65 Exhaust valves Open at BBDC deg 66 Close at ATDC deg 29 Ignition system Fully transistorized battery ignition Distributor type Not applicabl...

Страница 29: ...ystem Equipped H2OS Compression Ratio with Tolerance 9 2 1 0 3 8 6 1 0 3 8 8 1 0 3 Cylinder Head Material Aluminum Alloy gravity cast Cylinder Block Material Cast Iron No of Mounting Points including...

Страница 30: ...haft Seal Type Mechanical Ceramic Thermostat Coolant C22NE 22LE 20LE Type Bypass Oil Pump Filter C22NE 22LE 20LE Type Gear Pump Location Front of Engine Drive Direct Crankshaft Driven Filter Type Full...

Страница 31: ...LE Material Aluminium Alloy Finish Type Tin coated Strutless Piston Rings C22NE 22LE 20LE Function top to bottom Ring 1 Compression Ring Ring 2 Compression Ring Ring 3 Oil Ring Description Ring 1 Rect...

Страница 32: ...E TA TC TD TC ENGINE TYPE C22NE FUEL CONTROL SYSYTEM OPEN LOOP CLOSED LOOP CLOSED LOOP COMPRESSION RATIO 9 2 1 FUEL OCTANE ROD 91RON 85RON 85RON FUEL TYPE UN LEADED UN LEADED UN LEADED HO2 NO YES YES...

Страница 33: ...PEN LOOP COMPRESSION RATIO 80RON FUEL OCTANE ROD 85RON 91RON 91RON 85RON 80RON FUEL TYPE UN LEADED LEADED LEADED LEADED LEADED UN LEADED UN LEADED LN LEADED UN LEADED HO2 YES NO NO NO NO EVAP CANISTER...

Страница 34: ...CONTROL SYSYTEM OPEN LOOP OPEN LOOP OPEN LOOP OPEN LOOP COMPRESSION RATIO 8 6 1 8 8 1 FUEL OCTANE ROD 80RON 80RON 80RON 91RON FUEL TYPE LEADED LEADED LEADED LEADED HO2 NO NO NO NO EVAP CANISTER YES YE...

Страница 35: ...crankcase vapours via the Engine Vent Pipe to the Cam Support Cover where separation of oil and exhaust gases occur The oil drains into the Cylinder Head via the Camshaft Support The gases pass throug...

Страница 36: ...justing Screw 4 P S Adjusting Plate 5 P S Adjusting Nut 6 Alternator Fan Drive Belt 7 A C Compressor Drive Belt 8 P S Pump Drive Belt 9 Tensioner Bolt 10 Tensioner Pulley 11 Pulley Dust Shield Cover 1...

Страница 37: ...inlet hose 4 Remove power steering pump drive belt and power steering pump from engine 5 Remove all cable connections hoses and lines from engine 6 Remove accelerator cable from inlet pipe 7 Remove e...

Страница 38: ...wer engine into engine compartment and insert guide bushings on cylinder block into transmission Tighten Torque Transmission to cylinder block M10 45 N m 4 6 kgf m Transmission to cylinder block M12 6...

Страница 39: ...to the corresponding operation Installation 7 Install radiator according to the corresponding operation 8 Install air inlet hose 9 Install all electrical cable connections hoses and lines to engine 1...

Страница 40: ...haft gear aligns with the mark on toothed belt rear cover 2 Check the timing belt for worn cracks or oil adhesion 3 Check that the cast on the water pump aligns with the counterpart on cylinder block...

Страница 41: ...pulley while counterholding on the fastening bolt of toothed belt drive gear 3 Install the fan shroud Tighten Torque Crankshaft pulley bolts 20 N m 2 1 kgf m 4 Install the fan belt 5 Install the V bel...

Страница 42: ...erclockwise until pointer 2 comes to the right stop 3 If necessary tighten the fastening bolt of toothed belt tension roller 4 Rotate the crankshaft twice 720 in the engine rotational direction until...

Страница 43: ...move the fan belt 6 Remove the fan shroud 7 Remove the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear 8 Remove the toothed belt from cover Adjust Turn the cran...

Страница 44: ...n 1 Install a new toothed belt while keeping tension side taut Adjust Toothed belt tension see operation Toothed Belt Tension 2 Install the toothed belt to the cover 3 Install the crankshaft pulley wh...

Страница 45: ...ld to cylinder head 22 N m 2 2 kgf m Front exhaust pipe to exhaust manifold 25 N m 2 6 kgf m Gasket Intake Manifold Cylinder Head Removal 1 Remove air intake hose 2 Remove drive belt for alternator 3...

Страница 46: ...seal lips of shaft seal ring slightly Seal Ring Thermostat Housing Cylinder Head Removal 1 Open radiator drain tap and collect coolant 2 Remove toothed belt rear cover and toothed belt according to t...

Страница 47: ...corresponding operation Tighten Torque Thermostat housing to cylinder head 15 N m 1 5 kgf m Seal Ring Front Camshaft Housing Replace Removal Mark running direction of toothed belt Remove toothed belt...

Страница 48: ...rhold at hex head of camshaft camshaft housing cover Toothed belt see operation Toothed Belt Replace Note operating erection of toothed belt Tighten Torque Camshaft pulley to cammshaft 45 N m 3 7 kgf...

Страница 49: ...toothed belt tension roller according to the operation Toothed Belt Tension Roller 4 Remove fastening bolt while counterholding with 5 8840 2598 0 Holding wrench 5 Remove toothed belt drive gear while...

Страница 50: ...N m 13 3 kgf m 5 Install toothed belt according to the operation Toothed Belt Toothed Belt Tension Roller Removal 1 Mark operating direction of toothed belt 2 Remove toothed belt according to the ope...

Страница 51: ...6A 34 ENGINE MECHANICAL C22NE 22LE 20LE COMPONENT PARTS CYLINDER HEAD A 1 Camshaft Housing Cover 2 Camshaft Housing 3 Camshaft 4 Cylinder Head A Valve Drive...

Страница 52: ...GINE MECHANICAL C22NE 22LE 20LE 6A 35 HYDRAULIC VALVE LIFTER 1 Hydraulic Valve Lifter 1 Oil reservoir 2 Piston with ball head moving 3 Pressure Cylinder fixed 4 Check ball 5 Pressure chamber 6 Oil fee...

Страница 53: ...g on base provided 3 Remove rear sealing gasket and plate camshaft housing with taking care not to damage housing 4 Remove thrust plate 5 Remove camshaft 6 Remove front sealing gasket and plate from c...

Страница 54: ...e valve 6 Remove V belt for alternator 7 Remove front toothed belt cover according to the corresponding operation 8 Bring piston of 1st cylinder to TDC and mark the position 9 Remove camshaft housing...

Страница 55: ...over Torque Angle Method Cylinder head to cylinder block 25 N m 2 5 kgf m Further turn angle 90 90 90 Tighten cylinder head bolts from inside outwards In four stages in a spiral pattern 5 Install rear...

Страница 56: ...gear in the direction of the engine rotation until the cam of hydraulic valve lifter being replaced stands vertically Removal 4 Apply 5 8840 0457 0 to the camshaft housing valve spring cap and tension...

Страница 57: ...t in camshaft housing Adjust Adjustment of the hydraulic valve liters is not required Pretension is provided by the design Installation 1 Remove 5 8840 0457 0 and install the camshaft housing cover 2...

Страница 58: ...face to sealing surface Dimension I 74 0 mm Cylinder Head Removal and Installation Important Only remove cylinder head with engine cold room temperature Removal 1 Remove the alternator power steering...

Страница 59: ...inder head bolts spirally from the outside inwards first 1 4 then 1 2 revolution Removal 1 Remove the camshaft housing from cylinder head 2 Remove the cam followers thrust pieces and hydraulic valve l...

Страница 60: ...Sealing Compound TB1207C to sealing surface of cylinder head 3 Install the camshaft housing on cylinder head Torque Angle Method Cylinder head and camshaft housing with new cylinder head bolts to cyli...

Страница 61: ...lic valve lifters Lay aside in installation positions 2 Remove the spark plugs exhaust manifold and intake manifold from cylinder head Removal 1 Mark valves 2 Remove the tension valve springs with 5 8...

Страница 62: ...ert a new valve stem seal with 5 8840 2601 0 1 5 Drive the valve stem seal carefully in to stop with light hammer blow Installation 1 Install the valve springs and valve spring caps 2 Install the tens...

Страница 63: ...ly Use commercially available grinding tool Important Use only fine grained pastes for grinding Lubricate valve stem before grinding in Clean After grinding carefully clean valve and valve soat Valve...

Страница 64: ...f dimension A is exceeded use new valves Check valve stem projection again If dimension A is exceeded replace cylinder head Cylinder Head Overhaul Cylinder head disassembled Valve Grind Important Ensu...

Страница 65: ...der head Flywheel Removal 1 Remove transmission and clutch 2 Remove flywheel while locking with 5 88400 446 0 Torque Angle Method Flywheel to crankshaft 65 Nm 6 5 kgf m 30 to 45 Important Use new bolt...

Страница 66: ...ox 8mm 0 30in deep with 8mm 0 25in diameter drill 3 Separate starter ring gear with chisel on the drilling point Installation 1 Install starter ring gear with inner chamfered edge to flywheel 2 Heat s...

Страница 67: ...aling ring using 5 8840 0455 0 5 Install the rear toothed belt cover and toothed belt according to the corresponding operations 6 Replace the sealing ring with a new one 7 Tighten the belt to the cran...

Страница 68: ...il baffle plate Clean Sealing surfaces Installation 1 Apply a bead of Sealing Compound TB120TC or eguivalent to joint of oil pump 2 Install baffle plate or reuse baffle plate with valcanized gasket Ca...

Страница 69: ...ICAL C22NE 22LE 20LE Tighten Torque Oil intake pipe to oil pump 8N m 0 8 kgf m Oil intake pipe bracket to cylinder block 6 N m 0 6 kgf m Oil pan to cylinder block 8 N m 0 8 kgf m with vulcanized gaske...

Страница 70: ...l con rod bearing cap Torque Angle Method Con rod bearing cap to con rod 35N m 3 5 kgf m 45 to 60 Important Use new bolts 3 Install oil pan according to the corresponding operation Piston with Con Rod...

Страница 71: ...linder head according to the corresponding operations 2 Install sealing Gasket or replace if damaged 3 Install camshaft housing to cylinder head 4 Install cylinder head according to the corresponding...

Страница 72: ...tion beads on con rod point to the flattening on the piston pin eye Firmly seated piston pin cannot be pushed in Carry out installation quickly Piston Rings Removal 1 Remove piston with con rod accord...

Страница 73: ...s of steel band rings each 25 to 50 mm 1 to 2in to the left or right of the intermediate ring gap 3 Install piston rings 4 Offset ring gaps by approx 180 5 Install second piston ring with identificati...

Страница 74: ...ry Crankshaft pulse pickup sensor rotor inspection and repair Inspect the crankshaft pulse pickup sensor rotor for excessive wear and damage Replace the crankshaft pulse pickup rotor if the inspection...

Страница 75: ...rankshaft sealing flywheel drive plate and aggregates according to the corresponding operations Inspection Bearing play bearing cover removed Measure With Plastigage ductile plastic threads Cut thread...

Страница 76: ...e bearing cap and shell 2 Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed Installation 1 Lay a length of Plastigage across width of crank pin...

Страница 77: ...f the three measurements by three to obtain a mean diameter The top illustration shows con rod measuring points The second illustration shows main bearing measuring points Measure Crankshaft main and...

Страница 78: ...w Oil Pump Removal 1 Remove rear toothed belt cover and oil pan according to the corresponding operations 2 Remove oil filter wiring plug from oil pressure switch oil pump from cylinder block and oil...

Страница 79: ...lug 30 N m 3 0 kgf m Oil Pump Overhaul Removal 1 Remove oil pump according to the corresponding operation 2 Remove oil cover and pressure control valve Inspect Clearance between gear pair and housing...

Страница 80: ...with pointed drift turn in self tapping screw and edge out Important Cover oil duct in cylinder head with piece of cloth 3 Pull out valve retainer using commercially available tool 4 Remove ball and s...

Страница 81: ...ENGINE MECHANICAL C22NE 22LE 20LE Installation 1 Install new pressure valve into cylinder head with suitable pipe until stop 2 Install core hole plugs into cylinder head with suitable pipe to end of c...

Страница 82: ...Engine cooling 2 Check coolant level Inspection Use 5 8840 0277 0 tester 5 8840 2603 0 adaptor Cooling System Fill Up and Bleed Important Radiator and heater core are made from alminium To avoid corr...

