Page 1 WORKSHOP MANUAL TF SERIES GASOLINE ENGINE (C22NE, 22LE, 20LE) SECTION 6, 6A, 6B, 6C, 6D, 6E, 6F, 6G, 6H & 6J...
Page 2: Engine Diagnosis
THIS MANUAL INCLUDES FOLLOWING SECTIONS SECTION CONTENTS Engine Diagnosis Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Ignition System Starting and Charging System Driveability and Emissions Engine Exhaust Engine Lubrication Engine Speed Control System Induction...
Page 3 NOTICE Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully 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 on the latest product information available at the time of publication.
Page 4: Table Of Contents
INDEX ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-1 SECTION 6 ENGINE DIAGNOSIS CONTENTS PAGE Engine Diagnosis....................... 6- 2 Hard Starting ......................... 6- 2 Engine Compression Test Procedure ................. 6- 3 Rough Engine Idling or Engine Stalling..............6- 4 Rough Engine Running ....................6- 5 Hesitation........................
Page 5: Engine Diagnosis
6-2 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Engine Diagnosis Hard Starting 1.Starting Motor Does Not Turn Over Trouble Shooting Procedure Turn on headlights and starter switch. Condition Possible cause Correction Headlights go out or dim Battery run down or under Recharge or replace battery...
Page 6: Engine Compression Test Procedure
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-3 3.Trouble in Fuel System Condition Possible cause Correction Starting motor turns over and Fuel tank empty Fill spark occurs but engine does not start. Water in fuel system Clean Fuel filter clogged Replace filter...
Page 7: Rough Engine Idling Or Engine Stalling
6-4 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Rough Engine Idling or Engine Stalling Condition Possible cause Correction Trouble in fuel injection system Idle air control valve defective Replace Throttle shutting off incomplete Correct or replace Throttle position sensor circuit Correct or replace...
Page 8: Rough Engine Running
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-5 Rough Engine Running Condition Possible cause Correction Engine misfires regularly Ignition coil layer shorted Replace Spark plugs fouling Clean or install hotter type plug Spark plug(s) insulator nose Replace leaking Fuel injector(s) defective Replace...
Page 9: Hesitation
6-6 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Hesitation Condition Possible cause Correction Hesitation on acceleration Throttle Position Sensor Replace throttle valve assembly adjustment incorrect Throttle Position Sensor circuit Correct or replace open or shorted Excessive play in accelerator Adjust or replace...
Page 10: Engine Lacks Power
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-7 Engine Lacks Power Condition Possible cause Correction Trouble in fuel system Fuel Pressure Control Valve not Replace working normally Fuel injector clogged Clean or replace Fuel pipe clogged Clean Fuel filter clogged or fouled...
Page 11: Engine Noisy
6-8 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Condition Possible cause Correction Engine overheating Level of Engine Coolant too low Replenish Thermo switch or fan motor Replace defective Thermostat defective Replace Engine Coolant pump defective Correct or replace Radiator clogged Clean or replace...
Page 12: Abnormal Noise Due To Hydraulic Lash Adjustor
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-9 Abnormal Noise Due to Hydraulic Lash Adjuster Should abnormal noise due to the hydraulic lash adjuster trouble be heard immediately after the engine is started, inspect as follows: Condition Possible cause Correction Abnormal noise is heard...
Page 13 6-10 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Troubleshooting Procedure Short out each spark plug and listen for change in engine noise. Condition Possible cause Correction Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and (Piston makes noise each time it...
Page 14: Abnormal Combustion
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-11 Abnormal Combustion Condition Possible cause Correction Trouble in fuel injection system Fuel pressure control valve Replace defective Fuel filter clogged Replace Fuel pump clogged Clean or replace Fuel tank or fuel pipe clogged Clean or replace...
Page 15: Engine Oil Consumption Excessive
6-12 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Engine Oil Consumption Excessive Condition Possible cause Correction Oil leaking Oil pan drain plug loose Retighten or replace gasket Oil pan setting bolds loosened Retighten Oil pan gasket broken Replace gasket Front cover retaining bolts loose or...
Page 16: Fuel Consumption Excessive
ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) 6-13 Fuel Consumption Excessive Condition Possible cause Correction Trouble in fuel system Mixture too rich or too lean due to Refer to "Abnormal Combustion" trouble in fuel injection system Fuel cut function does not act Refer to "Abnormal Combustion"...
Page 17: Malfunction Indicator Lamp
6-14 ENGINE DIAGNOSIS (C22NE, 22LE, 20LE) Malfunction Indicator Lamp The instrument panel "CHECK ENGINE" Malfunction Indicator lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition Possible cause Correction "CHECK ENGINE" MIL does not...
Page 18: Engine Mechanical
INDEX ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-1 SECTION 6A ENGINE MECHANICAL CONTENTS PAGE General Description......................6A- 4 ENGINE PICTORIAL ....................6A- 6 Main Data and Specification ................... 6A-11 CRANK CASE VENTILATION SYSTEM ..............6A-18 ENGINE ASSEMBLY & LOOSE PARTS ..............6A-19 OPERATIONS ON ENGINE AGGREGATES..............
Page 19 6A-2 ENGINE MECHANICAL (C22NE, 22LE, 20LE) PAGE Camshaft Housing, Check for Plance Surface ............6A-41 Cylinder Head, Removal and Installation ..............6A-41 Cylinder Head, Disassemble and Assemble ............. 6A-44 Valve, Grind ......................... 6A-46 Valve Seating, Mill....................... 6A-47 Cylinder Head, Overhaul..................... 6A-47 Flywheel ........................
Page 20 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-3 PAGE Radiator ........................6A-67 Thermostat........................6A-67 Water Pump ......................... 6A-68 Coating sealing surfaces with Silicone Grease ............6A-68 Alternator ........................6A-68 Starter .......................... 6A-68 V-belt Tension of Alternator ..................6A-69 FULE INJECTION SYSTEM....................6A-70 Map Sensor........................
Page 21: General Description
6A-4 ENGINE MECHANICAL (C22NE, 22LE, 20LE) GENERAL DESCRIPTION Engine Cleanliness And Care An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important.
Page 22 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-5 contributing to reliable engine performance: When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick up unit.
Page 23: Engine Pictorial
6A-6 ENGINE MECHANICAL (C22NE, 22LE, 20LE) ENGINE PICTORIAL Front View “4WD OIL PAN”...
Page 24 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-7 Inlet Side View “4WD OIL PAN”...
Page 25: Rear View
6A-8 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Rear View “4WD OIL PAN”...
Page 26 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-9 Exhaust Side View “4WD OIL PAN”...
Page 27: Top View
6A-10 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Top View...
Page 28: Main Data And Specification
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-11 Main Data and Specifications Engine - General C22NE 22LE 20LE Engine type Four-cycle, water cooled cross-flow with single over head camshaft Micro-computer control, fuel injection Combustion chamber type (Volume) Hemispherical (43.3cm <-- <-- Timing train system Belt drive <--...
Page 29 6A-12 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Engine - General C22NE 22LE 20LE Fuel pressure kg/cm (psi/Pa) 3.4 (48.4/334) <-- <-- Fuel filter type Cartridge paper element Air cleaner type Dry paper element <-- <-- Battery Type/V-Ax No. of units 50D20L (STD)
Page 30 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-13 Valve System C22NE 22LE 20LE Actuation Type Direct-acting Inverted Bucked Tappet Valve Clearance Adjustment Hydraulic Valve Rotor Type None Inlet-Valve Material Chromium Alloyed Steel -Seat Insert Material Sintered Iron Exhaust-Valve Material Head:Cr-Mn-Ni Alloyed Shaft:Cr-Si Alloyed&Cr plated...
Page 31 6A-14 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Crankshaft C22NE 22LE 20LE Material Nodular Cast Iron Bearing subjected to End Thrust Guide Bearing NO.3 Main Bearing-Material&Type Steel Backed Tri-metal Babbitt Front Seal-Diameter&Type 35.0mm Lip Seal Rear seal-Diameter&Type 90.0mm Micro-lip Seal Crankshaft Balancing Individually Balanced No.of Counterweights...
Page 32 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-15 Engine Specification Matrix for destination 99 HEC FOR TF MODEL: 2.2L VEHICLE MODEL TFR/S (141) AUSTRALIA CHILE COLOMBIA Major Description GUATEMALA ZEALAND COSTA RICA VEHICLE TYPE 4×2 4×2 4×4 4×2 VEHICLE IDENT. CODE ENGINE TYPE C22NE <--...
Page 33 6A-16 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 99 HEC FOR TF MODEL: 2.2L VEHICLE MODEL TFR/S(141) COLOMBIA SOUTH AFRICA EQUADOR VEHICLE TYPE 4×4 4×2 4×4 4×4 4×2 VEHICLE IDENT. CODE ENGINE TYPE <-- <-- <-- 22LE FUEL CONTROL SYSYTEM CLOSED LOOP...
Page 34 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-17 99 HEC FOR TF MODEL: 2.2L 2.0L VEHICLE MODEL TFR/S (141) EQUADOR CHILE, GULF, KENYA, EGYPT SOUTH AFRICA CHINA, NIGERIA, PHILIPPINE VEHICLE TYPE 4×4 4×2 4×4 4×2 VEHICLE IDENT. CODE ENGINE TYPE 22LE <--...
Page 35: Crankcase Ventilation System
6A-18 ENGINE MECHANICAL (C22NE, 22LE, 20LE) CRANKCASE VENTILATION SYSTEM The Engine Ventilation System passes 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.
Page 36: Engine Assembly & Loose Parts
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-19 ENGINE ASSEMBLY & LOOSE PARTS Loose Parts 10 Tensioner Pulley 11 Pulley Dust Shield Cover 1 Alternator 12 Pulley Spacer 2 P/S Pivot Spacer 13 A/C Compressor Bracket 3 P/S Adjusting Screw 14 Pulley Bolt...
Page 37: Operations On Engine Aggregates
6A-20 ENGINE MECHANICAL (C22NE, 22LE, 20LE) OPERATIONS ON ENGINE AGGREGATES Engine Damping Blocks (Engine Without Transmission) Removal Remove bonnet. Remove radiator. Remove air inlet hose. Remove power steering pump drive belt and power steering pump from engine. Remove all cable connections, hoses and lines from engine.
Page 38 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-21 Remove upper bolts of left and right engine mounting from damping blocks. Raise engine slightly. Remove lower bolts of left and right damping blocks. Remove damping blocks. Attach engine to cable, support transmission with car jack and remove upper transmission fastening bolt.
Page 39 6A-22 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Install exhaust pipe to manifold. Install power steering pump and V-belt. Adjust Adjust power steering pump V-belt tension according to the corresponding operation. Installation Install radiator according to the corresponding operation. Install air inlet hose.
Page 40 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-23 Toothed Belt and Timing Check Removal Remove the belts on the bracket for alternator. Remove the fan. Remove the V-belt for power steering. Remove the V-belt for A/C. Remove the fan belt. Remove the fan shroud.
Page 41 6A-24 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Installation Install the toothed belt to the cover. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear. Install the fan shroud. Tighten(Torque) Crankshaft pulley bolts - 20 N.m (2.1 kgf.m) Install the fan belt Install the V-belt for A/C.