Страница 83: ...em 7 Confirm that the temperature gauge reads half or more of full scale and that the thermostat is activated Then continue idling 5 minutes more and switch off the engine and allow it to cool 8 After...

Страница 84: ...stall the cooling fan 4 Install all V belts 5 Install the lower and upper hose Thermostat Removal 1 Remove water outlet nozzles with thermostat from thermostat housing 2 Remove coolant hose and collec...

Страница 85: ...cording to the corresponding operation 3 Install coolant hoses 4 Fill cooling system and bleed according to the corresponding operation Alternator Removal 1 Remove ground cable from battery 2 Remove c...

Страница 86: ...lamping bracket and lower alternator bracket and moving alternator Tighten Torque Clamping bracket to alternator 25 N m 2 6 kgf m Lower alternator bracket 25 N m 2 6 kgf m V Belt Tension of Power Stee...

Страница 87: ...ush MAP sensor into the manifold 2 Install the mounting bolts and tighten them 3 Connect electrical connector 4 Connect the battery cable Pressure Regulator Removal 1 Remove vacuum hose 2 Remove fuel...

Страница 88: ...d coolant temperature sensor Tighten Torque Temperature sensor to intake pipe 10 N m 1 0 kgf m Wiring harness plug to temperature sensor Inspection Coolant level Idle Air Control IAC Valve Removal 1 R...

Страница 89: ...6A 72 ENGINE MECHANICAL C22NE 22LE 20LE Crank Position Sensor Removal 1 Remove crank position sensor Installation 1 Install crank position sensor...

Страница 90: ...y fuel that may leak out When the disconnect is completed place the towel in an approved container 1 Depressurize the fuel system 2 Disconnect the fuel inlet 3 Disconnect the fuel return line 4 Remove...

Страница 91: ...ion sensor 2 Install wiring harness connector Accelerator Pedal and Cable Removal 1 Remove pad stopper from pedal stop bolt Measure Dimension A RD 15mm 0 5mm 0 59in 0 02in LD 14mm 0 5mm 0 55in 0 02in...

Страница 92: ...n the element by blowing with compressed air of about 490 kPa 71 psi from the clean side if it is extremely dirty Installation 1 Install air cleaner element 2 Attach the air cleaner duct cover to the...

Страница 93: ...mportant CD engine oils designed by manufacturers specially for diesel engines are not suitable for petrol engines unless a sufficient performance class for petrol engines e g API SF CCMC G4 is also i...

Страница 94: ...ystem continued Fan Type Visco Clutch Fan Number of blades 5 Distribution of blades asymmetric Diameter mm Radiator cap Boiling point 123 C Opening pressure kPa bar 120 to 135 1 20 to 1 35 Thermostat...

Страница 95: ...er is not more than max 25 Cylinder Head Cylinder Head Gasket Thickness installed mm 1 15 to 1 30 Valve seat width at cylinder head inlet mm 1 0 to 1 5 outlet mm 1 7 to 2 2 Valve stem play inlet mm 0...

Страница 96: ...NE MECHANICAL C22NE 22LE 20LE 6A 79 Cylinder Head continued Valve System Valve lifter valve play compensator hydraulic Valve rotators inlet or outlet outlet Valve play warm or cold inlet mm 0 outlet m...

Страница 97: ...artment only supplies valves with a length of 103 8mm inlet valve and 103 6mm outlet valve only Camshaft Identification letter J Colour code Normal size 0 1mm undersize violet Radial runout mm 0 03 En...

Страница 98: ...44 86 45 7 0 5 Piston diameter must be measured at the position D inclusive Crankshaft Cylinder Block continued Cylinder Bore Rebore cylinder Permissible oversize to 0 5mm see parts microfiche After...

Страница 99: ...diate ring gap Piston Pin Length mm 61 5 Diameter mm 21 Type Shrunk into con rod Play mm in piston 0 011 to 0 014 in con rod none Installation When installing piston pins heat con rods to approx 280 C...

Страница 100: ...ndersize for Production and Customer Service Bearing journal and colour code from 57 7320 green to 57 7385 blue 57 7385 brown to 57 7450 blue 26 100 26 050 48 738 48 720 26 580 26 460 Bearing shell id...

Страница 101: ...GINE MECHANICAL C22NE 22LE 20LE Piston Pins Dimensions Length mm Diameter mm 61 5 21 Type Shank fit in con rod Clearance In piston mm In con rod mm 0 011 to 0 014 0 Installation See operation Con rod...

Страница 102: ...diameter in mm width in mm width in mm Standard Size for Production and Service from 57 974 white to 57 981 over 57 981 green to 57 988 over 57 988 brown to 57 995 26 002 25 950 48 988 48 970 26 580...

Страница 103: ...ible lateral run out of installed starter ring gear to flywheel 0 5mm Precision turning Permissible removal of material in clutch disc lining surface area 0 3mm In order to achieve the functional rela...

Страница 104: ...el to crankshaft 65 1 6 6 30 to 45 Front exhaust pipe to exhaust manifold 25 2 5 Guide sleeve for pressure bearing to transmission 22 2 2 Intake manifold to cylinder head 22 2 2 Lower alternator brack...

Страница 105: ...ART NAME 5 8840 2634 0 Aligner 5 8840 2593 0 Cutter set 5 8840 2594 0 Spring Compressor 5 8840 0451 0 Installer 5 8840 0452 0 Remover Installer 5 8840 2596 0 Distance Gauge 5 8840 0455 0 Assembly Slee...

Страница 106: ...LE 6A 89 ITEM NO ILLUSTRATION PART NO PART NAME 5 8840 0459 0 Installer 5 8840 0460 0 Installer 5 8840 0446 0 Flywheel Holder 5 8840 2598 0 Holding Wrench 5 8840 2599 0 Reamer Set 5 8840 2600 0 Socket...

Страница 107: ...B 7 Water Pump and Associated Parts 6B 7 Removal 6B 7 Inspection 6B 7 Installation 6B 8 Thermostat 6B 9 Removal 6B 9 Inspection 6B 9 Installation 6B 9 Fan clutch with Cooling Fan 6B 9 Inspection and R...

Страница 108: ...rized type where the water pump which is cambelt driven forces the circulation of the coolant through the cylinder block and head The thermostat regulates the flow of coolant between the radiator and...

Страница 109: ...atings Paints greases or 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...

Страница 110: ...specific gravity of engine coolant in the cooling system temperature ranges from 0 C to 50 C using a suction type hydrometer then determine the density of the engine coolant by referring to the table...

Страница 111: ...gine oil level or use of improper engine oil Replenish or change oil Clogged exhaust system Clean exhaust system or replace faulty parts Faulty Throttle Position sensor Replace throttle valve assembly...

Страница 112: ...hen drain it Install the reserve tank and hoses 4 Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze but no more than 70 percent antifreeze 4 Refill the cool...

Страница 113: ...adiator hose on inlet pipe side 4 Remove timing belt refer to Timing Belt in this manual 5 Remove water pump assembly Inspection Make necessary repair and parts replacement if extreme wear or damage i...

Страница 114: ...g water pump coat sealing surface with silicon grease 2 Install water pump assembly and tighten bolts to the specified torque Torque 25 N m 2 5 kgf m 3 Timing belt Install timing belt refer to timing...

Страница 115: ...amage is found during inspection Installation 1 Before installing thermostat coat sealing surface with silicon grease 2 Install O ring 3 Install thermostat housing and tighten bolts to the specified t...

Страница 116: ...in unit Warm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 80 C when measured with the thermistor Then confirm that the fan clutch can be turned with consi...

Страница 117: ...diator Lower Hose 5 Cooling Fan Shroud 6 Cooling Fan Removal 1 Disconnect battery ground cable 2 Loosen a drain plug to drain engine coolant EC 3 Disconnect radiator inlet hose and outlet hose 4 Disco...

Страница 118: ...71 Radiator Core 1 A bent fin may result in reduced ventilation and overheating may occur All bent fins must be straightened Pay close attention to the base of the fin when it is being straightened 2...

Страница 119: ...r bubbles come up to the radiator filler neck replenish with EC Repeat until the EC level does not drop any further Install the radiator cap and stop the engine Replenish EC to the MAX line on the res...

Страница 120: ...6B 14 ENGINE COOLING SPECIAL SERVICE TOOL ITEM NO ILLUSTRATION PART NO PART NAME 1 5 8840 0277 0 Tester radiator cap 2 5 8840 2603 0 Adapter radiator cap...

Страница 121: ...spection 6C 7 In Tank Fuel Filter 6C 7 Fuel Pump 6C 8 Fuel Pump and Associated Parts 6C 8 Removal 6C 8 Installation 6C 9 Fuel Pump Relay 6C 9 General Description 6C 9 Fuel Tank 6C 10 Fuel Tank and Ass...

Страница 122: ...6C 2 ENGINE FUEL PAGE Fuel Tank 6C 15 Removal 6C 16 Installation 6C 16 Main Data and Specifications 6C 17...

Страница 123: ...6 Fuel Rail 7 Intake Manifold 8 Fuel Pressure Control Valve 9 Duty Solenoid Valve 10 Throttle Valve 11 Canister 12 Check and Relief Valve 13 Drain hose 14 2 Way Valve This illustration is based on th...

Страница 124: ...extend engine oil life Using leaded gasoline can damage the emission control system and could result in loss of emission warranty coverage All cars are equipped with an Evaporative Emission Control Sy...

Страница 125: ...ng such information to the fuel injector valves to effect an appropriate air fuel ratio The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft...

Страница 126: ...ON When repair to the fuel system has been completed start engine and check the fuel system for loose connections or leakage For the fuel system diagnosis see Section Driveability and Emissions 1 Disc...

Страница 127: ...engine side and fuel tank side 4 Install fuel filler cap 5 Connect the battery ground cable Inspection After installation start engine and check for fuel leak age In Tank Fuel Filter The filter is lo...

Страница 128: ...heck the fuel system for loose connection or leakage For the fuel system diagnosis see Section Driceability and Emission 1 Disconnect battery ground cable 2 Loosen fuel filler cap 3 Support underneath...

Страница 129: ...fuel and tighten fuel filler cap 4 Connect battery ground cable Fuel Pump Relay General Description In order to control the FPAS operation the FPAS relay is provided When the starter switch is turned...

Страница 130: ...TION When repair to the fuel system has been completed start engine and check the fuel system for loose connection or leakage For the fuel system diagnosis see Section Driveability and Emission 1 Disc...

Страница 131: ...the fixing bolts to the specified torque Torque 68 N m 6 9 kgf m 2 Install fuel pump and sender assembly by fitting in the snap ring 3 Install roll over float valve 1 4 Lift up fuel tank assembly and...

Страница 132: ...1 Fuel Filler Cap Inspection Check the seal ring in the filler cap for presence of any abnormality and for seal condition Replace the filler cap if abnormal CAUTION The fuel filler cap valve has char...

Страница 133: ...ENGINE FUEL 6C 13 Fuel Filter Removal and Installation 3 1 2 Removal 1 Inlet and outlet fuel hose 2 Fuel filter Installation 2 Fuel filter 1 Inlet and outlet fuel hose...

Страница 134: ...es NOTE Immediately plug the fuel hoses Do not work in close proximity to sparks or an open flame Important Operations Installation 1 Fuel Filter 1 Install the fuel filter to the fuel pump in the dire...

Страница 135: ...TO ROLLOVER VALVE WITH CANISTER ROLLOVER VALVE 7 6 5 8 4 1 2 3 Removal 1 Fuel hose Delivery 2 Fuel hose Return 3 Evapo fuel hose 4 Breather hose 5 Fuel filler hose 6 Fuel Pump 7 Fuel tank 8 Roll over...

Страница 136: ...ry ground cable Loosen fuel filler cap Drain fuel Tighten drain plug to the specified torque after drain fuel N m kgf m 20 2 0 NOTE Cover fuel hose with waste to prevent any dust entering Installation...

Страница 137: ...ENGINE FUEL 6C 17 Main Data and Specifications Torque Specification N m kgf m 68 6 9...

Страница 138: ...D1 ENGINE ELECTRICAL CONTENTS PAGE Battery 6D1 2 General Description 6D1 2 Service Precaution 6D1 2 Diagnosis 6D1 3 Battery Charging 6D1 4 Jump Starting 6D1 4 Removal 6D1 6 Installation 6D1 6 Main Dat...

Страница 139: ...attery fluid 3 The battery is much less vulnerable to self discharge than a conventional type battery Service Precaution CAUTION Always use the correct fastener in the proper location When you replace...

Страница 140: ...Voltage Check 1 Put voltmeter test leads to battery terminals a VOLTAGE IS 12 4V OR ABOVE Go to Step 5 b VOLTAGE IS UNDER 12 4V Go to procedure 2 below 2 Determine fast charge amperage from specificat...

Страница 141: ...ely charge the battery Never partially charge the battery Jump Starting Jump Starting with an Auxiliary Booster Battery CAUTION Never push or tow the vehicle in an attempt to start it Serious damage t...

Страница 142: ...to the positive terminal of the booster battery Attach the other end of the same cable to the positive terminal of the discharged battery Do not allow the vehicles to touch each other This will cause...

Страница 143: ...stallation 1 Install battery 2 Install retainer 3 Instal retainer screw and rods NOTE Make sure that the rod is hooked on the body side 4 Install positive cable 5 Install negative cable Main Data and...

Страница 144: ...6D2 2 Service Precaution 6D2 2 Diagnosis 6D2 2 Ignition Coil 6D2 2 Removal 6D2 2 Installation 6D2 2 Spark Plug 6D2 3 Removal 6D2 3 Inspection and Repair 6D2 3 Installation 6D2 4 Crankshaft Angle Sens...

Страница 145: ...hose 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...

Страница 146: ...aving low heat value hot type plug if fuel and electrical systems are normal Use spark plugs having high heat value cold type plug if insulator and electrode are extremely burned Sooty Spark Plugs Muc...

Страница 147: ...s extremely worn Bend the ground electrode to adjust the spark plug gap Installation 1 Spark plugs Tighten spark plugs to the specified torque Torque 25 N m 2 5 kgf m Crankshaft Angle Sensor Removal 1...

Страница 148: ...s General Specifications Ignition System Ignition Form Electronic Ignition System El system with Crankshaft angle Sensor Spark Plug Type No of Coils and Type Coil Location Torque Electronic Spark Cont...

Страница 149: ...Removal 6D3 3 Installation 6D3 3 Disassembled View 6D3 4 Inspection and Repair 6D3 5 Characteristic Test 6D3 6 Charging System 6D3 7 General Description 6D3 7 General On Vehicle Inspection 6D3 8 Gene...

Страница 150: ...ecaution 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...

Страница 151: ...ground cable 2 Remove harness connectors 1 and 2 3 Remove bolts from starter Installation 1 Install starter assembly 2 Install mounting bolts and tighten bolts to specified torque Torque 25 N m 2 5 k...

Страница 152: ...AND CHARGING SYSTEM Disassembled View Legend 1 Bolt 2 Magnetic Switch 3 Gear Case 4 Piston 5 Piston Shaft 6 Center Bracket 7 Armature 8 Yoke Assembly 9 Brush and Brush Holder 10 Washer 11 Rear Cover 1...

Страница 153: ...ure core armature core and shaft Replace commutator if there is continuity i e internally grounded Brush Measure the length of brush Replace with a new one if it is below the limit Brush Holder Check...

Страница 154: ...is locked when it is rotated in reverse If not replace the pinion Characteristic Test For easily confirming the characteristics conduct the noload test as follows Rating as short as 30 seconds require...

Страница 155: ...tor installed on the rear end cover The generator does not require particular maintenance such as voltage adjustment The rectifier connected to the stator coil has eight diodes to transform AC voltage...

Страница 156: ...on connector side If lamp comes on Repair or replace the generator Generator Removal 1 Disconnect battery ground cable 2 Move drive belt tensioner to loose side using wrench then remove drive belt 3...

Страница 157: ...age Circuit Diagram Legend 1 Battery 2 Ignition Lock 3 Charge Telltale 4 Resistor for attainment of load current with the battery set in series 5 Voltmeter 6 Ammeter 7 Generator Installation 1 Install...

Страница 158: ...Germany Direction of rotation clockwise 14V Generator Operating Voltage 50A Stabilised output at 25 C at 1800 RPM 13 5 Volts 90A Stabilised output at 25 C at 1800 RPM 13 5 Volts Generator Connetions B...

Страница 159: ...the S lead and turns the regulator Hybrid base current to T15 OFF removing rotor current resulting in a decrease in output voltage to below the regulating voltage T15 base current turns ON and the who...

Страница 160: ...ness connectors b Poor contact between rectifier and regulator c High resistance in fusible link assembly Caution When bench testing the generator it is important that the warning lamp wattage of 2 wa...

Страница 161: ...y 1 Mark the relative positions of the end housings in relation to the stator assembly to aid reassembly Use a permanent marking pen do not use centre punched as this can cause misalignmnet of the hou...

Страница 162: ...ents except the rotor and stator with an approved cleaning agent Ensure that all traced of oil and dirt are removed If an abrasive cleaner is used to remove scale and paint from the housings take care...

Страница 163: ...rd voltage drop across the diode should be obtained Reverse the test probes a high resistance reading or a higher reverse voltage should be obtained For 8 diode rectifier plates tests for G and H shou...

Страница 164: ...en phases using a low reading ohmmeter designed for this purpose the values are given at the rear of this instruction 3 Rotor Inspect the rotor for insulation resistance to ground using an insulation...

Страница 165: ...nd down the tabs and solder the brush lead taking care not to allow the solder to run up the lead which will reduce flexibility Use 60 40 resin cored solder 5 Ball bearing Please note the bearings use...

Страница 166: ...th surfaces before fitting Fit the three retaining screws to the rectifier then install into slipring end housing Tighten the B bolt to the reuired torque f To refit the stator make sure the spigot su...

Страница 167: ...cation of cell failure If the battery test is clear proceed with the Generator tests as follows Care should be taken when making the following connections It is recommended that the battery negative t...

Страница 168: ...st at full load Increase engine speed until the altenator is running at 6000 rpm switch on electrical loads until the generator voltage drops to 13 5 volts for 12 v systems and 26 volts for 24 v syste...

Страница 169: ...w 1 6 2 3 0 1 0 2 Bearing retaining plate screw 2 1 3 0 0 2 0 3 Through bolt 3 8 5 5 0 4 0 6 Winding resistance between phases Stator Rotor 70 Amp generator 0 086 10 2 6 0 13 85 Amp generator 0 058 10...

Страница 170: ...ase and startpoint connections Note the average of these two waveforms are identical from no load to 100 output of rated load Voltage phase Voltage startpoint 6 9v rated output 7 2v Zero output Note T...

Страница 171: ...out Table 32 Pin Red Connector Row J2 6E1 38 COMPONENT LOCATOR 6E1 39 Engine Component Locator Table 6E1 41 Undercarriage Component Locator Table 6E1 41 UNDERHOOD U H FUSE AND RELAY PANEL 6E1 42 INSTR...

Страница 172: ...46 Diagnostic For Closed Loop System 6E1 46 Enable Criteria 6E1 46 Trip 6E1 46 THE DIAGNOSITIC EXECUTIVE 6E1 47 Diagnostic Information 6E1 47 Malfunction Indicator Lamp MIL 6E1 47 Extinguish the MIL...

Страница 173: ...N SYSTEM DIAGNOSIS 6E1 62 EVAP CANISTER PURGE SOLENOID IF APPLICABLE 6E1 62 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER IF APPLICABLE 6E1 62 IDLE AIR CONTROL IAC VALVE 6E1 62 FUEL SYSTEM PRESSUR...

Страница 174: ...le 6E1 71 B1 HO2S BANK 1 If applicable 6E1 71 B1 HO2S READY BANK 1 If applicable 6E1 71 IAC CONTROL STEP 6E1 71 IAT INTAKE AIR TEMPERATURE 6E1 71 BATTERY 6E1 72 INJ PULSE WIDTH 6E1 72 FUELING MODE If...

Страница 175: ...AL CHECK 6E1 81 INTERMITTENT 6E1 81 Hard Start Symptom 6E1 82 Surges and or Chuggles symptom 6E1 84 Lack of Power Sluggish or Spongy Symptom 6E1 86 Detonation Spark Knock Symptom 6E1 88 Rough Unstable...

Страница 176: ...1 117 Fuel Pressure Relief Procedure 6E1 119 Fuel Pressure Gauge Installation 6E1 119 Fuel System Diagnosis 6E1 119 MANIFOLD ABSOLUTE PRESSURE MAP OUTPUT CHECK 6E1 123 Circuit Description 6E1 123 Test...

Страница 177: ...est Description 6E1 138 DTC Flash DTC 21 Throttle Position TP Sensor Circuit High Input 6E1 138 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 13 02 SENSOR CIRCUIT NOT READY DETECTED IF APPLICABLE 6E1 141 Circ...

Страница 178: ...t Temperature Sensor 6E1 154 DTC Flash DTC 14 ECT Sensor Circuit High Input 6E1 154 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 15 ENGINE COOLANT TEMPERATURE ECT SENSOR CIRCUIT LOW INPUT 6E1 157 Circuit Des...

Страница 179: ...P SENSOR SIGNAL INCORRECT 6E1 169 Circuit Description 6E1 169 Conditions for Setting the DTC 6E1 169 Action Taken When the DTC Sets 6E1 169 Conditions for Clearing the MIL DTC 6E1 169 Diagnostic Aids...

Страница 180: ...181 Conditions for Setting the DTC 6E1 181 Action Taken When the DTC Sets 6E1 181 Conditions for Clearing the MIL DTC 6E1 181 Diagnostic Aids 6E1 181 DTC Flash DTC 49 System Voltage High 6E1 182 DIAG...

Страница 181: ...tor if necessary 6E1 192 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 41 IGNITION COIL DRIVER B SHORT TO BATTERY 6E1 195 Circuit Description 6E1 195 Conditions for Setting the DTC 6E1 195 Action Taken When t...

Страница 182: ...1 202 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 35 IDLE AIR CONTROL IAC ERROR 6E1 203 Circuit Description 6E1 203 Conditions for Setting the DTC 6E1 203 Action Taken When the DTC Sets 6E1 204 Conditions f...

Страница 183: ...e Emission EVAP Control system Canister Purge Control Valve Circuit Low Error 6E1 214 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 62 EVAPORATIVE EMISSION EVAP CONTROL SYSTEM CANISTER PURGE CONTROL VALVE CIR...

Страница 184: ...C 6E1 223 Action Taken When the DTC Sets 6E1 223 Conditions for Clearing the DTC 6E1 223 Diagnostic Aids 6E1 223 DTC Flash DTC 93 Quad Driver Sub Module 6E1 224 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 5...

Страница 185: ...Setting the DTC 6E1 231 Action Taken When the DTC Sets 6E1 231 Conditions for Clearing the DTC 6E1 231 Diagnostic Aids 6E1 231 DTC Flash DTC 92 Tacho Out High Error 6E1 232 DIAGNOSTIC TROUBLE CODE DT...

Страница 186: ...eived Response Was Not Correct 6E1 242 DIAGNOSTIC TROUBLE CODE DTC Flash DTC 84 NO RESPONSE FROM IMMOBILIZER 6E1 243 Circuit Description 6E1 243 Condition for Setting the DTC 6E1 243 Action Taken When...

Страница 187: ...Installation 6E1 250 HEATED OXYGEN SENSOR HO2S If applicable 6E1 250 Removal 6E1 250 Inspection 6E1 250 Installation 6E1 251 INTAKE AIR TEMPERATURE IAT SENSOR 6E1 251 Removal 6E1 251 Installation 6E1...

Страница 188: ...6E1 257 Measurement 6E1 258 Installation 6E1 258 INTAKE AIR DUCT 6E1 258 Removal 6E1 258 Installation 6E1 259 KNOCK SENSOR 6E1 259 Removal 6E1 259 Installation 6E1 259 OIL PRESSURE SWITCH 6E1 260 Rem...

Страница 189: ...E1 266 FUEL PRESSURE RELIEF 6E1 267 FUEL PUMP ASSEMBLY 6E1 267 Removal 6E1 267 Inspection 6E1 268 Installation 6E1 268 FUEL PUMP RELAY 6E1 269 Removal 6E1 269 Installation 6E1 269 FUEL RAIL ASSEMBLY 6...

Страница 190: ...ION TIMING ADJUSTMENT 6E1 277 EVAP CANISTER HOSES IF APPLICABLE 6E1 277 EVAP CANISTER IF APPLICABLE 6E1 278 Removal 6E1 278 Inspection 6E1 278 Installation 6E1 278 EVAP CANISTER PURGE VALVE SOLENOID I...

Страница 191: ...1 286 FUEL CONTROL HEATED OXYGEN SENSOR IF APPLICABLE 6E1 286 INTAKE AIR TEMPERATURE IAT SENSOR 6E1 287 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 6E1 287 ENGINE CONTROL MODULE ECM 6E1 287 ECM FUNCTION 6E1...