Page 42: Toothed Belt Tension, Adjust
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-25 Toothed Belt Tension, Adjust (Engines with toothed belt tension roller) Removal Refer to 6A-23. Toothed Belt and Timing check and removal steps. Adjust Loosen the fastening bolt of the toothed belt tension roller. Turn the toothed belt tension roller at adjustment eccentric(1) in the direction of arrow (counterclockwise), until pointer (2) comes to the right stop.
Page 43: Toothed Belt, Replace
6A-26 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Toothed Belt, Replace (Engine with toothed belt tension roller) Removal Remove the belts on the bracket for alternator. Remove the fan. Remove the V-belt for power steering. Remove the V-belt for A/C. Remove the fan belt.
Page 44 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-27 Adjust Loosen the fastening bolt of the toothed belt tension roller and turn the adjustment eccentric in the direction of arrow (clockwise) until pointer (1) comes to the left stop. Remove the toothed belt.
Page 45: Operations On Installed Engine
6A-28 ENGINE MECHANICAL (C22NE, 22LE, 20LE) OPERATIONS ON INSTALLED ENGINE SEALING OPERATIONS Gasket, Exhaust Manifold, Cylinder Head Removal Remove front exhaust pipe from exhaust manifold. Remove exhaust manifold heat shield. Remove exhaust manifold retaining nut. Remove exhaust manifold from cylinder head.
Page 46: Seal Ring, Camshaft Housing, Timing Side
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-29 Seal Ring, Camshaft Housing, Timing Side Removal Remove front toothed belt cover toothed belt from camshaft timing gear according to the corresponding operation. Remove camshaft housing cover and camshaft timing gear. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.
Page 47: Seal Ring - Front Camshaft Housing, Replace
6A-30 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Install cable to temperature sensor. Install upper bolts of rear toothed belt rear cover. Install camshaft timing gear then check timing according to the corresponding operation. Install camshaft housing cover. Install toothed belt and front cover.
Page 48 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-31 Installation Camshaft pulley-counterhold 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⋅m) Tighten (Torque)
Page 49: Toother Belt Rear Cover
6A-32 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Toothed Belt Rear Cover (Engine with toothed belt tension roller) Removal Mark operating direction of toothed belt. Remove toothed belt according to the operation "Toothed Belt". Remove toothed belt tension roller according to the operation "Toothed Belt Tension Roller ".
Page 50: Toother Belt Tension Roller
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-33 Installation Install toothed belt rear cover. Install camshaft pulley while counterholding at camshaft hex head. Install camshaft housing cover. Tighten (Torque) Toothed belt rear cover to oil pump and camshaft housing - 6 N⋅m/4 lbf ft.
Page 51: Component Parts
6A-34 ENGINE MECHANICAL (C22NE, 22LE, 20LE) COMPONENT PARTS CYLINDER HEAD Camshaft Housing Cover Valve Drive Camshaft Housing Camshaft Cylinder Head...
Page 52: Hydraulic Valve Lifter
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-35 HYDRAULIC VALVE LIFTER Hydraulic Valve Lifter Oil reservoir Piston with ball head (moving) Pressure Cylinder (fixed) Check ball Pressure chamber Oil feed...
Page 53: Operations On Cylinder Head And Camshaft Housing
6A-36 ENGINE MECHANICAL (C22NE, 22LE, 20LE) OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING Camshaft Removal Remove cylinder head according to the corresponding operation. Remove camshaft housing from cylinder head and lay housing on base provided Remove rear sealing gasket and plate camshaft housing with taking care not to damage housing.
Page 54: Camshaft Housing Removal And Installation
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-37 Camshaft Housing, Removal and Installation See operation Camshaft Cylinder Head Important! Remove cylinder head only from cold engine (room temperature). Removal Remove ground cable from battery. Open radiator drain tap and collect coolant. Remove air intake hose.
Page 55 6A-38 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Clean All sealing surfaces, drill holes in cylinder head bolts. Check cylinder block and cylinder head for plane surface according to the corresponding operations. Installation Install cylinder head sealing with marking "OBEN/TOP" facing upwards and to right side of engine.
Page 56: Hydraulic Valve Lifers, Replace
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-39 Hydraulic Valve Lifters, Replace Removal Remove the spark plug connectors and spark plugs. Remove the camshaft housing cover. Removal Turn the crankshaft at fastening bolt of toothed belt drive gear in the direction of the engine rotation until the cam of hydraulic valve lifter being replaced stands vertically.
Page 57 6A-40 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Inspection All parts, if necessary replace. When replacing camshaft, always replace all cam followers. Installation Insert hydraulic valve lifter (1) in camshaft housing. Coat sliding surfaces of rocker arm with Mcs, Paste and insert in camshaft housing.
Page 58: Camshaft Housing, Check For Plance Surface
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-41 Camshaft Housing, Check for Plane Surface Clean Sealing surfaces. Inspection Check length and width of sealing surface for deformation and diagnosis for warpage and use straight edge feeler gauge. Measure Height of camshaft housing (sealing surface to sealing surface).
Page 59 6A-42 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Removal Remove the camshaft housing cover and camshaft pulley by counter-holding at the hex head of camshaft. Removal Remove the fastening bolts from camshaft housing. Removal Remove the exhaust pipe from exhaust manifold. Loosen the cylinder head bolts spirally from the outside inwards (first 1/4, then 1/2 revolution).
Page 60 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-43 Installation Install the cylinder head gasket. Mark "OBEN/TOP" on top and turn it towards timing side of engine. Place cylinder head on cylinder block. Installation Insert the hydraulic valve lifters (3), thrust pieces (2) and cam followers (1) with MoS2 paste.
Page 61: Cylinder Head, Disassemble And Assemble
6A-44 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Installation Install the fastening bolts. Loosen the lower alternator fastening bolt. Install the alternator, power steering and V-belts. Cylinder Head, Disassemble and Assemble Removal Remove the hydraulic valve lifters. Lay aside in installation positions.
Page 62 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-45 Inspection Sealing surfaces for plane surface, guides, sliding and bearing points for wear-see operation “Cylinder Head. Overhaul”. Installation Coat the valves with engine oil and insert in cylinder head. Install the valve spacer ring or valve rotator(exhaust) and valve spring seal(intake).
Page 63: Valve, Grind
6A-46 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Valve, Grind Valves can be reused once or twice after regrinding-only if there are no crater-like burns on the valve cone. Excessive grinding can cause the upper valve head edge to become too thin.
Page 64: Valve Seating, Mill
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-47 Valve Seating, Mill Place cylinder head on block of wood. Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-8840- 2593-0. Valve seat-45°, side face, upper correction-30°, side face (arrows on cutter). Valve seat width: Inlet-1.0 to 1.5 mm/0.04 to 0.06 in.
Page 65: Flywheel
6A-48 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Inspection Check contact pattern (I) on valve seat and in cylinder head. Clean Valves, valve guides, cylinder head. Flywheel Removal Remove transmission and clutch. Remove flywheel while locking with 5-88400-446-0. Torque - Angle Method Flywheel to crankshaft - 65 Nm/6.5 kgf⋅m.+30°...
Page 66: Starter Ring Gear(Manual Transmission)
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-49 Starter Ring Gear (Manual Transmission) Removal Remove flywheel according to the corresponding operation. Drill starter ring gear underneath tooth gap approx. 8mm/0.30in. deep with 8mm/0.25in. diameter drill. Separate starter ring gear with chisel on the drilling point.
Page 67: Seal Ring, Crankshaft
6A-50 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Seal Ring, Crankshaft (Oil Pump Housing) Removal Remove toothed belt rear cover according to the corresponding operation. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.
Page 68: Gasket, Oil Pan
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-51 Reassembly Reassemble clutch assembly. Disassembly Disassemble clutch assembly to flywheel using 5-8840-2634-0 Torque Angle-Method Clutch assembly to flywheel-17.6Nm/1.8 kgf Gasket, Oil Pan Removal Loosen fixing bolts. Remove oil pan from oil pump and cylinder block.
Page 69 6A-52 ENGINE MECHANICAL (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...
Page 70: Operations On Crank Drive
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-53 OPERATIONS ON CRANK DRIVE Con-Rod Bearing Removal Remove oil pan according to the corresponding operation. Remove con-rod bearing cap and con-rod bearing after marking both sides. Clean Con-rod journal, con-rod bearing cap Installation Install new bearing shafts lightly coated with engine oil.
Page 71: Con-Rod
6A-54 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Installation Install piston with con-rod by inserting with engine oil. Coat piston rings with engine oil and compress with piston ring compressor. Important! Installation position: Arrow / notch on piston head on timing side of engine...
Page 72 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-55 Heat a new con-rod to 280°C in the oil bath. Install the con-rod to the piston and insert the piston pin. Important! Since the con-rods have no weight balancing studs, re-working is not possible.
Page 73 6A-56 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Installation Install oil scraper ring. Offset ring gaps of steel band rings each 25 to 50 mm/1 to 2in. to the left or right of the intermediate ring gap. Install piston rings. Offset ring gaps by approx. 180°.
Page 74: Operations On Removed Engine
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-57 OPERATIONS ON REMOVED ENGINE Crankshaft Removal Mount the engine on an engine overhaul stand with appropriate adapters. Remove the aggregates, flywheel/drive disc, oil pan, and oil pump according to the corresponding operation. Mark the con-rod bearing cover.
Page 75 6A-58 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Apply a bead of sealant (TB-1207C or equivalent) in the grooves of both bearing shells Important! After installation of bearing cover, press in sealing compound again from above, until compound emerges at the joints.
Page 76: Bearing Free Play Measurement
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-59 Inspection Out-of-round (run-out)-middle bearing shell removed when mounting on front and rear bearing. Permissible out-of-round - see "Technical Data" Bearing Free Play Measurement Two methods for measuring bearing free play are described - 1. Plastigage method and 2. micrometer and gauge method.
Page 77: Micrometer And Gauge Method
6A-60 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Clean Plastigage from journals. Lightly coat journals and bearings with engine oil. Installation Install bearing cap and shell using new bolts. Torque - Angle Method Main bearing cap bolt - 60 N⋅m (6.1 kgf⋅m) +40° to 50°.
Page 78: Bypass Valve
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-61 Bypass Valve Removal Remove oil filter. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking out bypass valve from seating. Installation Install bypass valve using drift (diameter approx.
Page 79: Oil Pump Safety Valve
6A-62 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Oil Pump Safety Valve Removal Remove closure plug. Remove seal ring. Remove spring. Remove piston. Installation Install piston (observe installation position). Install spring. Install seal ring. Install closure plug. Tighten (Torque) Closure plug - 30 N⋅m (3.0 kgf⋅m)
Page 80: Operations On Oil Circulation
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-63 OPERATIONS ON OIL CIRCULATION Cylinder Head Safety Valve Removal Remove cylinder head according to the corresponding operation. Make hole in core plugs with pointed drift, turn in self tapping screw and edge out. Important! Cover oil duct in cylinder head with piece of cloth.
Page 81 6A-64 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Installation Install new pressure valve into cylinder head - with suitable pipe until stop. Install core hole plugs into cylinder head - with suitable pipe to end of chamfer.
Page 82: Operations On Cooling Sysytem
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-65 OPERATIONS ON COOLING SYSTEM Caution! Before working with the cooling system, be sure to confirm that the temperature of the engine is cooled down. Failure to observe this may cause burn. Cooling System, Check for Leaks...