Страница 192: ...L CIRCUIT 6E1 295 FUEL RAIL 6E1 295 IDLE AIR CONTROL IAC VALVE 6E1 296 RUN MODE APPLICABLE TO CLOSED LOOP SYSTEMS 6E1 296 STARTING MODE 6E1 297 THROTTLE BODY UNIT 6E1 297 ELECTRONIC IGNITION SYSTEM 6E...

Страница 193: ...DRIVEABILITY AND EMISSIONS 6E1 23 PAGE SYSTEM FALUT DETECTION 6E1 303 POSITIVE CRANKCASE VENTILATION PCV SYSTEM 6E1 304 CRANKCASE VENTILATION SYSTEM PURPOSE 6E1 304 SPECIAL SERVICE TOOLS 6E1 305...

Страница 194: ...5 6 7 8 9 ROLL OVER FLOAT VALVE FUEL PUMP TWC CONVERTER CRANKSHAFT POSITION SENSOR KNOCK SENSOR COOLANT TEMPERATURE SENSOR FUEL INJECTOR MAP SENSOR AIR CLEANER HEATED OXYGEN SENSOR IGNITION PLUG IAT...

Страница 195: ...op U H FUSE BLOCK To Stop Lamp Engine Control Module ECM R A1 A2 B11 E8 B R B L B W O ECM Grounds Engine Block Diag Serial Data HOT IN START AND RUN Meter Fuse 15A I P FUSE BLOCK Malfunction Indicator...

Страница 196: ...rge Solenoid 1 25 R W 0 85G W 2B R 0 85G R 0 85G B 0 85G 1 25 R W 0 85 L Y Fuel Injector Fuse 20A Fuel Pump A4 A6 A8 A9 A7 A5 E16 Fuel Injector Control 4 A B 3 A B 2 A B 1 A B Engine Control Module EC...

Страница 197: ...6E1 27 HOT IN START AND RUN IG Coil Fuse 15A I P FUSE BLOCK 0 85 B O Ignition Coil 1 25 G 1 25 L Engine Control Module ECM E1 E4 E3 Electronic Spark Timing Control 1 25 B 1 25 B E2 0 5 R 0 5 G Cranks...

Страница 198: ...6E1 28 DRIVEABILITY AND EMISSIONS...

Страница 199: ...6E1 29 HOT WITH FUEL PUMP RELAY ENERGIZED O2 Sensor 10A U H FUSE BLOCK 0 85 R G 0 5 BLK 0 5 L 0 5WHT 0 5RED 0 5 P 0 5 BLK RED Engine Control Module ECM O2 Sensor Low O2 Sensor High Heated O2 Sensor D...

Страница 200: ...6E1 30 DRIVEABILITY AND EMISSIONS 0 5 YEL 0 5 YEL Knock Sensor Input Knock Sensor KS F6 Engine Control Module ECM...

Страница 201: ...DRIVEABILITY AND EMISSIONS 6E1 31...

Страница 202: ...ILITY AND EMISSIONS A C Compressor Relay Control A16 MAG Clutch Compressor Relay Thermo 1 2 3 4 Relay A C Compressor Joint To HA09 0 5 BR 0 5 GR R B10 0 5 G B HOT IN START AND RUN 2 1 4 3 Engine Contr...

Страница 203: ...DRIVEABILITY AND EMISSIONS 6E1 33 Engine Control Module ECM B16 0 5 L 0 5 L W 0 5 L R Idle Air Control IAC Valve 0 5 L B B15 D C B A B13 B14 IAC A High IAC A Low IAC B High IAC B Low A B...

Страница 204: ...6E1 34 DRIVEABILITY AND EMISSIONS...

Страница 205: ...Coil Ground B B 0V 0V E4 Electronic Spark Timing Coil Driver B L 12V 14V E5 Crank Position Sensor High G 1V 1V General Description and Operation Crank Position Sensor E6 Not Used E7 Vss Input W 9V 11...

Страница 206: ...Sensor F7 Not Used F8 Not Used F9 Not Used F10 Intake Air Temperature Sensor Y G 2V 2V General Description and Operation IAT F11 Not Used F12 Heated O2 Sensor Low If applicable General Description and...

Страница 207: ...tery R W 12V 14V Chassis Electrical A6 Injector 4 Cyl G 0V 14V General Description and Operation Fuel Injector A7 Injector 1 Cyl G W 0V 14V General Description and Operation Fuel Injector A8 Injector...

Страница 208: ...nd Operation B6 Not Used B7 Map Input W 5 0V 0V 10kpa 1 0V 5V 104kpa General Description and Operation Manifold Absolute Sensor B8 Throttle Position Sensor B 1 0V 1 0V General Description and Operatio...

Страница 209: ...DRIVEABILITY AND EMISSIONS 6E1 39 COMPONENT LOCATOR...

Страница 210: ...applicable VEHICLE SPEED SENSOR VSS FUEL FILTER THROTTLE POSITION SENSOR MAP SENSOR EVAP PURGE CONTROL SOLENOID VALVE FUEL INJECTOR IGNITION COIL KNOCK SENSOR CRANKSHAFT POSITION SENSOR HEATED OXGEN S...

Страница 211: ...nside of the right fender 9 Throttle Position TP Sensor On the front of the throttle body 10 Idle Air Control IAC Valve Under the TP sensor 11 EVAP Canister Purge Control Solenoid On the intake manifo...

Страница 212: ...6E1 42 DRIVEABILITY AND EMISSIONS UNDERHOOD U H FUSE AND RELAY PANEL INSTRUMENT PANEL I P FUSE BLOCK...

Страница 213: ...technical assistance for similar cases where repair history may be available Combine technician knowledge with efficient use of the available service information INTERMITTENTS Conditions that are not...

Страница 214: ...s have been calibrated to run with OEM parts Small leaks in the exhaust system near the heated oxygen sensor can also cause the MIL Check Engine lamp to turn on Aftermarket electronics such as cellula...

Страница 215: ...llaneous test are as follows Check powertrain lamp This test allows to turn on and off the powertrain warning lamp in the instrument cluster Fuel Pump Fuel pump test allows to turn on and off the fuel...

Страница 216: ...p cycle means that engine at temperature must reach a minimum of 70 C 160 F and rise at least 22 C 40 F over the course of a trip COMMON OBD TERMS Diagnostic For Closed Loop System When used as a noun...

Страница 217: ...is set and the Malfunction Indicator Lamp MIL Check Engine lamp is illuminated Malfunction Indicator Lamp MIL The Malfunction Indicator Lamp MIL looks the same as the MIL you are already familiar with...

Страница 218: ...tic chart in DRIVEABILITY AND EMISSIONS Following the output of DTC12 the Check Engine MIL will indicate a DTC three times if a DTC is present or it will simply continue to output DTC12 If more than o...

Страница 219: ...o alert the driver 2 The Diagnostic Trouble Codes DTC can be displayed by shorting together terminals and of the Data Link Connector DLC located behind front console The CHECK ENGINE indicator will fl...

Страница 220: ...MISSIONS Tech 2 Scan Tool From 98 MY Isuzu dealer service departments are recommended to use Tech 2 Please refer to Tech 2 user guide Legend 1 PCMCIA Card 2 RS 232 Loop Back Connector 3 SAE 16 19 Adap...

Страница 221: ...ct the DLC cable to the Tech 2 5 4 Make sure the vehicle ignition is off 5 Connect the Tech 2 SAE 16 19 adapter to the vehicle DLC 6 The vehicle ignition turns on 7 Verify the Tech 2 power up display...

Страница 222: ...ystem F1 RPM Control F2 IAC Control F3 IAC Reset F4 Fuel System F1 Fuel Trim Reset F2 Fueling Mode F7 Air Fuel Ratio Note F3 F4 not applicable to TF models Note Selection Table Appricable Version Engi...

Страница 223: ...manufacturer Clearing Diagnostic Trouble Codes Important Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure If the fault that caused the DTC...

Страница 224: ...function FUEL CONTROL HEATED OXYGEN SENSORS IF APPLICABLE The main function of the fuel control heated oxygen sensors is to provide the control module with exhaust stream oxygen content information t...

Страница 225: ...s 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 insul...

Страница 226: ...sh lamp control and command the MIL OFF 2 Observe the MIL Did the MIL turn OFF Go to Step 4 Go to MIL Check Engine Lamp On Steady 4 Attempt to start the engine Did the engine start and continue to run...

Страница 227: ...t d Step Action Value s Yes No 9 1 Refer to Engine Control Module ECM in On Vehicle Service 2 Attempt to display ECM data with the Scan Tool Does the Scan Tool display ECM engine data Go to Step 2 Go...

Страница 228: ...6E1 58 DRIVEABILITY AND EMISSIONS...

Страница 229: ...nd for the A C thermostat relay to prevent the evaporator from forming ice When the A C request signal is received by the ECM the ECM supplies a ground from the compressor clutch relay if the engine o...

Страница 230: ...st input to the ECM The Scan Tool can display when the ECM has commanded the A C clutch ON The Scan Tool should have the ability to override the A C request signal and energize the A C compressor rela...

Страница 231: ...tep 6 6 1 Reinstall the A C Compressor Clutch Relay 2 Using a fused jumper ground the A C Compressor Clutch Relay control circuit at the ECM connector 3 Ignition ON Engine OFF Does the A C Compressor...

Страница 232: ...MISSION CANISTER IF APPLICABLE If the canister is cracked or damaged replace the canister If fuel is leaking from the canister replace the canister and check hoses and hose routing IDLE AIR CONTROL IA...

Страница 233: ...Description Number s below refer to the step number s on the Diagnostic Chart 2 Relieve the fuel pressure by connecting 5 8840 0378 0 T Joint to the fuel pressure connection on the fuel rail Caution I...

Страница 234: ...kPa 43psi 2nd Reading 2 205kPa 29psi 205kPa 29psi 196kPa 28psi 274kPa 39psi Amount of Drop 1st Reading 2nd Reading 91kPa 14psi 91kPa 14psi 100kPa 15psi 22kPa 4psi Av Drop 166kPa 24psi 10kPa 1 5psi 156...

Страница 235: ...amp position 6 Connect the leads from the 5 8840 2392 0 Digital Voltmeter DVM to the fuel injector tester Refer to the illustrations associated with the test description 7 Set the DVM to the tenths s...

Страница 236: ...ted in step 1 Repeat until you have a subtracted value for each injector For any injector is the subtracted value in step 2 greater than the specified value 0 6V Go to Step 4 Go to Step 7 7 Caution In...

Страница 237: ...rst pressure reading for one fuel injector The result is the pressure drop value 9 Obtain a pressure drop value for each fuel injector 10 Add all of the individual pressure drop values This is the tot...

Страница 238: ...e the system is being checked In this case refer to the Symptoms portion of the manual and make a careful physical inspection of all components and wiring associated with the affected system There is...

Страница 239: ...or damage If the harness is not damaged observe an affected sensor s displayed value on the Scan Tool with the ignition ON and the engine OFF while you move the connectors and the wiring harnesses rel...

Страница 240: ...e voltage measure near the specified value 0V Go to Step 9 Go to Step 12 9 Measure the voltage between the ECT sensor signal circuit at the ECM harness connector and ground Does the voltage measure ne...

Страница 241: ...hermistor which changes internal resistance as the temperature changes When the sensor is cold high resistance the ECM monitors a high signal voltage and interprets that as a cold engine As the sensor...

Страница 242: ...a 3000 mV threshold voltage LEAN Should change constantly while in Closed Loop indicating that the ECM is controlling the air fuel mixture properly ELECTRIC SPARK CONTROL Scan Tool Range 64 CA to 64...

Страница 243: ...ine software and calibration Review Technical Service Bulletins for most current level Depends on latest level of engine software and calibration Review Technical Service Bulletins for most current le...

Страница 244: ...ion Fuel Control HO2S DTC DTC13 IAT Intake Air Temp Engine Degrees C Degrees F 0 100 C 32 F 212 F depends on underhood 0 80 C depends 32 F 176 F on underhood General Description and Operation Intake A...

Страница 245: ...e km h 0 0 General Description Evaporative EVAP Emission System IF APPLICABLE EVAP Emission Control System Purpose The basic Evaporative Emission EVAP Control System used on all vehicle is the charcoa...

Страница 246: ...uum 3 Canister Body 4 Carbon 5 Filter 6 Grid 7 Air Flow During Purge Throttle position is above 7 throttle position sensor Results of Incorrect Operation Poor idle stalling and poor driveability can b...

Страница 247: ...sis 1 7 5 6 2 3 4 Legend 1 Intake Manifold 2 Fuel Vapor Purge Control Solenoid 3 Fuel Vapor Canister 4 Check and Relief valve 5 Fuel Tank 6 Pressure Vacuum Vented 7 Rollover Valve Visual Check of Cani...