Page 83: Refill Coolant
6A-66 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Important! Do not loosen or open the radiator cap when coolant is hot. Doing so may cause hot water or steam to splash out, resulting in burn. When opening the radiator cap, be sure to confirm the coolant is cold.
Page 84: Engine External Parts
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-67 ENGINE EXTERNAL PARTS Radiator Removal Remove the upper hose and lower hose. Remove all V-belts. Remove the cooling fan. Remove the fan guide. Remove the radiator. Installation Install the radiator. Install the fan guide.
Page 85: Water Pump
6A-68 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Water Pump Removal Remove lower hose band from pipe band and collect coolant. Remove front toothed belt cover according to the corresponding operation. Remove water pump from cylinder block after releasing tension on toothed belt.
Page 86: V-Belt Tension Of Alternator
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-69 Tighten (Torque) Starter to cylinder block: Engine side - 45 N⋅m (4.6 kgf⋅m) Transmission side - 75 N⋅m (7.6 kgf⋅m) Starter support to cylinder block - 25 N⋅m (2.5 kgf⋅m) Re-connect cables. V-belt Tension of Alternator Measure Measure V-belt tension of alternator.
Page 87: Fuel Injection System
6A-70 ENGINE MECHANICAL (C22NE, 22LE, 20LE) FUEL INJECTION SYSTEM MAP SENSOR Removal Disconnect the battery cable. Disconnect the electrical connector from the sensor. Remove the mounting bolts securing the sensor to the manifold. Remove the sensor from the intake manifold.
Page 88: Ect
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-71 Installation Connect the connectors. Install ECM to the proper position. Tighten 4 screws to the bracket. Install the ECM cover. Install the center console assembly. Removal Remove wiring harness plug and coolant temperature sensor.
Page 89: Crank Position Sensor
6A-72 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Crank Position Sensor Removal Remove crank position sensor. Installation Install crank position sensor.
Page 90: Fuel Injector
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-73 FUEL INJECTOR Removal Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components. Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections.
Page 91: Oxygen Sensor
6A-74 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Oxygen Sensor (If applicable) Removal Remove wiring harness plug. Remove oxygen sensor from the front exhaust pipe. Tighten (Torque) Oxygen sensor in exhaust pipe - 30 N⋅m (3.1 kgf⋅m) Throttle Valve Position Sensor Removal Remove wiring harness connector.
Page 92: Air Cleaner Filter
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-75 Air Cleaner Filter Removal Remove positive ventilation hose connector. Remove intake air temperature sensor. Remove mass air flow sensor. Remove air cleaner duct assembly. Remove air cleaner element. Inspection Check the air cleaner filter for damage or dust clogging.
Page 93: Technical Data
6A-76 ENGINE MECHANICAL (C22NE, 22LE, 20LE) TECHNICAL DATA SOHC Gasoline Engine C22NE/22LE/20LE Engine Oil Viscosity The following engine oils can be used: A = single-grade oils B = multigrade oils C = easy run oils depending on the outside temperature.
Page 94: Radiator Cap
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-77 Cooling System Radiator Type: Cross-flow Radiator core surface in cm 2000 Cooling system capacity (in litres): Anti-freeze Mixture Anti-freeze Mixture Required Up to-10°C Up to-20°C Up to-30°C Up to-40°C Quantity Quantity in litres Quantity in litres...
Page 95 6A-78 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Adjustment Values/Checking Values Valve clearance Inlet Hydraulic valve lash adjustment Outlet No adjustment necessary 1.0 ∼ 1.1mm Spark plugs - electrode gap Compression The difference in compression between the individual cylinders in the engine must not exceed 100 kPa (1 bar).
Page 96 ENGINE 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 outlet...
Page 97 6A-80 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Cylinder Head (continued) Valve Dimensions C 20 NE A in mm B in mm C(diameter in mm) and identification mark Normal K Oversize K1 Oversize K2 Oversize A 0.075 0.150 0.250 Inlet valve 104.2 103.8...
Page 98 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-81 Crankshaft, Cylinder Block Cylinder Grinding and Piston dimensions Cylinder Grinding and Piston Dimensions Size Cylinder bore dia. in mm Cylinder to Related piston dia. in mm Piston head Crankshaft co- efficient housing co-efficient over...
Page 99 6A-82 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Crankshaft, Cylinder Block (continued) Piston Rings Square ring Height Tapered ring Height Oil scraper Height Ring gap offset 180° Note that the upper steel band ring gap is offset 25 to 50mm to the left and the lower 25 to 50mm to the right opposite the intermediate ring gap.
Page 100 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-83 Crankshaft, Cylinder Block (continued) Crankshaft Grinding Dimensions Crankshaft Guide Con-rod journal Con-rod width jounal bearing 1 to 4 I, II, IV, V Diameter Widtht Diameter Width Normal size Bearing journal and colour code from 57.9820 green...
Page 101 6A-84 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Piston Pins Dimensions Length 61.5 Diameter Type Shank-fit in con-rod Clearance In piston 0.011 to 0.014 In con-rod Installation See operation “Con-rod, Replace”...
Page 102 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-85 Con-rod Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g. As the con-rods have no counterweights, re-working is not possible. Con-rods must be replaced only as a set.
Page 103 6A-86 ENGINE MECHANICAL (C22NE, 22LE, 20LE) Crankshaft, Cylinder Block (continued) Flywheel Starter ring gear Before fitting, heat ring gear to 180°C - 230°C Lateral run-out Permissible 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...
Page 104: Recommended Torque Values
ENGINE MECHANICAL (C22NE, 22LE, 20LE) 6A-87 Recommended Torque Values N⋅m (kgf⋅m) Bearing cover to cylinder block ..................+40° to 50° Bracket for alternator to cylinder block ................Bracket for engine damping block to transmission ............Bracket for engine damping block to engine block ............
Page 105: Special Service Tools
6A-88 ENGINE MECHANICAL (C22NE, 22LE, 20LE) SPECIAL SERVICE TOOLS ITEM NO. ILLUSTRATION PART NO. PART 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 Sleeves 5-8840-2597-0 Installer 5-8840-0457-0 Remover / Installer...
Page 106 ENGINE MECHANICAL (C22NE, 22LE, 20LE) 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 Wrench 5-8840-2601-0 Installer...
Page 107: Special Service Tool
INDEX ENGINE COOLING 6B-1 SECTION 6B ENGINE COOLING CONTENTS PAGE General Description......................6B- 2 Service Precaution ......................6B- 3 Diagnosis......................... 6B- 5 Draining and Refilling Cooling System................. 6B- 6 Water Pump........................6B- 7 Water Pump and Associated Parts................6B- 7 Removal ........................
Page 108: General Description
6B-2 ENGINE COOLING General Description Legend 1 Water Pump 5 Coolant Distributor 2 Thermostat 6 Cylinder Block and Head 3 Radiator 7 Throttle Body 4 Reserve Tank 8 Heater The Cooling System is a pressurized type, where the water pump, which is cambelt driven, forces the circulation of the coolant through the cylinder block and head.
Page 109: Service Precaution
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 110 Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system. • Calculating mixing ratio Mixing ratio Antifreeze solution (Lit/gal.)
Page 111: Diagnosis
ENGINE COOLING 6B-5 Diagnosis Engine Cooling Trouble Condition Possible cause Correction Engine overheating Low Engine Coolant level Replenish Thermo mater unit faulty Replace Faulty thermostat Replace Faulty Engine Coolant temperature Repair or replace sensor Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of Replenish or change oil...
Page 112: Draining And Refilling Cooling System
6B-6 ENGINE COOLING Draining and Refilling Cooling System Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the "MIN" and "MAX" lines of reserve tank when the engine is cold.
Page 113: Water Pump
ENGINE COOLING 6B-7 Water Pump Water Pump and Associated Parts Legend 2 O-Ring 1 Water Pump Assembly 3 Bolt Removal 1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt, refer to "Timing Belt" in this manual. 5.
Page 114: Installation
6B-8 ENGINE COOLING • Play or abnormal noise in the bearing • Cracks or corrosion in the impeller Installation 1. Before installing water pump, coat sealing surface with silicon grease. 2. Install water pump assembly and tighten bolts to the specified torque.
Page 115: Thermostat
ENGINE COOLING 6B-9 Thermostat Removal 1. Disconnect battery ground cable. 2. Drain engine coolant from the radiator and engine. 3. Disconnect radiator hose from the inlet pipe. 4. Remove thermostat housing. 5. Remove thermostat from thermostat housing. Inspection Suspend the thermostat in a water-filled container using thin wire.
Page 116 6B-10 ENGINE COOLING If the fan clutch rotates more readily, however, this indicates that the silicon grease is leaking internally. Replace the fan clutch with a new one. 2. Inspection (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.
Page 117: Radiator
ENGINE COOLING 6B-11 Radiator Radiator and Associated Parts Legend 1 Radiator 4 Radiator Lower Hose 2 Radiator Cap 5 Cooling Fan Shroud 3 Radiator Upper Hose 6 Cooling Fan Removal 1. Disconnect battery ground cable. 2. Loosen a drain plug to drain engine coolant (EC). 3.
Page 118: Inspection
6B-12 ENGINE COOLING Inspection Radiator Cap Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 88.3 - 1117.7 (13.5 - 17.8) Cap tester: 5-8840-0277-0 Adapter: 5-8840-2603-0...
Page 119: Installation
ENGINE COOLING 6B-13 Installation 1. Install radiator assembly, taking care not to damage the radiator core. 2. Install the radiator assembly. 3. Connect reserve tank hose. 4. Connect radiator inlet hose and outlet hose. 5. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank.
Page 120: Special Service Tool
6B-14 ENGINE COOLING SPECIAL SERVICE TOOL ITEM NO. ILLUSTRATION PART NO. PART NAME 5-8840-0277-0 Tester; radiator cap 5-8840-2603-0 Adapter; radiator cap...
Page 121: Engine Fuel
INDEX ENGINE FUEL 6C-1 SECTION 6C ENGINE FUEL CONTENTS PAGE General Description......................6C- 3 Service Precaution ......................6C- 4 Fuel Metering ........................6C- 5 Fuel Filter......................... 6C- 6 Fuel Filter and Associated Parts................6C- 6 Removal ........................6C- 6 Inspection ........................6C- 7 Installation ........................
Page 122 6C-2 ENGINE FUEL PAGE Fuel Tank ......................... 6C-15 Removal ........................6C-16 Installation ........................6C-16 Main Data and Specifications ..................6C-17...
Page 123: General Description
ENGINE FUEL 6C-3 General Description This illustration is based on the with canister model. Legend 1 Filter Cap 8 Fuel Pressure Control Valve 2 Fuel Tank 9 Duty Solenoid Valve 3 Rollover Valve * 10 Throttle Valve 4 Fuel Pump 11 Canister * 5 Fuel Filter 12 Check and Relief Valve *...
Page 124: Service Precaution
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 125: Fuel Metering
ENGINE FUEL 6C-5 Fuel Metering Engine Control Module (ECM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold.
Page 126: Fuel Filter
6C-6 ENGINE FUEL Fuel Filter Fuel Filter and Associated Parts Legend 1 Fuel Hose 3 Fixing bolt 2 Fuel Filter Removal CAUTION: 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".
Page 127: Inspection
ENGINE FUEL 6C-7 Inspection 1. Replace the fuel filter if the fuel leaks from fuel filter body or if the fuel filter body itself is damaged. 2. Replace the filter if it is clogged with dirt or sediment. 3. Check the drain and if it is clogged with dust, clean it out with air.
Page 128: Fuel Pump
6C-8 ENGINE FUEL Fuel Pump Fuel Pump and Associated Parts Legend 1 Fuel Pump and Sender Assembly 2 Fuel Tank Assembly Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage.
Page 129: Installation
ENGINE FUEL 6C-9 NOTE: • After removing pump assembly (1), cover fuel tank to prevent any dust entering. • Remove the fuel pump lock. Installation 1. Install FPAS assembly (1). 2. Install fuel tank assembly (2). Refer to "Fuel Tank Installation".
Page 130: Fuel Tank
6C-10 ENGINE FUEL Fuel Tank Fuel Tank and Associated Parts (1, 2) Legend 5 Fuel Pump and Sender Assembly 1 Roll Over&Float Valve (If applicable) 6 Fuel Tank Assembly 2 Hose; Evaporative Fuel (If applicable) 7 Hose; Fuel Delivery 3 Hose; Air Breather 8 Hose;...
Page 131: Installation
ENGINE FUEL 6C-11 6.Disconnect air breather hose (3) and fuel filler hose (4) at the fuel filler neck. NOTE: Cover fuel hose to prevent any dust entering. 7.Remove the four fuel tank assembly fixing bolts at four corners of the tank. 8.Let down the tank and disconnect the wiring connectors and the emission hose at the emission port on the fuel pump and sending assembly (5).
Page 132: Fuel Filler Cap
6C-12 ENGINE FUEL Fuel Filler Cap General Description Fuel filler cap includes vacuum valve. In case any high vacuum happen in tank, the valve works to adjust the pressure to prevent the tank from being damaged. Legend 1 Fuel Filler Cap Inspection Check the seal ring in the filler cap for presence of any abnormality and for seal condition.
Page 133: Fuel Filter
ENGINE FUEL 6C-13 Fuel Filter Removal and Installation Removal 1. Inlet and outlet fuel hose 2. Fuel filter Installation 2. Fuel filter 1. Inlet and outlet fuel hose...
Page 134 6C-14 ENGINE FUEL Important Operations - Removal 1. Inlet and Outlet Fuel Hose Use a rag to prevent the fuel from flowing from the fuel hoses. NOTE: Immediately plug the fuel hoses. Do not work in close proximity to sparks or an open flame. Important Operations - Installation 1.
Page 135: Fuel Tank
ENGINE FUEL 6C-15 Fuel Tank Removal and Installation WITH CANISTER APPLICABLE TO ROLLOVER VALVE WITH CANISTER & ROLLOVER VALVE Removal Installation 1. Fuel hose (Delivery) To install, follow the removal steps in the reverse order. 2. Fuel hose(Return) 3. Evapo fuel hose 4.
Page 136 6C-16 ENGINE FUEL Removal Preparation • Disconnect battery 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 7.
Page 137: Main Data And Specifications
ENGINE FUEL 6C-17 Main Data and Specifications Torque Specification N⋅m (kgf⋅m) 68 (6.9)
Page 138: Engine Electrical
INDEX ENGINE ELECTRICAL 6D1-1 SECTION 6D1 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 ........................
Page 139: Battery
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 140: Diagnosis
ENGINE ELECTRICAL 6D1-3 Diagnosis 1. Visual Inspection Inspect the battery for obvious physical damage, such as a cracked or broken case, which would permit electrolyte loss. Replace the battery if obvious physical damage is discovered during inspection. Check for any other physical damage and correct it as necessary.
Page 141: Battery Charging
6D1-4 ENGINE ELECTRICAL Battery Charging Observe the following safety precautions when charging the battery: 1. Never attempt to charge the battery when the fluid level is below the lower level line on the side of the battery. In this case, the battery must be replaced. 2.
Page 142 ENGINE ELECTRICAL 6D1-5 Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vahicle.
Page 143: Removal
6D1-6 ENGINE ELECTRICAL Removal 1. Remove negative cable (1). 2. Remove positive cable (2). 3. Remove retainer screw and rods (3). 4. Remove retainer (4). 5. Remove battery (5). Installation 1. Install battery. 2. Install retainer. 3. Instal retainer screw and rods. NOTE: Make sure that the rod is hooked on the body side.
Page 144 INDEX IGNITION SYSTEM 6D2-1 SECTION 6D2 IGNITION SYSTEM CONTENTS PAGE General Description......................6D2- 2 Service Precaution ......................6D2- 2 Diagnosis......................... 6D2- 2 Ignition Coil ........................6D2- 2 Removal ........................6D2- 2 Installation ........................6D2- 2 Spark Plug ........................6D2- 3 Removal ........................
Page 145: General Description
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 146: Spark Plug
IGNITION SYSTEM 6D2-3 Spark Plug Removal 1. Remove spark plugs. Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. • Check electrode and insulator for presence of cracks, and replace if any. •...
Page 147: Installation
6D2-4 IGNITION SYSTEM Cleaning Spark Plugs • Clean spark plugs with a spark plug cleaner. • Raise the ground electrode to an angle of 45 to 60 degrees. if electrode is wet, dry it gefore cleaning. • After spark plug is thoroughly cleaned, check insulator for presence of cracks.
Page 148: Main Data And Specifications
IGNITION SYSTEM 6D2-5 Main Data and Specifications General Specifications Ignition System Ignition Form Electronic Ignition System (El system) with Crankshaft angle Sensor Spark Plug Type Electronic Spark Control No. of Coils and Type 2 Solid State Coil Location Engine-mounted Torque 20 N.m (2.0 kgf.m)
Page 149: Starting And Charging System
INDEX STARTING AND CHARGING SYSTEM 6D3-1 SECTION 6D3 STARTING AND CHARGING SYSTEM CONTENTS PAGE Starting System ......................6D3- 2 General Description......................6D3- 2 Service Precaution ......................6D3- 2 Diagnosis......................... 6D3- 2 Starter ..........................6D3- 3 Removal ........................6D3- 3 Installation ........................6D3- 3 Disassembled View....................
Page 150: Starting System
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 151: Starter
STARTING AND CHARGING SYSTEM 6D3-3 Starter Removal 1. Battery 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 kgf.m) 3.
Page 152: Disassembled View
6D3-4 STARTING AND CHARGING SYSTEM Disassembled View Legend 1 Bolt 7 Armature 2 Magnetic Switch 8 Yoke Assembly 3 Gear Case 9 Brush and Brush Holder 4 Piston 10 Washer 5 Piston Shaft 11 Rear Cover 6 Center Bracket 12 Through Bolt...
Page 153: Inspection And Repair
STARTING AND CHARGING SYSTEM 6D3-5 Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection. Armature Check for continuity between commutator and segment. Replace commutator if there is no continuity (i.e., disconnected). Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core, armature core and shaft.
Page 154: Characteristic Test
6D3-6 STARTING AND CHARGING SYSTEM Continuity of Contacts With the plunger faced downward, push down the magnetic switch. In this state, check for continuity between terminals B and M. Replace, if there is no continuity (i.e., contacts are faulty). Pinion Check if the pinion rotates smoothly in drive direction by hand, or if it is locked when it is rotated in reverse.
Page 155: Charging System
STARTING AND CHARGING SYSTEM 6D3-7 Charging System General Description The charging system is an IC integral regulator charging system and its main components are connected as shown in illustration. The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover.
Page 156: General On-Vehicle Inspection
6D3-8 STARTING AND CHARGING SYSTEM General On-Vehicle Inspection The operating condition of charging system is indicated by the charge warning lamp. The warning lamp comes on when the starter switch is turned to "ON" position. The charging system operates normally if the lamp goes off when the engine starts. If the warning lamp shows abnormality or if undercharged or overcharged battery condition is suspected, perform diagnosis by checking the charging system as follows:...
Page 157: Installation
STARTING AND CHARGING SYSTEM 6D3-9 Generator Power 1. Adjust load resistor, if the required load currents are not attained. 2. The shape of the voltage curves on oscilloscope curve should be regular. 3. Test value: 5 to 7A. 4. If the required minimum current intensity is not attained, or if the oscilloscope picture shows variations, the alternator should be overhauled.
Page 158 6D3-10 STARTING AND CHARGING SYSTEM The generator has four external connections; the "B+" lead to battery positive, "L" lead to the warning lamp circuit(max. 2 watts), "S" lead to battery positive terminal for battery sensing and an earth connection. Explanation of type inscripiton Example:KC-A-->...
Page 159 STARTING AND CHARGING SYSTEM 6D3-11 Warning Do not reverse S and L connections as this will destroy the warning lamp circuit of the regulator. Ensure good electrical contact beween generator earth and battery negative, Operation With the Iginiton switch turnded "ON", current is supplied via the warning lamp to the "L"...
Page 160: Diagnosis
6D3-12 STARTING AND CHARGING SYSTEM Diagnosis The EP regulator incorporates diagnostics which will illuminate the warning lamp as a result of fault conditions in the generator and external circuitry. These conditions include: 1. An open circujit in the regulator battery sensing wire (S Terninal) 2.
Page 161: Disassembly
STARTING AND CHARGING SYSTEM 6D3-13 5. During current output tests please make sure that the ammeter is securely connceted into the charge circuit. 6. Some battery powered timing lights can produce high transient voltages when connected or disconnected. Only disconnect or connect timing lights when the engine is switched off.
Page 162: Clean
6D3-14 STARTING AND CHARGING SYSTEM 7. To remove the pulley, mount an 8mm Allen key in the vice with the short end upwards, place a 24mm ring spanner on the puley nut, position the internal hexagon of the rotor shaft onto the Allen ken, loosen the nut and remove the pulley.
Page 163 STARTING AND CHARGING SYSTEM 6D3-15 6 diode 8 diode Diode connections Stator connection B+Bolt Negative heatsink Positive heatsink Starpoint Power Diodes. Apply the negative test probe of the diode tester or a multimeter with a diode test feature to the positive heatsink and the positive probe alternatevely to A,B,C, a low resistance reading, or the forward voltage drop across the diode shoud be obtained.
Page 164 6D3-16 STARTING AND CHARGING SYSTEM Readings for Zener diode groups 011 to 042 Zener voltage at Positive Negative Fordward 5Ma. diode diode current Rating 17.8v-19.2v 18.8v-20.2v 19.8v-21.2v 20.8v-22.2v 21.8v-23.2v 22.8v-24.2v 17.8v-19.2v 18.8v-20.2v 19.8v-21.2v 20.8v-22.2v 21.8v-23.2v 22.8v-24.2v Note: Diode number is stamped on the rear of the diode. 2.
Page 165 STARTING AND CHARGING SYSTEM 6D3-17 4. Replacing the brushes (inbuilt regulator) Check the brushes for length, this is measured from the brush holder to the end of the brush along it's centre line. Also inspect for any sideways wear. If worn replace both brushes. The minimum length is 3.8mm.
Page 166: Reassembly
6D3-18 STARTING AND CHARGING SYSTEM Reassembly Generator (a) Press new bearing onto slipring end of the rotor taking care to aplly the force to the bearing inner race only, otherwise the bearing will be noisy and it's life will be shortened. (b) Fit a new bearing to the drive end housing, fit the bearing plate, and four retaining screws, press the rotor into the bearing, using a support tool to take the thrust against the...