Страница 248: ...fully warmed up The engine has been running for a specified time The IAT reading is above 10 C 50 F The EVAP purge vacuum switch is a normally closed switch positioned in the purge line between the c...

Страница 249: ...1 Filler Cap 2 Fuel Tank 3 Rollover Valve 4 Fuel Pump 5 Fuel Filter 6 Fuel Rail 7 Intake Manifold 8 Fuel Pressure Regulator 9 Duty Solenoid Valve Evap Purge Control Solenoid 10 Throttle Valve 11 Cani...

Страница 250: ...er failure yes 19 19 58X signal incorrect yes 24 24 Vehicle Speed Senser fault yes 33 33 Manifold Absolute Pressure Sensor too high yes 34 34 MAP too low yes 49 49 Batt voltage too high yes 69 69 Inta...

Страница 251: ...ems are caused by faulty electrical connections or wiring Perform a careful visual physical check for the following conditions Poor mating of the connector halves or a terminal not fully seated in the...

Страница 252: ...display the engine coolant temperature and note the value 2 Check the resistance of the engine coolant temperature sensor 3 Refer to Temperature vs Resistance chart in Diagnostic Trouble Code 14 for r...

Страница 253: ...pair Go to Step 14 14 Check IAC operation Perform the procedure in the diagnostic chart Diagnostic Trouble Code 35 Step 6 Was a problem found Verify repair Go to Step 15 15 Check for water or alcohol...

Страница 254: ...respond quickly to different throttle positions If it doesn t check for silicon or other contaminants from fuel or use of improper RTV sealant The sensors may have a white powdery coating Silicon cont...

Страница 255: ...use of fouling must be determined before replacing the spark plugs Was a problem found Verify repair Go to Step 15 15 1 Check the injector connectors 2 If any of the connectors are connected at an imp...

Страница 256: ...equired Verify repair Go to Step 5 5 Check for proper ignition voltage output with the spark tester Use commercially available tool Was a problem found Verify repair Go to Step 6 6 1 Remove the spark...

Страница 257: ...orrect camshaft Loose timing belt Was a problem found Verify repair Go to Step 12 12 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunction...

Страница 258: ...sent Go to Step 5 Verify Repair 5 1 Check for obvious overheating problems Low engine coolant Restricted air flow to radiator or restricted water flow through radiator Incorrect coolant solution It sh...

Страница 259: ...iagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the following Visual physical inspection Scan tool data All electrical...

Страница 260: ...ep 7 Go to Step 5 5 1 Visually Physically inspect for the following conditions Restricted air intake system Check for a restricted air filter element or foreign objects blocking the air intake system...

Страница 261: ...s a problem found Verify repair Go to Step 13 13 Check the following engine mechanical problems Low compression Leaking cylinder head gasket Worn or incorrect camshaft Sticking or leaking valves Broke...

Страница 262: ...ery feed to fuel pump relay Is the action complete Verify repair 6 1 Connect a test light between the two wires that connect to the fuel pump relay pull in coil 2 Ignition ON Did the test light illumi...

Страница 263: ...Did the test light illuminate for 2 seconds when the fuel pump was commanded ON Go to Step 17 Go to Step 14 14 1 Re connect the horn relay in its proper location 2 Check for a short circuit blown fus...

Страница 264: ...out pins 5 6 of ALDL Connector Fixed under center console panel short When you do this Check Engine Lamp will blink and engine rpm will rise to 100 to 1600rpm 4 In this condition connect CO meter wit...

Страница 265: ...much too often Go to Step 5 Go to Step 6 5 Review the items in Step 4 with the customer and advise as necessary Is the action complete System OK 6 1 Visually Physically check Vacuum hoses for splits k...

Страница 266: ...ical Diagnosis Verify repair 14 Check the air intake system and the crankcase for air leaks Was a problem found Verify repair Go to Step 15 15 1 Review all the diagnostic procedures within this table...

Страница 267: ...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 4 Go to Visual Physic al Check 4 1 Check for a...

Страница 268: ...lugs Was a problem found Verify repair Go to Step 6 6 1 Visually Physically inspect the secondary ignition wires Check for the following conditions Verify that all ignition wire resistance are less th...

Страница 269: ...problem found Verify repair Go to Step 11 11 1 Review all the diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the fol...

Страница 270: ...Electrical Diagnosis Was a problem found Verify repair Go to Step 5 5 Monitor 02 Status on the Scan Tool Is the 02 Status in the rich condition If applicable Go to Step 6 Go to Step 7 6 Check items t...

Страница 271: ...orm the Injector Coil Balance Test Was a problem found Verify repair Go to Step 13 13 1 Check for fuel in the pressure regulator vacuum hose 2 If fuel is present replace the fuel pressure regulator as...

Страница 272: ...as a problem found Verify repair Go to Step 20 20 Check for faulty motor mounts Refer to Engine Mechanical for inspection of mounts Was a problem found Verify repair Go to Step 21 21 1 Review all the...

Страница 273: ...ite powdery coating Silicon contamination sends a rich exhaust signal which causes the ECM to command an excessively lean air fuel mixture Was a problem found Verify repair Go to Step 5 5 Check the fu...

Страница 274: ...erify repair Go to Step 15 15 1 Remove the spark plugs and check for gas or oil fouling cracks wear improper gap burned electrodes of heavy deposits 2 If spark plugs are fouled the cause of fouling mu...

Страница 275: ...nostic OBD System Check Engine starts and runs no ECM codes set Customer complains of vibration ECM Power and Ground Check On Board Diagnostic OBD System Check Chassis Electrical ECM Power and Ground...

Страница 276: ...heck 2 Fuel injector and fuel injector balance test 3 EVAP emission canister purge control solenoid valve check If applicable 4 Ignition system 5 IAC operation MAP Output Check Throttle Linkage IAC Sy...

Страница 277: ...injector and fuel injector balance test Vibrations Transmission Driveshaft and Axle Catalyst Monitor 1 OBD system check 2 Careful visual physical inspection 3 Heated oxygen sensors If applicable Exhau...

Страница 278: ...ulation or a wire broken inside the insulation Check for the following items Poor connection or damaged harness Inspect the ECM harness and connectors for improper mating broken locks improperly forme...

Страница 279: ...12 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 14 Go to Step 13 13 Repair the faulty wire Verify Repair 14 R...

Страница 280: ...ssure indicated Go to Fuel System Electrical Test Go to Fuel System Diagnosis 25 1 Install switch box Injector Adaptor Cable 5 8840 2589 0 and Fuel Injector Tester 5 8840 2618 0 to the injector connec...

Страница 281: ...found Verify Repair Go to Step 33 33 Replace the EPROM or ECM Note Refer to 6E 243 Verify Repair 34 1 Test the fuel for contamination 2 If a problem is found clean the fuel system and correct the cont...

Страница 282: ...6E1 112 DRIVEABILITY AND EMISSIONS...

Страница 283: ...n pulses are present the ECM de energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped The fuel pump delivers fuel to the fuel rail and injectors then...

Страница 284: ...houlder fitting cap 2 Install fuel pressure gauge 5 8840 0378 0 to the fuel feed line located in front of and above the right side valve cover 3 Reinstall the fuel pump relay Fuel System Electrical Te...

Страница 285: ...4 Go to Step 12 12 1 Honk the horn to verify that the horn relay is functioning 2 Substitute the horn relay for the fuel pump relay 3 Leave the test light connected as in step 12 4 Command the fuel pu...

Страница 286: ...6E1 116 DRIVEABILITY AND EMISSIONS...

Страница 287: ...nds after the ignition switch is turned ON or 2 seconds after the engine stops running The in tank fuel pump is an electric pump within an integral reservoir The in tank fuel pump supplies fuel throug...

Страница 288: ...lowing procedure Remove the fuel rail but leave the fuel lines and injectors connected to the fuel rail Refer to Fuel Rail Assembly in On Vehicle Service Lift the fuel rail just enough to leave the fu...

Страница 289: ...l pressure within the specified limits 283 376 kPa 41 55 psi Go to Step 3 Go to Step 17 3 Does the fuel pressure indicated by the fuel pressure gauge remain constant Note The fuel pressure will drop w...

Страница 290: ...ank and inspect for leaky hose or in tank fuel line Was a problem found Verify repair Go to STep 8 15 1 If the pliers are still clamped to the fuel supply hose remove the locking pliers 2 With suitabl...

Страница 291: ...3 22 1 Command the fuel pump ON with the Scan Tool 2 Using suitable pliers which will not damage the fuel hose gradually apply pressure with the pliers to pinch the flexible fuel return hose closed Do...

Страница 292: ...6E1 122 DRIVEABILITY AND EMISSIONS...

Страница 293: ...4 8 volts at wide open throttle The MAP sensor is also used under certain conditions to measure barometric pressure allowing the ECM to make adjustments for different altitudes Test Description Impor...

Страница 294: ...AP port sealing rubber damaged or split Intake vacuum leaks at Vacuum leaks at throttle body If a problem is found repair as necessary Was a problem found 4 Start the engine 5 Apply 34 kPa 10 Hg of va...

Страница 295: ...en met The engine run time after start is more than 60 seconds The engine coolant temperature is above 30 C 86 F The fuel control system is operating in the Closed Loop mode If applicable Diagnostic A...

Страница 296: ...vacuum to the purge control solenoid with the hand vacuum pump 5 Start the engine run at 2500 RPM 6 Using the Scan Tool command the purge control solenoid ON Did the vacuum drop when the purge was tu...

Страница 297: ...to Step 12 11 Repair the short to voltage in the wire between the solenoid and the ECM Is the action complete Verify repair 12 Does the ignition feed terminals light the test lamp Go to Step 13 Go to...

Страница 298: ...6E1 128 DRIVEABILITY AND EMISSIONS...

Страница 299: ...most of the ECM controlled outputs The ECM monitors throttle position and compares actual throttle positions from the TP sensor to a predicted TP value calculated from engine speed Diagnostic Aids Che...

Страница 300: ...Engine Control Module ECM for a short to voltage Was the problem found Verify Repair Go to Step 11 5 Check the TP sensor signal circuit between the TP sensor and the ECM the following conditions A sh...

Страница 301: ...tal Multimeter DVM set to measure voltage between the ground circuit and the 5 volt signal circuit both at the wiring harness TP sensor connector 3 Ignition ON engine OFF Does the DVM indicate the fol...

Страница 302: ...6E1 132 DRIVEABILITY AND EMISSIONS...

Страница 303: ...signal is used by the engine control module ECM for fuel control and most of the ECM controlled outputs If the ECM detects a low inpedance short to ground in the Throttle Position sensor or circuit th...

Страница 304: ...le Position Sensor display on the Scan Tool is the Throttle Position Sensor below the specified value 0 19V Go to Step 4 Go to Step 3 3 1 Ignition ON engine OFF 2 Using a Scan Tool monitor info for Di...

Страница 305: ...Position signal circuit for an open short to ground or short to the sensor ground circuit 3 If the Throttle Position sensor signal circuit is open or shorted to ground repair it as necessary Was the T...

Страница 306: ...6E1 136 DRIVEABILITY AND EMISSIONS...

Страница 307: ...ow impedance short to battery in the Throttle Position sensor or circuit then a code 21 will set Conditions for setting the DTC Throttle Position Sensor signal is greater than 4 69 volts Engine revolu...

Страница 308: ...eading DTC Flash DTC 21 Throttle Position TP Sensor Circuit High Input Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignit...

Страница 309: ...any of these components cause the Throttle Position Sensor values displayed to change Verify repair Go to Step 8 8 1 Ignition OFF disconnect the ECM 2 Ignition ON engine OFF 3 Check for a short to B o...

Страница 310: ...6E1 140 DRIVEABILITY AND EMISSIONS...

Страница 311: ...xygen sensor is ready for use as a feedback for fuel control system Then the DTC 13 will set Conditions for Setting the DTC Engine run time is longer than 60 seconds All the above conditions are met a...

Страница 312: ...g the wiring harness and related connectors If the fault is induced the HO2S signal voltage will change This may help isolate the location of the malfunction DTC Flash DTC 13 O2 Sensor Circuit Not Rea...

Страница 313: ...M disconnected check continuity of the HO2S low circuit 3 If the HO2S low circuit measures over 5 ohms repair open or poor connection as necessary Was a HO2S low circuit problem found and corrected Ve...

Страница 314: ...6E1 144 DRIVEABILITY AND EMISSIONS...

Страница 315: ...ow for an extended period of time This code detects a lean oxygen sensor reading Conditions for Setting the DTC Engine run time is longer than 60sec Engine coolant temperature is above 70 C 158 F Thro...