Page 167: Inspection
STARTING AND CHARGING SYSTEM 6D3-19 Inspection Generator Before any in field testing can be undertaken it is important that the battery's conditions is established and the terminals are clean and tight. Check the condition of the generator drive belt and ensure that it is adjusted in accordance with the engine manufacturer's recommnedations.
Page 168 6D3-20 STARTING AND CHARGING SYSTEM Load regulation test Increase the engine speed until the generator is running at 6000 rpm, increase the load to 90% of full output a decrease in the regulating voltage should not exceed 0.50 volts for 12 v and 0.70 v for 24 v regulators of the readings obtained in the previous test.
Page 169: Technical Data
STARTING AND CHARGING SYSTEM 6D3-21 Technical Data (mm) Brush wear - Minimum Length Sliprings Minimum Diameter 26.7 Sliprings Trueness <0.06 Pole claws Trueness <0.05(93.25±0.05) Torque N.m(kgf.m) Pulley retaining nut 54-68(5.5-6.9) Capacitor retaining screw 2.7-3.8(0.3-0.4) Capacitor whiz nut 1.5-2.2(0.1-0.2) B+ terminal nut M8 7.5-8.5(0.8-0.9) B+ terminal rectifier nut 6.0-7.5(0.6-0.8)
Page 170 6D3-22 STARTING AND CHARGING SYSTEM Output wave forms for phase 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: The phase frequency is one third of the startpoint frequency.
Page 171: Driveability And Emissions
INDEX DRIVEABILITY AND EMISSIONS 6E1-1 SECTION 6E DRIVEABILITY AND EMISSIONS CONTENTS PAGE SPECIFICATION......................6E1- 24 Tightening Specifications ..................6E1- 24 EMISSION CONTROL SYSTEM SCHEMATICS ............6E1- 24 DIAGRAMS AND SCHEMATICS .................. 6E1- 25 ECM Pinout Table, 32-Pin Blue Connector-Row "J1".......... 6E1- 35 ECM Pinout Table, 32-Pin Blue Connector-Row "J1"..........
Page 172 6E1-2 DRIVEABILITY AND EMISSIONS PAGE MAINTENANCE SCHEDULE..................6E1- 44 VISUAL/PHYSICAL ENGINE COMPARTMENT INSPECTION........6E1- 44 BASIC KNOWLEDGE OF TOOLS REQUIRED............6E1- 44 SERIAL DATA COMMUNICATIONS ................6E1- 44 ON-BOARD DIAGNOSTIC (OBD) ................6E1- 44 ON-BOARD DIAGNOSTIC TESTS ................6E1- 44 COMPREHENSIVE COMPONENT MONITOR DIAGNOSTIC OPERATION ....
Page 173 DRIVEABILITY AND EMISSIONS 6E1-3 PAGE Clear DTC Information ....................6E1- 54 PRIMARY SYSTEM-BASED DIAGNOSTICS ............... 6E1- 54 FUEL CONTROL HEATED OXYGEN SENSORS (IF APPLICABLE)......6E1- 54 HO2S HEATER ......................6E1- 54 ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK........... 6E1- 55 Circuit Description....................6E1- 55 Diagnostic Aids.......................
Page 174 6E1-4 DRIVEABILITY AND EMISSIONS PAGE Multiple ECM Information Sensor DTCs Set ............. 6E1- 69 ENGINE SCAN TOOL DATA DEFINITIONS AND RANGES........6E1- 71 A/C CLUTCH ......................6E1- 71 A/C REQUEST ......................6E1- 71 AIR/FUEL RATIO ..................... 6E1- 71 BARO kPa ........................ 6E1- 71 DECELERATION FUEL CUT OFF................
Page 175 DRIVEABILITY AND EMISSIONS 6E1-5 PAGE Legend ........................6E1- 76 Results of Incorrect Operation ................6E1- 76 Diagnosis......................... 6E1- 77 Legend ........................6E1- 77 Visual Check of Canister..................6E1- 77 Evaporative Emission Canister Purge Control Solenoid Valve Check (If applicable) ....................... 6E1- 78 Circuit Description....................
Page 176 6E1-6 DRIVEABILITY AND EMISSIONS PAGE ENGINE CRANKS BUT WILL NOT RUN ..............6E1-108 Circuit Description....................6E1-108 Diagnostic Aids....................... 6E1-108 Engine Cranks But Will Not Run ................6E1-108 FUEL SYSTEM ELECTRICAL TEST................6E1-113 Circuit Description....................6E1-113 Diagnostic Aids....................... 6E1-113 Test Description...................... 6E1-114 Fuel Pressure Relief Procedure................
Page 177 DRIVEABILITY AND EMISSIONS 6E1-7 PAGE DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=22) THROTTLE POSITION (TP) SENSOR CIRCUIT LOW INPUT........6E1-133 Circuit Description....................6E1-133 Conditions for setting the DTC ................6E1-133 Action Taken when the DTC Sets................6E1-133 Conditions for Clearing the MIL/DTC ..............6E1-133 Diagnostic Aids.......................
Page 178 6E1-8 DRIVEABILITY AND EMISSIONS PAGE Circuit Description....................6E1-149 Conditions for setting the DTC ................6E1-149 Action Taken When the DTC Sets ................. 6E1-149 Conditions for Clearing the MIL/DTC ..............6E1-149 Diagnostic Aids....................... 6E1-150 DTC (Flash DTC=45) 02 Sensor Too Rich ..............6E1-150 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=14) EINGINE COOLANT TEMPERATURE(ECT) SENSOR CIRCUIT HIGH INPUT ..
Page 179 DRIVEABILITY AND EMISSIONS 6E1-9 PAGE Test Description...................... 6E1-161 DTC (Flash DTC=16) KS Sensor Disconnected Malfunction ........6E1-162 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=18) DIGITALLY CONTROLED SIGNAL TO NOISE ENHANCEMENT FILTER FAILURE................6E1-165 Circuit Description....................6E1-165 Conditions for Setting the DTC................6E1-165 Action Taken When the DTC Sets .................
Page 180 6E1-10 DRIVEABILITY AND EMISSIONS PAGE Conditions for Clearing the MIL/DTC ..............6E1-173 Diagnostic Aids....................... 6E1-174 DTC (Flash DTC=33) Manifold Absolute Pressure (MAP) Too High ......6E1-174 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=34) MANIFOLD ABSOLUTE PRESSURE (MAP) TOO LOW ..........6E1-177 Circuit Description....................
Page 181 DRIVEABILITY AND EMISSIONS 6E1-11 PAGE Conditions for Clearing the MIL/DTC ..............6E1-187 Diagnostic Aids....................... 6E1-188 Test Description...................... 6E1-188 Intake Air Temperature Sensor................6E1-188 DTC (Flash DTC=71) Intake Air Temperature (IAT) Sensor Too Low ...... 6E1-188 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=17) INJECTOR CIRCUIT MALFUNCTION................
Page 182 6E1-12 DRIVEABILITY AND EMISSIONS PAGE Conditions for Setting the DTC................6E1-199 Action Taken When the DTC Sets ................. 6E1-199 Conditions for Clearing the MIL/DTC ..............6E1-199 Diagnostic Aids....................... 6E1-200 DTC (Flash DTC=63) Ignition Coil Driver"B" Short To Ground ....... 6E1-200 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=64) IGNITION COIL DRIVER "A"...
Page 183 DRIVEABILITY AND EMISSIONS 6E1-13 PAGE Conditions for Setting the DTC................6E1-211 Action Taken When the DTC sets................6E1-211 Conditions for Clearing the DTC ................6E1-211 Diagnostic Aids....................... 6E1-212 Test Description...................... 6E1-212 DTC (Flash DTC=57) Check Engine Lamp High Error ......... 6E1-212 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=61) EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CANISTER PURGE CONTROL VALVE CIRCUIT LOW ERROR (IF APPLICABLE) .....
Page 184 6E1-14 DRIVEABILITY AND EMISSIONS PAGE DTC (Flash DTC=87) A/C Compressor Clutch Relay Low Error ......6E1-218 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=88) A/C COMPRESSOR CLUTCH RELAY HIGH ERROR ..........6E1-221 Circuit Description....................6E1-221 Conditions for Setting the DTC................6E1-221 Action Taken When the DTC Sets ................. 6E1-221 Conditions for Clearing the DTC ................
Page 185 DRIVEABILITY AND EMISSIONS 6E1-15 PAGE Diagnostic Aids....................... 6E1-227 DTC (Flash DTC=55) Electrically Erasable Programmable Read-Only Memory Error .................... 6E1-228 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=91) TACHO OUT LOW ERROR ..................6E1-229 Circuit Description....................6E1-229 Conditions for Setting the DTC................6E1-229 Action Taken When the DTC Sets .................
Page 186 6E1-16 DRIVEABILITY AND EMISSIONS PAGE Action Taken When the DTC sets................6E1-237 Conditions for Clearing the DTC ................6E1-237 Diagnostic Aids....................... 6E1-238 Test Description...................... 6E1-238 Fuel Pressure Relief Procedure................6E1-238 Fuel Pressure Gauge Installation ................6E1-238 DTC (Flash DTC=32) Fuel Pump Relay Shorted To Battery ........ 6E1-238 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC=83) RECEIVED RESPONSE WAS NOT CORRECT............
Page 187 DRIVEABILITY AND EMISSIONS 6E1-17 PAGE Condition for Setting the DTC................6E1-247 Action Taken When the DTC Sets ................. 6E1-247 Condition for Clearing the MIL/DTC ..............6E1-247 Diagnostic Aids....................... 6E1-247 DTC (Flash DTC=86) Received Incorrect Security Code .......... 6E1-248 ON-VEHICLE SERVICE PROCEDURE ECM AND SENSOR ........6E1-249 CRANKSHAFT POSITION (CKP) SENSOR..............
Page 188 6E1-18 DRIVEABILITY AND EMISSIONS PAGE Installation....................... 6E1-255 VEHICLE SPEED SENSOR (VSS) ................6E1-255 Removal........................6E1-255 Inspection........................ 6E1-256 Installation....................... 6E1-256 AIR INDUCTION SYSTEM.................... 6E1-257 AIR FILTER........................6E1-257 Removal........................6E1-257 Installation....................... 6E1-257 IDLE AIR CONTROL (IAC) VALVE ................6E1-257 Removal........................6E1-257 Cleaning and Inspection ..................6E1-257 Measurement......................
Page 189 DRIVEABILITY AND EMISSIONS 6E1-19 PAGE Inspection........................ 6E1-263 FUEL FILTER........................ 6E1-263 Removal........................6E1-263 Inspection........................ 6E1-263 Installation....................... 6E1-264 FUEL INJECTORS......................6E1-264 Removal........................6E1-264 Inspection........................ 6E1-264 Installation....................... 6E1-264 FUEL PRESSURE REGULATOR................. 6E1-265 Removal........................6E1-265 Installation....................... 6E1-266 FUEL PRESSURE RELIEF................... 6E1-267 FUEL PUMP ASSEMBLY ..................... 6E1-267 Removal........................