Страница 316: ...contamination If none of the above conditions are present replace the affected HO2S DTC Flash DTC 44 O2 Sensor Too Lean Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check perfo...

Страница 317: ...ue s Yes No 8 1 Ignition OFF 2 Reconnect the ECM leave the sensor disconnected 3 Ignition ON Does the Scan Tool indicate HO2S voltage near the specified value 430 450mV Refer to Diagnostic Aids Go to...

Страница 318: ...6E1 148 DRIVEABILITY AND EMISSIONS...

Страница 319: ...for an extended period of time This code detects a rich oxygen sensor reading Conditions for setting the DTC Engine run time is longer than 60sec Engine coolant temperature is above 70 C 158 F Thrott...

Страница 320: ...ge is limited within a range between 300mV to 600mV check the HO2S high and low circuit wiring and associated terminal connections If the wiring and connections are OK replace the HO2S DTC Flash DTC 4...

Страница 321: ...2 Disconnect HO2S and jumper the HO2S high and low circuits ECM side to ground 3 Using a Scan Tool monitor HO2S voltage Is HO2S voltage below the specified value 10mV Go to Step 8 Go to Step 9 8 Repl...

Страница 322: ...6E1 152 DRIVEABILITY AND EMISSIONS...

Страница 323: ...ngine the ECT signal voltage should measure about 1 5 to 2 0 volts If the ECM detect a continuous open in the ECT sensor or circuit then a code 14 will set Conditions for Setting the DTC Engine runnin...

Страница 324: ...sor appears to be OK the fault is intermittent refer to Diagnostic Aids Engine Coolant Temperature Sensor C F OHMS Temperature vs Resistance Values approximate 100 212 177 80 176 332 60 140 667 45 113...

Страница 325: ...s require replacement Verify repair Go to Step 8 7 1 Ignition OFF 2 Disconnect the ECM and check the ECT sensor ground circuit for an Short to ground 3 If the ECT sensor ground circuit is Short to gro...

Страница 326: ...6E1 156 DRIVEABILITY AND EMISSIONS...

Страница 327: ...ith a fully warmed up engine the ECT signal voltage should measure about 1 5 to 2 0 volts Conditions for Setting the DTC Engine running time is longer than 30 secs The ECT sensor signal indicates an e...

Страница 328: ...is the case replace the ECT sensor If the ECT sensor appears to be OK the fault is intermittent refer to Diagnostic Aids Engine Coolant Temperature Sensor C F OHMS Temperature vs Resistance Values app...

Страница 329: ...M and check the ECT circuit for a an open or a short to battery in the sensor circuit 3 If the ECT circuit is short to battery or open repair it as necessary Was the ECT signal circuit shorted to grou...

Страница 330: ...6E1 160 DRIVEABILITY AND EMISSIONS...

Страница 331: ...e ECM will use a calculated spark retard value in order to minimize the knock during the conditions when the knock is likely to occur The calculated value will vary based on the engine speed and load...

Страница 332: ...Go to Step 4 Go to Step 12 4 Listen to the engine while raising and lowering the engine speed Is a knock or audible noise present Go to Step 5 Go to Step 6 5 Repair the mechanical engine problem or a...

Страница 333: ...ating temperature 3 Operate the vehicle within the conditions for setting this Diagnostic Trouble Code as specified in the supporting text Does the Scan Tool indicate that this diagnostic has ran and...

Страница 334: ...6E1 164 DRIVEABILITY AND EMISSIONS...

Страница 335: ...unction Indicator Lamp MIL will illuminate the second time the fault is detected The ECM will use a calculated spark retard value in order to minimize the knock during the conditions when the knock is...

Страница 336: ...the Diagnostic Trouble Code 2 Using a Scan Tool monitor the Specific DTC information for DTC 18 3 Observe the test results Does the Scan Tool indicate the DTC 18 Go to Step 3 Go to Diagnostic Aids 3 1...

Страница 337: ...tage or a short to ground 5 If a wiring problem is found repair as necessary Was a problem found Go to Step 10 Go to Step 9 8 Replace the KS Sensor Refer to Knock Sensor Is action complete Go to Step...

Страница 338: ...6E1 168 DRIVEABILITY AND EMISSIONS...

Страница 339: ...the DTC Engine is running Number of revolutions with pulses not equal to 58 is greater than 20 Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL after the fault...

Страница 340: ...e for 1 minute 3 Observe Diagnostic Trouble Codes Is Diagnostic Trouble Code 18 set Go to Step 4 Refer to Diagnostic Aids 4 1 Disconnect the ECM and CKP sensor 2 Check for an open or a short to ground...

Страница 341: ...24 will set Conditions for Setting the DTC Vehicle speed is less than 3 km h Engine is running MAP is less than 24kPa Throttle closed and in Drive Engine Speed is between 2000 RPM and 5000 RPM Followi...

Страница 342: ...in the sensor ground circuit Verify repair 4 1 Ignition ON 2 Using a Digital Voltmeter DVM measure at the VSS connector between ground and voltage supply Was the measurement near the specified value...

Страница 343: ...ake Air Temperature IAT sensor The MAP sensor is the main sensor used in this calculation and measuring engine load is its main function The ECM monitors the MAP signals for voltages outside the norma...

Страница 344: ...the engine idling note the MAP value on the Scan Tool Is the MAP reading above the specified value About 4V 90 kPa Go to Step 4 Go to Step 3 3 1 Ignition ON engine OFF 2 Using the Scan Tool monitor in...

Страница 345: ...to Step 9 Go to Step 12 9 Check the MAP sensor ground circuit between the MAP sensor and the ECM for the following conditions A short to ground An open circuit A short to voltagen Was the problem fou...

Страница 346: ...6E1 176 DRIVEABILITY AND EMISSIONS...

Страница 347: ...ts from the MAP sensor the CKP Sensor and the Intake Air Temperature IAT sensor The MAP sensor is the main sensor used in this calculation and measuring engine load is its main function The ECM monito...

Страница 348: ...h DTC 34 Manifold Absolute Pressure MAP Too Low Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition ON engine OFF 2 Wit...

Страница 349: ...ry Did the terminal require replacement Verify repair Go to Step 11 8 1 Ignition OFF 2 Disconnect the ECM and check the MAP signal circuit for an open short to ground or short to the sensor ground cir...

Страница 350: ...6E1 180 DRIVEABILITY AND EMISSIONS...

Страница 351: ...s above a calibrated value This malfunction detects an over voltage condition in the battery voltage circuit Conditions for Setting the DTC Engine is running Battery Voltage is greater than 17 2V Acti...

Страница 352: ...ean the battery terminals 2 Clean the battery ground cable connection if corrosion is indicated Is the battery voltage greater than the specified value 16V Replace battery Go to Step 4 4 1 Turn OFF al...

Страница 353: ...the ECM detects an excessively high signal voltage on the intake air temperature sensor signal circuit Conditions for Setting the DTC The engine is running IAT sensor temperature is greater than 140...

Страница 354: ...tain temperature If this is the case replace the IAT sensor If the IAT sensor appears to be OK the fault is intermittent refer to Diagnostic Aids Intake Air Temperature Sensor C F OHMS Temperature vs...

Страница 355: ...ECM and check the IAT sensor ground circuit for an open 3 If the IAT sensor ground circuit is open repair it as necessary Was the IAT sensor ground circuit open Verify repair Go to Step 9 8 1 Ignitio...

Страница 356: ...6E1 186 DRIVEABILITY AND EMISSIONS...

Страница 357: ...to monitor a lower voltage Diagnostic Trouble Code 71 will set when the ECM detects an excessively low signal voltage short to ground on the intake air temperature sensor signal circuit Conditions for...

Страница 358: ...tion refer to the Temperature vs Resistance Value table The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be stored above or...

Страница 359: ...Scan Tool Is the intake air temperature below the specified value 36 C 32 8 F Go to Step 6 Go to Step 5 5 1 Ignition OFF 2 Disconnect the PCM electrical connectors 3 Check the IAT sensor signal circu...

Страница 360: ...6E1 190 DRIVEABILITY AND EMISSIONS...

Страница 361: ...de is also set if an injector driver is shorted to voltage This code an injectors short to ground battery or a disconnected injector then a DTC 17 will be set Conditions for Setting the DTC The actual...

Страница 362: ...dy the injector driver circuit is shorted to voltage 10 Normal injector resistance is slightly more than if tested directly at the injector because it includes resistance of the harness wires The norm...

Страница 363: ...st connector 2 Ignition ON 3 Use a test light commercial available connected to ground to probe the injector connector terminal 4 Only the Ign terminal should illuminate the test high Besides the Ign...

Страница 364: ...6E1 194 DRIVEABILITY AND EMISSIONS...

Страница 365: ...oduces a voltage in the secondary coils which fires the spark plug The circuit between the coil driver and the ignition control circuit is monitored for a short to battery on the Electronic Spark Timi...

Страница 366: ...DTC 41 Ignition Coil Driver B Short To Battery Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Check for a faulty connection o...

Страница 367: ...e coil driver and the ignition control circuit is monitored for a short to battery on the Electronic Spark Timing A coil driver A line When the ECM detects a problem in the ignition control circuit it...

Страница 368: ...Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Check for a faulty connection or damaged terminals at the ignition coil Was a problem found Verify repair Go to Step 3 3 Ch...

Страница 369: ...oduces a voltage in the secondary coils which fires the spark plug The circuit between the ECM and the ignition control module is monitored for a short to ground on the Electronic Spark Timing B coil...

Страница 370: ...s the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Check for a faulty connection or damaged terminals at the ignition control module Was a problem found Verify...

Страница 371: ...coil driver and the ignition control circuit is monitored for a short to ground on the Electronic Spark Timing A coil drive A line When the ECM detects a problem in the ignition control circuit it wi...

Страница 372: ...faulty connection or damaged terminals at the ignition control module Was a problem found Verify repair Go to Step 3 3 Check for a faulty connection or damaged terminals at the ECM connector Was a pr...

Страница 373: ...to bypass the throttle bore To decrease idle speed it extends the IAC valve pintle towards its seat reducing bypass air flow A Scan Tool will read the ECM commands to the IAC valve in counts Higher c...

Страница 374: ...high air fuel ratio The idle speed may be too high or too low Engine speed may vary up and down and disconnecting the IAC valve does not help Diagnostic trouble code 44 may be set Scan Tool oxygen O2...

Страница 375: ...eck the IAC passages Are the IAC passages blocked Go to Step 4 Go to Step 5 4 Clear any obstruction from the IAC passages Is the action complete Verify repair 5 Replace the IAC Refer to On Vehicle Ser...

Страница 376: ...3 9 1 Check the resistance between the IAC terminal B and terminal C 2 Check the resistance between the IAC terminal A and terminal D Is the resistance infinite Go to Step 11 Go to Step 12 10 Replace...

Страница 377: ...hrough the meter fuse The engine control module ECM turns the MIL ON by grounding the MIL driver circuit Conditions for setting the DTC This code detects a low impedance short to ground on an open con...

Страница 378: ...M Terminal End View for terminal locations of the ECM ground circuits DTC Flash DTC 56 Check Engine Lamp Low Error Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed G...

Страница 379: ...the ECM battery feed circuit Is the action complete Verify repair 16 Locate and repair the short to ground in the MIL feed circuit to the instrument cluster and replace the fuse Is the action complet...

Страница 380: ...6E1 210 DRIVEABILITY AND EMISSIONS...

Страница 381: ...ed directly to the MIL indicator The engine control module ECM turns the MIL ON by grounding the MIL driver circuit Conditions for setting the DTC This code detects a low impedance short to battery on...

Страница 382: ...Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition OFF disconnect ECM 2 Ignition ON observe the MIL Is the MIL ON Go to Step 3 Go to Step...

Страница 383: ...rge solenoid output Then DTC 61 will set Conditions for Setting the DTC Driver feedback information shows a low state at its operation even when commanded high Action Taken When the DTC Sets The ECM w...

Страница 384: ...wiring harness connector from the EVAP Canister Purge Control Solenoid 3 Ignition ON Engine OFF 4 Using a Digital Voltmeter DVM check for voltage on the Engine IG Fuse pin of the EVAP Canister Purge C...

Страница 385: ...contact on the canister purge solenoid output Then DTC 62 will set Conditions for Setting the DTC Driver feedback information shows a high state at its operation even when commanded low Action Taken...

Страница 386: ...Aids Go to Step 3 3 1 Ignition OFF 2 Disconnect the EVAP Canister Purge Control Solenoid from the wiring harness connector from the EVAP Canister Purge Control Solenoid Using a DVM check the resistanc...