Page 190 6E1-20 DRIVEABILITY AND EMISSIONS PAGE IGNITION COIL ......................6E1-274 Removal........................6E1-274 Installation....................... 6E1-274 SPARK PLUGS......................6E1-275 Removal........................6E1-275 Inspection........................ 6E1-275 Installation....................... 6E1-276 SPARK PLUG CABLES ....................6E1-276 Inspection........................ 6E1-276 EMISSIONS ........................6E1-277 CATALYTIC CONVERTER (IF APPLICABLE)............. 6E1-277 AIR CONDITIONING RELAY ..................6E1-277 Removal........................
Page 191 DRIVEABILITY AND EMISSIONS 6E1-21 PAGE Installation....................... 6E1-281 WEATHER-PACK CONNECTOR ................. 6E1-282 Tools Required......................6E1-282 Removal........................6E1-282 Installation....................... 6E1-283 COM-PACK III....................... 6E1-283 METRI-PACK ........................ 6E1-283 Tools Required......................6E1-283 Removal........................6E1-283 Installation....................... 6E1-284 GENERAL DESCRIPTION.................... 6E1-285 ECM AND SENSORS ....................6E1-285 58X REFERENCE ECM INPUT ..................6E1-285 A/C REQUEST SIGNAL....................
Page 192 6E1-22 DRIVEABILITY AND EMISSIONS PAGE FUEL METERING ......................6E1-292 ACCELERATION MODE ....................6E1-292 ACCELERATOR CONTROLS ..................6E1-292 BATTERY VOLTAGE CORRECTION MODE............... 6E1-293 CLEAR FLOOD MODE ....................6E1-293 DECELERATION FUEL CUTOFF (DFCO) MODE ............6E1-293 ENGINE SPEED/VEHICLE SPEED/FUEL DISABLE MODE ........6E1-293 FUEL CUTOFF MODE....................
Page 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...
Page 194: Specification
6E1-24 DRIVEABILITY AND EMISSIONS SPECIFICATIONS Tightening Specifications ⋅ ⋅ ⋅ ⋅ Application Lb Ft. Lb In. Crankshaft Position Sensor Mounting Bolt Engine Coolant Temperature Sensor Fuel Pressure Regulator Attaching Screw Fuel Rail Bolts Heated Oxygen Sensor (If applicable) Spark Plugs Throttle Body Mounting Bolts VSS Retaining Bolt Intake Manifold to Cylinder Head...
Page 195: Diagrams And Schematics
DRIVEABILITY AND EMISSIONS 6E1-25 DIAGRAMS AND SCHEMATICS HOT AT ALL TIMES HOT IN START AND RUN Meter Fuse FUSE Fuse FUSE Stop BLOCK BLOCK Vehicle Speed Sensor Stop 0.85 Lamp Instrument Panel(I/P) Cluster 16 15 14 13 12 11 10 9 Malfunction 8 7 6 5 4 3 2 1 Indicator...
Page 196 6E1-26 DRIVEABILITY AND EMISSIONS HOT WITH FUEL PUMP RELAY ENERGIZED HOT AT ALL TIMES HOT IN RUN AND START Fuel Engine Injector Fuse Fuse Fuse 2B/R Canister 0.85G/W Purge Solenoid Fuel Pump 0.85G/R 0.85G/B 1.25 1.25 0.85 0.85G Engine Fuel Control Injector Module...
Page 197 DRIVEABILITY AND EMISSIONS 6E1-27 HOT IN START AND RUN Coil FUSE Fuse BLOCK 0.85 Crankshaft Ignition Position Coil Sensor 1.25 1.25 1.25 1.25 Engine Electronic Spark Control Timing Control Module (ECM)
Page 198 6E1-28 DRIVEABILITY AND EMISSIONS...
Page 199 DRIVEABILITY AND EMISSIONS 6E1-29 (If Applicable) HOT WITH FUEL PUMP RELAY ENERGIZED Sensor FUSE BLOCK 0.85 0.5RED Heated Sensor 0.5WHT BLK/ Engine Control Sensor Sensor Module High (ECM)
Page 200 6E1-30 DRIVEABILITY AND EMISSIONS Engine Control Module (ECM) Knock Sensor Input 0.5 YEL Knock 0.5 YEL Sensor (KS)
Page 201 DRIVEABILITY AND EMISSIONS 6E1-31...
Page 202 6E1-32 DRIVEABILITY AND EMISSIONS HOT IN START AND RUN Joint To HA09 Relay:A/C Relay Compressor Thermo Clutch (Compressor) GR/R Engine Control Compressor Module Relay (ECM) Control...
Page 203 DRIVEABILITY AND EMISSIONS 6E1-33 Idle Air Control (IAC) Valve Engine Control Module High High (ECM)
Page 204 6E1-34 DRIVEABILITY AND EMISSIONS...
Page 205: Ecm Pinout Table, 32-Pin Blue Connector-Row "J1
DRIVEABILITY AND EMISSIONS 6E1-35 ECM Pinout Table, 32-Pin Blue Connector-Row “J1” PIN Function Wire Color IGN ON ENG RUN Refer To Electronic Spark Timing Coil Driver A Coil Ground A Coil Ground B Electronic Spark Timing Coil Driver B Crank Position Sensor High General Description and Operation, Crank Position Sensor...
Page 206: Ecm Pinout Table, 32-Pin Blue Connector-Row "J1
6E1-36 DRIVEABILITY AND EMISSIONS ECM Pinout Table, 32-Pin Blue Connector-Row “J1” PIN Function Wire Color IGN ON ENG RUN Refer To Crankshaft Position Sensor General Description and Operation, Crankshaft Position Sensor Not Used Not Used Not Used Not Used Knock Sensor Input General Description and Operation, Knock Sensor Not Used...
Page 207: Ecm Pinouts
DRIVEABILITY AND EMISSIONS 6E1-37 ECM PINOUTS ECM Pinout Table, 32-Pin Red Connector-Row “J2” PIN Function Wire Color IGN ON ENG RUN Refer To Power Ground A 0.0V Appropriate Sensor Sensor Ground B 0.0V Appropriate Sensor 5 Volt Reference Signal 5.0V Appropriate Sensor Battery Feed Chassis Electrical...
Page 208: Ecm Pinout Table, 32-Pin Red Connector-Row "J2
6E1-38 DRIVEABILITY AND EMISSIONS ECM Pinout Table, 32-Pin Red Connector-Row “J2” PIN Function Wire Clolr IGN ON ENG RUN Rdfer To Appropriate Sensor 5 Volt Reference Signal A Appropriate Sensor 5 Volt Reference Signal B Not Used Check Engine Lamp Chassis Electrical Tacho-meter Signal 8-10V...
Page 209: Component Locator
DRIVEABILITY AND EMISSIONS 6E1-39 COMPONENT LOCATOR...
Page 210 6E1-40 DRIVEABILITY AND EMISSIONS VEHICLE FUEL FILTER SPEED SENSOR (VSS) HO2S(if applicable) THREE-WAY CATALYTIC CONVERTER (if applicable) IAC VALVE THROTTLE BODY MAP SENSOR THROTTLE POSITION SENSOR EVAP PURGE CONTROL SOLENOID VALVE INTAKE AIR TEMPERATURE SENSOR FUEL INJECTOR IGNITION COIL AIR CLEANER HEATED OXGEN SENSOR...
Page 211: Engine Component Locator Table
DRIVEABILITY AND EMISSIONS 6E1-41 Engine Component Locator Table Number Name Location Engine Coolant Temperature (ECT) Sensor Front of engine, next to the thermostat housing Heated Oxygen Sensor (HO2S) On the exhaust pipe, left side of engine, immediately behind the exhaust manifold Air Cleaner Left front the engine bay Intake Air Temperature (IAT) Sensor...
Page 212: Underhood (U/H) Fuse And Relay Panel
6E1-42 DRIVEABILITY AND EMISSIONS UNDERHOOD (U/H) FUSE AND RELAY PANEL INSTRUMENT PANEL (I/P) FUSE BLOCK...
Page 213: Diagnosis
DRIVEABILITY AND EMISSIONS 6E1-43 DIAGNOSIS Call technical assistance for similar cases where repair history may be available. Combine technician STRATEGY-BASED knowledge with efficient use of the available service DIAGNOSTICS information. INTERMITTENTS STRATEGY-BASED DIAGNOSTICS Conditions that are not always present are called The strategy-based diagnostic is a uniform approach intermittents.
Page 214: Verifying Vehicle Repair
6E1-44 DRIVEABILITY AND EMISSIONS near the heated oxygen sensor can also cause the VERIFYING VEHICLE REPAIR MIL (“Check Engine“ lamp) to turn on. Aftermarket electronics, such as cellular phones, Verification of the vehicle repair will be more stereos, and anti-theft devices, may radiate EMI into comprehensive vehicles with...
Page 215: Basic Knowledge Of Tools Required
DRIVEABILITY AND EMISSIONS 6E1-45 BASIC KNOWLEDGE OF TOOLS • Fuel Pump: REQUIRED Fuel pump test allows to turn on and off the fuel pump. Notice: Lack of basic knowledge of this powertrain If turned off while the engine is running, the engine when performing diagnostic procedures could result in will stall.
Page 216: Input Components
6E1-46 DRIVEABILITY AND EMISSIONS COMMON OBD TERMS Input Components: Input components are monitored for circuit continuity Diagnostic For Closed Loop System: and out-of-range values. This includes rationality When used as a noun, the word diagnostic refers to checking. Rationality checking refers to indicating a any on-board test run by the vehicle's Diagnostic fault when the signal from a sensor does not seem Management System.
Page 217: The Diagnositic Executive
DRIVEABILITY AND EMISSIONS 6E1-47 • It informs the driver that a fault that affects vehicle satisfy the enabled criteria for a given diagnostic, and this diagnostic will consider this cycle to be one trip. emission levels has occurred and that the vehicle However, another diagnostic with a different set of should be taken for service as soon as possible.
Page 218: Reading Flash Diagnostic Trouble Codes
6E1-48 DRIVEABILITY AND EMISSIONS more than one DTC three has been stored in the ECM’s memory, the DTC(s) will be output from the lowest to the highest, with each DTC being displayed three times. Reading Diagnostic Trouble Codes Using a TECH 2 The procedure for reading diagnostic trouble code(s) is to used a diagnostic Tech 2.
Page 219: On-Board Diagnosis (Self-Diagnosis)
DRIVEABILITY AND EMISSIONS 6E1-49 Data Link Connector (DLC) located behind front On-Board Diagnosis (Self-Diagnosis) console. 1. The Engine Control Module (ECM) conducts a self- The CHECK ENGINE indicator will flash DTC 12 test of most of the wiring and components in the three times, followed by any DTC.
Page 220: Tech 2 Scan Tool
6E1-50 DRIVEABILITY AND EMISSIONS 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 (3) SAE 16/19 Adaptor (2) RS 232 Loop Back Connector...
Page 221: Getting Started
The power up screen is displayed when you power up Tech 2, the following steps must be performed: the tester with the Isuzu systems PCMCIA card. 1. The Isuzu 98 System PCMCIA card (1) inserts into Follow the operating procedure below. the Tech 2 (5) 2.
Page 222: Menu
6E1-52 DRIVEABILITY AND EMISSIONS Menu • The following table shows, the Tech 2 menu structure. F0: Diagnostic Trouble Codes F0: Read DTC Info Ordered By Priority F1: Clear DTC Information F1: Data Display F0: Engine Data F2: O2 Sensor Data F2: Snapshot F3: Miscellaneous Tests F0: Engine Check Light...