Страница 387: ...en when commanded high Action Taken When the DTC Sets The ECM will illuminate Malfunction Indicator lamp MIL Conditions for Clearing the DTC Once the ECM determines that a fault s has been rectified t...

Страница 388: ...g the Scan Tool monitor info for DTC 87 Does the Scan Tool indicate DTC 87 Refer to Diagnostic Aids Go to Step 3 3 1 Ignition OFF 2 Check for an open circuit at the pressure switch and thermo switch A...

Страница 389: ...or 3 Ignition ON Engine OFF Does the A C Compressor turn ON Go to Step 10 Go to Step 8 8 1 Ignition OFF 2 Check the A C Compressor Clutch circuit between the A C Compressor Clutch Relay and A C Compre...

Страница 390: ...6E1 220 DRIVEABILITY AND EMISSIONS...

Страница 391: ...earing the DTC Once the ECM determines that a fault s has been rectified then the CEL will switch OFF although the fault code will remain in the ECM memory Any fault codes will remain in ECM memory un...

Страница 392: ...derhood Electrical Center 3 Ignition ON engine OFF 4 Using a Digital Voltmeter DVM check for voltage on the Fused pins of the A C Compressor Clutch Relay connector Does the DVM read the following valu...

Страница 393: ...Setting the DTC If fault line from the QDSM is detected low Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL Conditions for Clearing the DTC Once the ECM deter...

Страница 394: ...nge in voltage will indicate the location of the fault This malfunction detects a Short to battery or Open Load or Short to ground at QDSM output DTC Flash DTC 93 Quad Driver Sub Module Step Action Va...

Страница 395: ...ed check sum Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL the first time the malfunction is detected Conditions for Clearing the MIL DTC Once the ECM deter...

Страница 396: ...ry EPROM Error Action Value s Yes No Was the On Board Diagnostic OBD System Check performed Go to step 2 Go to OBD System Check Refer to Service Bulletins Is there still a problem Go to step 3 Verify...

Страница 397: ...for Setting the DTC The ECM detects an internal program fault Action Taken When the DTC Sets The ECM will illuminate the malfunction indicator lamp MIL the first time the malfunction is detected Cond...

Страница 398: ...nly Memory Error Action Value s Yes No Was the On Board Diagnostic OBD System Check performed Go to step 2 Go to OBD System Check Refer to Service Bulletins Is there still a problem Go to step 3 Verif...

Страница 399: ...contact on the Tacho output the Diagnostic Trouble Code 91 will be set Conditions for Setting the DTC Driver feedback information shows a low state at its operation even when commanded low Action Tak...

Страница 400: ...and battery feed If a problem is found repair as necessary Verify repair Go to Step 7 7 1 Disconnect the meter cluster Panel 2 Check the tacho meter circuit for an open Was a problem found Go to Step...

Страница 401: ...battery or on the Tacho output then Diagnostic Trouble Code 92 will be set Conditions for Setting the DTC Driver feedback information shows a low state at its operation even when commanded low Action...

Страница 402: ...e still a problem Go to Step 8 Refer to CKP Sensor Signal Incorrect 7 1 Disconnect the ECM and CKP sensor 2 Check for a short to ground in the 58X reference circuit between the CKP sensor connector an...

Страница 403: ...ankshaft position pulses If no 58X crankshaft position pulses are present the ECM de energizes the fuel pump relay within 2 seconds after the ignition is turned ON or the engine is stopped The fuel pu...

Страница 404: ...Pressure Test chart should be used for diagnosis Caution To reduce the risk of fire and personal injury It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge Refer t...

Страница 405: ...between the ECM and the fuel pump relay Was a problem found Verify repair Go to Step 7 7 1 Check the fuel pump relay circuit for a poor terminal connection at the ECM 2 If a problem is found replace t...

Страница 406: ...Action Value s Yes No 12 Repair the open circuit in the fuel pump ground wire Is the action complete Verify repair 13 1 Re connect the horn relay in its proper location 2 Replace the fuel pump relay I...

Страница 407: ...to the fuel rail and injectors then to the fuel pressure regulator The fuel pressure regulator controls fuel pressure by allowing excess fuel to be returned to the fuel tank With the engine stopped an...

Страница 408: ...tainer when the disconnect is completed Fuel Pressure Relief Procedure 1 Remove the fuel cap 2 Remove the fuel pump relay from the underhood relay center 3 Start the engine and alow it to stall 4 Cran...

Страница 409: ...pump relay circuit for a poor terminal connection at the ECM 3 If a problem is found replace terminal as necessary Was a problem found Verify repair Go to Step 10 10 Replace the EPROM or ECM Is the ac...

Страница 410: ...d wire and the ground wire harness side 2 Command the fuel pump ON with a scan tool Did the test light illuminate for 2 seconds Go to Step 17 Go to Step 15 15 Repair the open circuit in the fuel pump...

Страница 411: ...esponse was not correct Action Taken When the DTC Sets Flashing the MIL The engine does not start Condition for Clearing the MIL DTC Use clear DTC information with Tech2 Refer to the immobilizer works...

Страница 412: ...check 2 Replace the ECM IMPORTANT The replacement ECM must be programmed Refer to On Vehicle Service in Engine Control Module and Sensors for procedures and Immobilizer system workshop manual And als...

Страница 413: ...from immobizer Action Taken When the DTC sets Flashing the MIL The Engine does not start Condition for Clearing the MIL DTC Use clear DTC information with Tech2 Refer to the immobilizer workshop manua...

Страница 414: ...er system 2 Disconnect the VEHICLE SPEED SENSOR LINE VSS OUT harness 3 Check for open or short to ground in the wire between the ECM and IMMOBILIZER CONTROL UNIT by DMM If a problem found repair as ne...

Страница 415: ...ty code secret key not programmed Action Taken When the DTC Sets Flashing the MIL The engine does not start Condition for Clearing the MIL DTC Use clear DTC information with Tech2 Refer to the immobil...

Страница 416: ...te DTC B Refer to Immobilizer workshop manual Go to Step 3 3 IMPORTANT The replacement ECM must be programmed Refer to On Vehicle Service in Engine Control Module and Sensors for procedures and Immobi...

Страница 417: ...hen the DTC Sets Flashing the MIL The engine does not start In case replacement ECM Action Taken When the DTC Sets Flashing the MIL Condition for Clearing the MIL DTC Use clear DTC information with Te...

Страница 418: ...DTC Flash DTC 86 Received Incorrect Security Code Step Action Value s Yes No 1 Was the On Board Diagnostic OBD system Check performed Go to Step 2 Go to OBD system check 2 Recheck the security code Is...

Страница 419: ...to Engine Mechanical Section 4 Disconnect electrical connector from the sensor 5 Remove the retaining bolt and sensor from the engine block Note Use caution to avoid any hot oil that might drip out I...

Страница 420: ...GEN SENSOR HO2S If applicable Removal 1 Disconnect the negative battery cable 2 The sensor is mounted on the exhaust pipe ahead of the catalytic converter 3 Disconnect pig tail electrical connector Im...

Страница 421: ...oval 1 Disconnect the negative battery cable 2 The IAT sensor is located in the intake air duct between the air filter and the throttle body 3 Disconnect the electrical connector from the sensor 4 Rem...

Страница 422: ...SD Damage Electronic components used in the control system are often designed to carry very low voltage Electronic components are susceptible to damage caused by electrostatic discharge Less than 100...

Страница 423: ...ition or walking a distance touch a known good ground before installing the parts Notice To prevent internal ECM damage the ignition must be OFF position in order to disconnect or reconnect power to t...

Страница 424: ...The pigtail is permanently attached to the switch Do not attempt to remove the wire from the switch Important Have container ready to catch the power steering fluid that leaks out of the line when the...

Страница 425: ...cable is properly adjusted also Refer to Throttle Cable Adjustment If the throttle shaft is not binding and the throttle cable is properly adjusted install a new TP sensor Installation 1 Install the...

Страница 426: ...e the VSS if the driven gear is chipped broken or worn 3 Inspect the O ring for wear nicks tears or looseness Replace the O ring if necessary Installation 1 Install the VSS in the transmission case wi...

Страница 427: ...connect the negative battery cable 2 Disconnect the IAC electrical connector 3 Remove the two screws and IAC valve from the throttle body Notice Do not clean the IAC valve by soaking it in solvent The...

Страница 428: ...rder to replace a valve IAC valve pintle shape and diameter are designed for the specific application Installation 1 Install IAC valve on the throttle valve body with the two screws Tighten the screws...

Страница 429: ...or Installation 6 Connect electrical connector at IAT sensor 7 Connect the negative battery cable Important Use an identical replacement part in order to replace a valve IAC valve pintle shape and dia...

Страница 430: ...nect electrical connector at Oil Pressure Switch 3 Unscrew Oil Pressure Switch from Oil Filter Mounting Housing Installation 1 Install Oil Pressure Switch into Oil Filter Mounting Housing and tighten...

Страница 431: ...ator control cable Inspection Check the following items and replace the control cable if any abnormality is found The control cable should move smoothly The control cable should not be bent or kinked...

Страница 432: ...rn up to the stopper screw If the valve lever does not reach the stopper screw repeat the procedure again from Step 1 ACCELERATOR PEDAL REPLACEMENT Removal 1 Disconnect the accelerator pedal control c...

Страница 433: ...filler cap if any abnormality is found WARNING REMOVE SLOWLY FUEL SPRAY MAY CAUSE INJURY FUEL FILTER Removal 1 Disconnect the negative battery cable 2 Remove the fuel filler cap 3 Disconnect the fuel...

Страница 434: ...type of cleaner as this may damage the fuel injector Important Fuel injectors are serviced as complete assembly only 1 Disconnect the negative battery cable 2 Disconnect al connector from fuel injecto...

Страница 435: ...uel lines or connections Reduce the chance of personal injury by covering the fuel line fitting with a shop towel before disconnecting the fittings The towel will absorb any fuel that may leak out Whe...

Страница 436: ...into the fuel rail 2 Install the fuel pressure regulator retaining bracket and tighten with a screw 3 Connect vacuum line onto the fuel pressure regulator 4 Install the fuel pump relay 5 Connect the n...

Страница 437: ...gs 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 from the underho...

Страница 438: ...ny of these condition exist replace the in tank fuel filter Installation 1 Insert the fuel pump assembly into fuel tank and place them in their position 2 Using commercially available tool tighten the...

Страница 439: ...injector spray tips Fitting should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passage Important An eight digit identification num...

Страница 440: ...manifold and insert the injectors into each port by pushing fuel rail 4 Install two fuel rail retaining bolts Tighten fuel rail retaining bolt to 19 N m 1 9kgf m 5 Place wiring harness in its place an...

Страница 441: ...ank to the frame 10 Lower tank assembly from the vehicle a little to make access space on top 11 Disconnect connectors at fuel pump 12 Remove pump tank assembly from the vehicle 13 Remove the tank und...

Страница 442: ...ery cable 2 Drain the cooling system Refer to Cooling System 3 Remove the air intake duct Refer to Air Intake Duct Removal Procedure 4 Remove the accelerator cable from throttle Refer to Accelerator C...

Страница 443: ...asting Installation 1 Install IAC valve onto the throttle body Refer to IAC valve Installation Procedure 2 Install TPS onto the throttle body if necessary Refer to TPS Installation Procedure 3 Place t...

Страница 444: ...ews 2 Reconnect the all connector 3 Reconnect the negative battery terminal IGNITION COIL Removal 1 Disconnect the negative battery cable 2 Disconnect all four spark plug cables from the coil 3 Discon...

Страница 445: ...g is excessive check the fuel and al system for possible causes of trouble If fuel and al system are normal install spark plugs of a higher heat range which have the same physical dimensions as the or...

Страница 446: ...g cables or the ignition coil are replaced previously before cables are removed from the ignition coil mark the cables and the coil so they can be reconnected in the same position Inspection Notice Ne...

Страница 447: ...tainer of the relay 4 Pull the relay straight up and out of the fuse and relay box Installation 1 Insert the relay into the correct place in the fuse and relay box with the catch slot aligned to retai...

Страница 448: ...d secure them with clamps EVAP CANISTER PURGE VALVE SOLENOID IF APPLICABLE Removal 1 Disconnect the negative battery cable 2 Disconnect al connector from EVAP purge solenoid located on the intake mani...

Страница 449: ...he terminal to be pulled into position within the connector 2 Pull carefully on the wire to install the connector terminal retainer CONNECTORS AND TERMINALS Use care when probing a connector and when...

Страница 450: ...p the aluminum mylar tape Do not remove the mylar 3 Untwist the conductors 4 Strip the insulation as necessary Installation 1 Splice the wires using splice clips and rosin core solder 2 Wrap each spli...

Страница 451: ...ed wire 2 Remove the insulation as required Installation 1 Use splice clips and rosin core solder in order to splice the two wires together 2 Cover the splice with tape in order to insulate it from th...

Страница 452: ...on and deposits on the terminals This protection is important because of the low voltage and the low amperage found in the electronic systems 1 Open the secondary lock hinge on the connector 2 Use too...

Страница 453: ...r the wire and the seal 5 Push the terminal and the connector to engage the locking tangs 6 Close the secondary locking hinge COM PACK III The Com Pack III terminal looks similar to some Weather Pack...

Страница 454: ...o referred to as pull to seat terminals 1 In order to install a terminal on a wire the wire must be inserted through the seal 2 and through the connector 3 2 The terminal 1 is then crimped onto the wi...

Страница 455: ...the A C mode is selected at the A C control switch The ECM uses this signal to adjust the idle speed before turning ON the A C clutch The A C compressor will be inoperative if this signal is not avail...

Страница 456: ...ens If the engine has not been run for several hours overnight the engine coolant temperature and intake air temperature displays should be close to each other A hard fault in the engine coolant senso...

Страница 457: ...h other A failure in the IAT sensor circuit will set DTC 69 or DTC 71 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR The MAP sensor responds to changes in intake manifold pressure vacuum the MAP sensor signal...

Страница 458: ...monitors numerous engine and vehicle functions via electronic sensors such as the throttle position sensor TPS heated oxygen sensor HO2S if applicable and vehicle speed sensor VSS The ECM also contro...

Страница 459: ...ontrol Fuel Injector Control Idle Air Control Electric Fuel Pump Relay Air Conditioning Compressor Clutch Relay Diagnostics OBD Malfunction Indicator Lamp Check Engine lamp Data Link Connector DLC Dat...

Страница 460: ...S may cause intermittent bursts of fuel from an injector and unstable idle because the ECM thinks the throttle is moving A hard failure in the TPS 5 volt reference or signal circuits will set either a...

Страница 461: ...lectrical equipment from the vehicle After this is done if the problem still exists it may be diagnosed in the normal manner ELECTROSTATIC DISCHARGE DAMAGE Electronic components used in the ECM are of...

Страница 462: ...und before installing the part AIR INDUCTION AIR INDUCTION SYSTEM The air induction system filters contaminants from the outside air and directs the progress of the air as it is drawn into the engine...

Страница 463: ...ution less 1000 rpm or manifold absolute pressure less than 10 kpa ENGINE SPEED VEHICLE SPEED FUEL DISABLE MODE The ECM monitors engine speed It turns off the fuel injectors when the engine speed incr...

Страница 464: ...EL METERING SYSTEM PURPOSE The basic function of the air fuel metering system is to control the air fuel delivery to the engine Fuel is delivered to the engine by individual fuel injectors mounted in...

Страница 465: ...fuel pump relay for two seconds to build up the fuel pressure quickly If the engine is not started within two seconds the ECM shuts the fuel pump off and waits until the engine is cranked When the en...

Страница 466: ...ed on ON then OFF When servicing the IAC it should only be disconnected or connected with the ignition OFF The position of the IAC pintle valve affects engine start up and the idle characteristics of...

Страница 467: ...e throttle body to warm the throttle valve and to prevent icing ELECTRONIC IGNITION SYSTEM CRANKSHAFT POSITION CKP SENSOR The crankshaft position CKP sensor provides a signal used by the engine contro...

Страница 468: ...he secondary voltage be receiving the primary voltage from ECM The primary voltage is generated at the coil driver located in the ECM The coil driver generate the primary voltage based on the X58 sign...

Страница 469: ...xture unburned Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps This is referred to as pre ignition Spark plugs may also misfir...

Страница 470: ...exhaust blow by and damage beyond simple gap wear may occur Cracked or broken insulators may be the result of improper installation damage during spark plug re gapping or heat shock to the insulator...

Страница 471: ...l not enable the A C compressor clutch if any of the following conditions are met The engine speed is greater than 6000 RPM The ECT is greater than 122 C 251 F The throttle is more than 95 open A C CL...

Страница 472: ...upplies a ground to energize the solenoid valve purge on The EVAP purge solenoid control is pulse width modulated PWM turned on and off several times a second The duty cycle pulse width is determined...

Страница 473: ...r line Disconnected or faulty EVAP purge control solenoid valve Open ignition feed circuit to the purge solenoid Damaged EVAP canister Leaking fuel sender assembly O ring Leaking fuel tank or fuel fil...

Страница 474: ...manifold While the engine is running exhaust gases and small amounts of the fuel air mixture escape past the piston rings and enter the crankcase these gases are mixed with clean air entering through...

Страница 475: ...MISSIONS 6E1 305 SPECIAL SERVICE TOOLS Legend 1 Tech 2 Scan Tool 2 Tech 2 AC DC Power Adapter 3 Tech 2 OBD DLC Interface Connector 4 Tech 2 DLC Interface Cable 5 Tech 2 RS232 Connector Port 6 Tech 2 1...

Страница 476: ...ultimeter Digital Voltmeter DVM 5 8840 2312 0 IAC Motor Analyzer 5 8840 2618 0 Fuel Injector Tester 5 8840 0385 0 Connector Test AdapterKit 5 8840 0279 0 Vacuum Pump with Gauge 5 8840 0632 0 Terminal...

Страница 477: ...EVAP canister purge vacuum to verify correct operation and vapor flow within the canister purge circuit 2 5 8840 2608 0 Ultrasonic Leak Detector is a microprocessor based device used to detect leaks...

Страница 478: ...Removal 6F 8 Installation 6F 9 Mid Pipe 6F 10 Mid Pipe and associated Parts 6F 10 Removal 6F 10 Installation 6F 11 Catalytic Converter If applicable 6F 12 Catalytic Converter and Associated Parts 6F 1...

Страница 479: ...6F 2 ENGINE EXHAUST PAGE Main Data and Specifications 6F 18 Torque Specification 6F 19...

Страница 480: ...ENGINE EXHAUST 6F 3 General Description This illustration is based on the 4 4 with TWC model...

Страница 481: ...installation of exhaust system supports is very important as improperly installed supports can cause annoying vibrations which can be difficult to diagnose Three Way Catalytic Converter If applicable...

Страница 482: ...fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or other corrosion inhibitors on threaded fasteners or fastener joint...

Страница 483: ...gasket 2 Front exhaust pipe 3 Center exhaust pipe damper rubber 4 Catalytic converter 5 Center exhaust pipe 6 Rear exhaust pipe damper rubber 7 Exhaust silencer with rear exhaust pipe 8 Rear exhaust p...

Страница 484: ...ary adjustments and part replacements if excessive wear or damage is discover during inspection 1 Front Exhaust Pipe 2 Center Exhaust Pipe and Catalytic Converter Flange Nut 3 Exhaust Pipe Damper Rubb...

Страница 485: ...Pipe Fixing Bolts and Nuts 1 3 2 4 Removal 1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Disconnect O2 sensor harness connector and remove front side...

Страница 486: ...ion 1 Install front exhaust pipe 3 and tighten four stud nuts Torque Stud Nuts 28 N m 2 9 kgf m Nuts 43 N m 4 4 kgf m 2 Tighten front side O2 sensor and reconnect O2 sensor harness connector If applic...

Страница 487: ...2 Mid Pipe Fixing Bolts 3 Mid Exhaust Pipe Mounting Rubber 4 Mid Pipe Removal 1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Remove front exhaust pipe...

Страница 488: ...ENGINE EXHAUST 6F 11 Installation 1 Install center exhaust pipe 4 and tighten four fixing bolts 2 and two bolts and nuts 1 to the specified torque Torque Fixing bolts 43 N m 4 4 kgf m Bolts 43 N m...

Страница 489: ...d cable 2 Raise the vehicle and support with suitable safety stands 3 Remove center exhaust pipe fixing bolts 4 Remove exhaust silencer fixing bolts 5 Remove catalytic converter 1 Installation 1 Insta...

Страница 490: ...on Exhaust Pipe Assembly 1 Check connections for looseness or damage 2 Check clamps for weakness crack or damage Catalytic Converter Check for dents or damage If any part of the converter is damaged o...

Страница 491: ...s on the converter front and rear pipes and connect the converter to the exhaust pipes Note When placing new gaskets check that U mark on the gasket is upside 2 Tighten the bolts with the specified to...

Страница 492: ...1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Remove four exhaust silencer fixing bolts 1 and two rear exhaust pipe fixing bolts and nuts 2 then disc...

Страница 493: ...T Installation 1 Install the exhaust silencer and tighten two bolts and nuts 2 on rear exhaust pipe to specified torque then tighten four bolts 1 on Catalytic Converter to specified torque Torque Bolt...

Страница 494: ...unting Rubber 3 Rear Exhaust Pipe Removal 1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Remove rear exhaust pipe fixing bolts and nuts then disconnect...

Страница 495: ...ameter thickness Front pipe mm in Middle pipe mm in Rear pipe mm in 42 7 1 5 1 8 0 059 Flange 54 0 1 5 2 0 0 059 50 8 1 5 2 0 0 059 Silencer Type Circular section shell construction of triple skin and...

Страница 496: ...ENGINE EXHAUST 6F 19 Main Data and Specifications Torque Specification N m kgf m...

Страница 497: ...eneral Description 6G 2 Service Precaution 6G 3 Oil Pump 6G 4 Oil Pump and Associated Parts 6G 4 Disassembly 6G 4 Inspection and Repair 6G 5 Reassembly 6G 5 Oil Pan 6G 6 Oil Pan and Associated Parts 6...

Страница 498: ...ow disposable oil filter to the main oil gallery in the cylinder Block An oil pump pressure relief valve and oil filter bypass valve are incorporated in the system From the main oil gallery in the cyl...

Страница 499: ...e fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or other corrosion inhibitors on threaded fasteners or fastener joi...

Страница 500: ...iated Parts Legend 1 Oil Pump Assembly 2 Oil Pressure Switch 3 Gasket 4 Sleeve Disassembly 1 Remove crankshaft timing pulley 2 Remove oil pan 3 Remove oil strainer 4 Remove oil pump assembly 5 Remove...

Страница 501: ...strip and straight edge Dimension 0 03 mm to 0 10 mm 0 0012 to 0 0039 in Oil Strainer Check the oil strainer for cracking and scoring If cracking and scoring are found the oil strainer must be replac...

Страница 502: ...3 Oil Pan 4 Oil Pan Gasket Important Disassembly 1 Loosen a drain plug to drain oil 2 Remove engine hood 3 Remove engine rear mounting 4 Remove transmission assembly 5 Remove engine front mounting 6...

Страница 503: ...y To install follows the disassembly steps in the reverse order Important Sealer Apply silicon into groove in oil pan lugs prior to fitment of oil pan to block remove excess sealer after oil pan is bo...

Страница 504: ...CONTROL SYSTEM CONTENTS PAGE Service Precaution 6H 2 Accelerator Pedal Control Cable 6H 2 Removal 6H 2 Inspection 6H 2 Installation 6H 2 Accelerator Pedal 6H 3 Accelerator pedal and Associated Parts 6...

Страница 505: ...cations Following these instructions can help you avoid damage to parts and systems Accelerator Pedal Control Cable Removal 1 Loosen the adjust nut on the cable bracket mounted 2 Remove cable clip 3 3...

Страница 506: ...cable 1 2 Accelerator pedal assembly 2 Installation 1 Accelerator pedal assembly 2 2 Accelerator pedal control cable 1 Adjustment Manual Transmission Rotate counterclockwise to loosen the locked nut a...

Страница 507: ...INDUCTION 6J 1 SECTION 6J INDUCTION CONTENTS PAGE Service Precaution 6J 2 Air Cleaner Filter 6J 2 Removal 6J 2 Inspection 6J 2 Installation 6J 2 INDEX...

Страница 508: ...specifications Following these instructions can help you avoid damage to parts and systems Air Cleaner Filter Removal 1 Remove positive ventilation hose connector 2 Remove intake air temperature sens...

Страница 509: ...ble for vehicles in all countries except the USA Canada Europe and Thailand All rights reserved This manual may not be reproduced in whole or in part without the permission in writing of ISUZU MOTORS...

Страница 510: ...No TFHEC WE 981 PRINTED IN JAPAN...

Результаты поиска

Содержание 20LE

Отзывы:

Бренды по названию

Популярные бренды

Isuzu 20LE, Руководство по ремонту

Результаты поиска

Содержание 20LE

Отзывы:

Бренды по названию

Популярные бренды