Page 223: Verifying Vehicle Repair
DRIVEABILITY AND EMISSIONS 6E1-53 VERIFYING VEHICLE REPAIR Verification vehicle repair will more comprehensive vehicles with system diagnostics. Following a repair, the technician should perform the following steps: 1. Review and record the customer complaint for the DTC which has been diagnosed. 2.
Page 224: Dtc Modes
6E1-54 DRIVEABILITY AND EMISSIONS PRIMARY SYSTEM-BASED DTC MODES DIAGNOSTICS There are 2 options available in the Scan Tool DTC mode to display the enhanced information available. PRIMARY SYSTEM-BASED After selecting DTC, the following menu appears: DIAGNOSTICS • DTC Info • Clear DTC Info There are primary system-based diagnostics which The following is a brief description of each of the sub evaluate system operation and its effect on vehicle...
Page 225: On-Board Diagnostic (Obd) System Check
DRIVEABILITY AND EMISSIONS 6E1-55 ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK HOT AT ALL TIMES Fuse FUSE Stop BLOCK Stop Lamp 0.5G 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 1.25 Engine Diag Serial Data Control Grounds Module...
Page 226: On-Board Diagnostic (Obd) System Check
6E1-56 DRIVEABILITY AND EMISSIONS 3. This test ensures that the ECM is capable of 7. A Scan Tool parameter which is not within the controlling the MIL and the MIL driver circuit is not typical range may help to isolate the area which is shorted to ground.
Page 227 DRIVEABILITY AND EMISSIONS 6E1-57 On-Board Diagnostic (OBD) System Check (Cont'd) Step Action Value(s) 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 to Step 10 Replace the EPROM or ECM.
Page 228 6E1-58 DRIVEABILITY AND EMISSIONS...
Page 229: A/C Clutch Control Circuit Diagnosis
DRIVEABILITY AND EMISSIONS 6E1-59 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS conditions are within acceptable ranges. With the A/C Circuit Description compressor relay energized, battery voltage is When air conditioning and blower fan are selected, supplied to the compressor clutch coil. and if the system has a sufficient refrigerant charge, a The ECM will enable the compressor clutch to engage 12-volt signal is supplied to the A/C request input of whenever A/C has been selected with the engine...
Page 230: Diagnostic Aids
6E1-60 DRIVEABILITY AND EMISSIONS • Thermo switch (FRT) is OFF. to be OK, observe the A/C clutch while moving • Pressure switch is OFF. connectors and wiring harnesses related to the A/C. • Ignition switch is OFF. A sudden clutch malfunction will indicate the source of the intermittent fault.
Page 231 DRIVEABILITY AND EMISSIONS 6E1-61 A/C Clutch Control Circuit Diagnosis (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the Engine Control Module (ECM) connectors from the ECM. 3. Check the A/C Compressor Clutch Relay control circuit between the ECM and Underhood Electrical Center for Verify Repair Go to Step 6 the following conditions:...
Page 232: Electric Ignition System Diagnosis
6E1-62 DRIVEABILITY AND EMISSIONS • If the canister is cracked or damaged, replace the ELECTRONIC IGNITION SYSTEM canister. DIAGNOSIS • If fuel is leaking from the canister, replace the If the engine cranks but will not run or immediately canister and check hoses and hose routing. stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is in the IDLE AIR CONTROL (IAC) VALVE...
Page 233: Fuel Metering System Check
DRIVEABILITY AND EMISSIONS 6E1-63 FUEL METERING SYSTEM CHECK Test Description Number(s) below refer to the step number(s) on the Some failures of the fuel metering system will result Diagnostic Chart: in an “Engine Cranks But Will Not Run” symptom. If 2.
Page 234: Injector Balance Test Procedure (Step7-11)
6E1-64 DRIVEABILITY AND EMISSIONS Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) CYLINDER 1st Reading (1) 296kPa 296kPa 296kPa 296kPa (43psi) (43psi) (43psi) (43psi) 2nd Reading (2) 205kPa 205kPa 196kPa 274kPa (29psi) (29psi) (28psi) (39psi) Amount of Drop 91kPa 91kPa...
Page 235: Injector Balance Test Procedure (Step7-11)
DRIVEABILITY AND EMISSIONS 6E1-65 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) Step Action Value(s) Was the “On-Board Diagnostic (OBD) System Go to OBD Check” performed? System Go to Step 2 Check 1. Turn the engine OFF. Notice: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure.
Page 236 6E1-66 DRIVEABILITY AND EMISSIONS Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd) Step Action Value(s) 1. Set the Injector Adapter Cable to injector #1. 2. Press the “Push to Start Test” button on the fuel injector tester.
Page 237 DRIVEABILITY AND EMISSIONS 6E1-67 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont'd) Step Action Value(s) 1. Connect the 5-8840-0378-0 Fuel Injector Tester and 5-8840-2589-0 Injector Adapter Cable to the fuel injector harness connector. 2. Set the amperage supply selector switch on the fuel injector tester to the “Balance Test”...
Page 238: Engine Control Module(Ecm) Diagnosis
6E1-68 DRIVEABILITY AND EMISSIONS If a diagnostic chart indicates that the ECM ENGINE CONTROL MODULE connections or the ECM is the cause of a problem, (ECM) DIAGNOSIS and the EPROM or ECM is replaced, but this does not correct the problem, one of the following may be the reason: •...
Page 239: Diagnostic Aids
DRIVEABILITY AND EMISSIONS 6E1-69 Check for the following conditions: Diagnostic Aids • Poor connection at ECM. Inspect the harness Important: Be sure to inspect ECM and engine connectors for backed-out terminals, improper grounds for being secure and clean. mating, broken locks, improperly formed...
Page 240 6E1-70 DRIVEABILITY AND EMISSIONS Multiple ECM Information Sensor DTCs Set (Cont'd) Step Action Value(s) Measure the voltage between the MAP sensor signal circuit at the ECM harness connector and ground. Does the voltage measure near the specified value? Go to Step 7 Go to Step 10 Measure the voltage between the TP sensor signal circuit at the ECM harness connector and ground.
Page 241 DRIVEABILITY AND EMISSIONS 6E1-71 the ECM monitors a high signal voltage and interprets ENGINE SCAN TOOL DATA that as a cold engine. As the sensor warms DEFINITIONS AND RANGES (decreasing resistance), the voltage signal will decrease and the ECM will interpret the lower voltage A/C CLUTCH - Scan Tool Displays ON or OFF - as a warm engine.
Page 242 6E1-72 DRIVEABILITY AND EMISSIONS used by the ECM to adjust fuel delivery and spark TYPICAL SCAN DATA VALUES timing according to incoming air density. Use the Typical Scan Data Values Table only after the BATTERY - Scan Tool Range 0-25.5 Volts - This On- Board Diagnostic System Check has been represents the system voltage measured by the ECM completed, no DTC(s) were noted, and you have...
Page 243 DRIVEABILITY AND EMISSIONS 6E1-73 2.2L/2.0L L-4 Engine Typical Data Scan Tool Units Typical Data Data List Values Refer To Parameter Displayed Values (IDLE) (2500 RPM) A/C Clutch Engine On/Off General Description and Operation, A/C Clutch Circuit Operation A/C Request Engine No/Off General Description and Operation, A/C Request...
Page 244 6E1-74 DRIVEABILITY AND EMISSIONS 2.2L/2.0 L-4 Engine (Cont'd) Typical Data Scan Tool Units Typical Data Data List Values Refer To Parameter Displayed Values (IDLE) (2500 RPM) 02 BLM Engine Cell number Diagnosis, Fuel Trim Cell Cell Number Diagnostic Weights (If applicable) HO2S Engine Millivolts...
Page 245 DRIVEABILITY AND EMISSIONS 6E1-75 2.2L/2.0L L-4 Engine (Cont'd) Typical Data Scan Tool Units Typical Data Data List Values Refer To Parameter Displayed Values (IDLE) (2500 RPM) PSP Switch Engine ON/OFF Power Steering Gear and (Power Steering Pump, General Pressure) Description, Pressure Switch 02 STATUS Engine...
Page 246: Legend
6E1-76 DRIVEABILITY AND EMISSIONS Evidence of fuel loss or fuel vapor odor can be caused Evap Control System The solenoid used with this canister uses Vacuum • Liquid fuel leaking from fuel lines, or fuel pump. Switch Valve to control purge. The ECM opens and •...
Page 247: Diagnosis
DRIVEABILITY AND EMISSIONS 6E1-77 Diagnosis Legend (1) Intake Manifold (4) Check and Relief valve (2) Fuel Vapor Purge Control Solenoid (5) Fuel Tank (3) Fuel Vapor Canister (6) Pressure/ Vacuum Vented (7) Rollover Valve Visual Check of Canister Cracked or damaged, replace canister.
Page 248: Evaporative Emission Canister Purge Control Solenoid Valve Check (If Applicable)
6E1-78 DRIVEABILITY AND EMISSIONS Evaporative Emission Canister Purge Control Solenoid Valve Check (If applicable) ENGINE CONTROL MODULE (ECM) MANIFOLD TO CANISTER VACUUM EVAPORATIVE EMISSION EVAPORETIVE CANISTER EMISSION PURGE CONTLOL CANISTER PURGE SOLENOID VALVE SOLENOID N.C. CONTROL DRIVER ENGINE FUSE IGNITION •...
Page 249: General Description
DRIVEABILITY AND EMISSIONS 6E1-79 General Description Legend (1) Filler Cap (7) Intake Manifold (2) Fuel Tank (8) Fuel Pressure Regulator (3) Rollover Valve (9) Duty Solenoid Valve (Evap. Purge Control (4) Fuel Pump Solenoid) (5) Fuel Filter (10) Throttle Valve (6) Fuel Rail (11) Canister (12) Check and Relief Valve...
Page 250: Ecm Diagnostic Trouble Codes
6E1-80 DRIVEABILITY AND EMISSIONS ECM Diagnostic Trouble Codes The following table lists the diagnostic trouble codes be faulty; notify the Tech 2 manufacturer of any DTCs supported a Tech 2 and to flash. If any DTCs not listed displayed that are not included in the following table. here are displayed by a Tech 2, the Tech 2 data may ECM Diagnostic Trouble Codes Flash DTC...
Page 251: Symptom Diagnosis
DRIVEABILITY AND EMISSIONS 6E1-81 SYMPTOM DIAGNOSIS • Poor mating of the connector halves or a terminal PRELIMINARY CHECKS not fully seated in the connector (backed out). Before using this section, perform the "On-Board • Improperly formed or damaged terminal. Diagnostic (OBD) System Check" and verify all of the •...
Page 252: Hard Start Symptom
6E1-82 DRIVEABILITY AND EMISSIONS Hard Start Symptom Step Action Value(s) DEFINITION: Engine cranks, but does not start for a long time. Does eventually run, or may start but immediately stalls. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System Go to Step 2...
Page 253 DRIVEABILITY AND EMISSIONS 6E1-83 Hard Start Symptom (Cont'd) Step Action Value(s) Check for proper ignition voltage output with a spark tester (Use commercially available tool). Was a problem found? Verify repair Go to Step 11 1. Remove the spark plugs and check for gas or oil fouling cracks, wear, improper gap, burned electrodes, heavy deposits, or improper heat range.
Page 254: Surges And/Or Chuggles Symptom
6E1-84 DRIVEABILITY AND EMISSIONS Surges and/or Chuggles Symptom Step Action Value(s) DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System...
Page 255 DRIVEABILITY AND EMISSIONS 6E1-85 Surges and/or Chuggles Symptom (Cont'd) Step Action Value(s) Visually/Physically inspect the secondary ignition wires. Check for the following conditions. • Verify that all ignition wire resistance are less than the specified value. • Verify that ignition wires are correctly routed to eliminate cross-firing.
Page 256: Lack Of Power, Sluggish Or Spongy Symptom
6E1-86 DRIVEABILITY AND EMISSIONS Lack of Power, Sluggish or Spongy Symptom Step Action Value(s) DEFINITION: Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part-way. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System...
Page 257 DRIVEABILITY AND EMISSIONS 6E1-87 Lack of Power, Sluggish or Spongy Symptom (Cont'd) Step Action Value(s) Check for the following engine mechanical problems: • Low compression • Leaking cylinder head gasket • Worn or incorrect camshaft • Loose timing belt Was a problem found? Verify repair Go to Step 12 1.
Page 258: Detonation/Spark Knock Symptom
6E1-88 DRIVEABILITY AND EMISSIONS Detonation/Spark Knock Symptom Step Action Value(s) DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System Go to Step 2...
Page 259 DRIVEABILITY AND EMISSIONS 6E1-89 Detonation/Spark Knock Symptom (Cont'd) Step Action Value(s) 1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: • Visual/physical inspection. • Scan tool data. •...
Page 260: Rough, Unstable, Or Incorrect Idle, Stalling Symptom (For Open Loop System)
6E1-90 DRIVEABILITY AND EMISSIONS Rough, Unstable, or Incorrect Idle, Stalling Symptom (For Open Loop System) Step Action Value(s) DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed?
Page 261 DRIVEABILITY AND EMISSIONS 6E1-91 Rough, Unstable, or Incorrect Idle, Stalling Symptom (For Open Loop System) Step Action Value(s) Check for a lose ignition coil ground. Refer to Electrical Ignition System. Was a problem found? Verify repair Go to Step 10 Check the items that can cause the engine to run lean.
Page 262: Rough, Unstable, Or Incorrect Idle, Stalling Sympton (For Closed Loop System)
6E1-92 DRIVEABILITY AND EMISSIONS Rough, Unstable, or incorrect Idle, Stalling Sympton (For Closed Loop System) Step Action Value(s) Was the “On-Board Diagnostic (OBD) System Check” Go to OBD performed? System Go to Step 2 Check 1. Read the “Caution” above. 2.
Page 263 DRIVEABILITY AND EMISSIONS 6E1-93 Rough, Unstable, or incorrect Idle, Stalling Sympton (For Closed Loop System) Step Action Value(s) 1. Reconnect the fuel pump relay. 2. Disconnect the fuel pump electrical connector at the fuel tank. 3. Using a test light connected to ground, probe the fuel pump feed wire (harness side).
Page 264: Idle Co Concentration Check And Adjustment
6E1-94 DRIVEABILITY AND EMISSIONS Idle CO Concentration Check and adjustment Before starting adjusting work, check and confirm the following conditions. Normal engine operating temperature. All accessories switched off. Throttle valve closed. Transmission in neutral. Before starting adjusting work, step on accelerator pedal a few times and do racing up to 3000rpm.
Page 265: Poor Fuel Economy Symptom
DRIVEABILITY AND EMISSIONS 6E1-95 Poor Fuel Economy Symptom Step Action Value(s) DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed?
Page 266 6E1-96 DRIVEABILITY AND EMISSIONS Poor Fuel Economy Symptom (Cont'd) Step Action Value(s) Check for proper calibration of the speedometer. Does the speed indicated on the speedometer closely match the vehicle speed displayed on the Scan Tool? Go to Step 14 Go to Step 13 Diagnose and repair the inaccurate speedometer condition as necessary.
Page 267: Dieseling, Run-On Symptom
DRIVEABILITY AND EMISSIONS 6E1-97 Dieseling, Run-On Symptom Step Action Value(s) DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check the ignition switch and adjustment. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System...
Page 268: Backfire Symptom
6E1-98 DRIVEABILITY AND EMISSIONS Backfire Symptom Step Action Value(s) DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System Go to Step 2 Check 1.
Page 269 DRIVEABILITY AND EMISSIONS 6E1-99 Backfire Symptom (Cont'd) Step Action Value(s) Check the intake and exhaust manifold(s) for casting flash. Refer to Engine Mechanical. Was a problem found? Verify repair Go to Step 11 1. Review all the diagnostic procedures within this table. 2.
Page 270: Cuts Out, Misses Symptom
6E1-100 DRIVEABILITY AND EMISSIONS Cuts Out, Misses Symptom Step Action Value(s) DEFINITION: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases. Was the On-Board Diagnostic (OBD) System Check Go to OBD performed? System Go to Step 2 Check 1.
Page 271 DRIVEABILITY AND EMISSIONS 6E1-101 Cuts Out, Misses Symptom (Cont'd) Step Action Value(s) 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. • Check for objects blocking the IAC passage or throttle bore, excessive deposits in the IAC passage and on the IAC pintle, and excessive deposits in the throttle bore and on the throttle plate.
Page 272 6E1-102 DRIVEABILITY AND EMISSIONS Cuts Out, Misses Symptom (Cont'd) Step Action Value(s) Check the following engine mechanical problems: • Low compression • Leaking cylinder head gasket • Worn or incorrect camshaft • Sticking or leaking valves • Valve timing • Broken valve springs •...
Page 273: Hesitation, Sag, Stumble Symptom
DRIVEABILITY AND EMISSIONS 6E1-103 Hesitation, Sag, Stumble Symptom Step Action Value(s) DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually most pronounced when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough.
Page 274 6E1-104 DRIVEABILITY AND EMISSIONS Hesitation, Sag, Stumble Symptom (Cont'd) Step Action Value(s) Check for a loose ignition control module ground. Was a problem found? Verify repair Go to Step 12 Visually/Physically inspect the secondary ignition wires. Check for the following conditions. •...
Page 275 DRIVEABILITY AND EMISSIONS 6E1-105 DEFAULT MATRIX TABLE SERVICE PROCEDURE DEFAULT STRATEGY A referral strategy has been established to assist the technician with additional information when the cause of the failure cannot be determined. If no problem is found after performing diagnostics, then refer to the default matrix table for further diagnostic information.
Page 276 6E1-106 DRIVEABILITY AND EMISSIONS Default Matrix Table (Cont'd) Strategy Based Initial Diagnosis Default Section(s) Diagnostic Charts Lack of Power, Sluggish 1. OBD system check. Refer to Exhaust System in Engine or Spongy 2. Fuel system diagnosis. Exhaust, Calibration ID/Service 3. Ignition system. Bulletins Detonation/Spark Knock 1.
Page 277 DRIVEABILITY AND EMISSIONS 6E1-107 Default Matrix Table (Cont'd) Strategy Based Initial Diagnosis Default Section(s) Diagnostic Charts Backfire 1. OBD system check. Exhaust System Diagnosis, Intake 2. Ignition system. Casting Flash, Ignition System 3. Fuel system diagnosis. Check 4. Fuel injector and fuel injector balance test. Misfire 1.
Page 278 6E1-108 DRIVEABILITY AND EMISSIONS ENGINE CRANKS BUT WILL NOT RUN To jet a half amount of the fuel required for a single Circuit Description combustion stroke to each cylinder. The electronic ignition system uses a dual coil method of spark distribution. In this type of ignition system, the Diagnostic Aids engine control module (ECM) triggers the correct An intermittent problem may be caused by a poor...
Page 279: Step Action Value(S)
DRIVEABILITY AND EMISSIONS 6E1-109 Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Disconnect the ignition secondary wire at the No.1. 2. Install a spark tester (Use commercially available tool) at the end of the disconnected ignition coil. 3.
Page 280: Verify Repair
6E1-110 DRIVEABILITY AND EMISSIONS Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) 1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes. 3. Replace any spark plugs with loose or missing electrodes or cracked insulators. Correct the Did your inspection reveal any spark plugs exhibiting fouling...
Page 281: Was A Problem Found
DRIVEABILITY AND EMISSIONS 6E1-111 Engine Cranks But Will Not Run (Cont'd) Step Action Value(s) Check the CKP High circuit between the sensor and the ECM for a short to ground or open circuit. Was a problem found? Verify Repair Go to Step 33 Replace the CKP position sensor.
Page 282 6E1-112 DRIVEABILITY AND EMISSIONS...
Page 283: Broken Locks, Improperly Formed Or Damaged
DRIVEABILITY AND EMISSIONS 6E1-113 Battery Joint Cable Engine Fuse Fuse Fuel Canister Purge Pump Control Solenoid Valve Relay Fuel Pump Fuse Fuel Injectors 0.85 1.25 1.25 Engine Control Module (ECM) FUEL SYSTEM ELECTRICAL TEST excess fuel to be returned to the fuel tank. With the Circuit Description engine stopped and ignition ON, the fuel pump can be When the ignition switch is first turned ON, the engine...
Page 284: Is The Action Complete
6E1-114 DRIVEABILITY AND EMISSIONS Test Description Fuel Pressure Relief Procedure Number(s) below refer to the step number(s) on the 1. Remove the fuel cap. Diagnostic Chart. 2. Remove the fuel pump relay from the underhood relay center. 2. If the fuel pump is operating but incorrect pressure 3.
Page 285: Was A Problem Found
DRIVEABILITY AND EMISSIONS 6E1-115 Fuel System Electrical Test (Cont'd) Step Action Value(s) Locate and repair open in the fuel pump relay ground circuit. Is the action complete? Verify repair Check for short or open between the ECM and the fuel pump relay.
Page 286 6E1-116 DRIVEABILITY AND EMISSIONS...
Page 287 DRIVEABILITY AND EMISSIONS 6E1-117 Battery Joint Cable Engine Fuse Fuse Fuel Canister Purge Pump Control Solenoid Valve Relay Fuel Pump Fuse Fuel Injectors 0.85 1.25 1.25 Engine Control Module (ECM) FUEL SYSTEM DIAGNOSIS The fuel pump is designed to provide fuel at a Circuit Description pressure above the pressure needed by the fuel When the ignition switch is turned ON, the engine...
Page 288 6E1-118 DRIVEABILITY AND EMISSIONS • Lift the fuel rail just enough to leave the fuel occur when installing the fuel pressure gauge. With the ignition switch ON and the fuel pump injector nozzles in the fuel injector ports. running, the fuel pressure indicated by the fuel Caution: In order to reduce the risk of fire and pressure gauge should be 283-376 kPa (41-55 personal injury that may result from fuel...
Page 289: Verify Repair Go To Step
DRIVEABILITY AND EMISSIONS 6E1-119 Fuel Pressure Relief Procedure Fuel Pressure Gauge Installation 1. Remove the fuel cap. 1. Remove the shoulder fitting cap. 2. Located on the intake manifold which is at the top 2. Install fuel pressure gauge 5-8840-0378-0 to the right part of the engine.
Page 290: Yes No
6E1-120 DRIVEABILITY AND EMISSIONS Fuel System Diagnosis (Cont'd) Step Action Value(s) Replace the fuel pump. Is the action complete? Verify repair 1. Disconnect the vacuum hose from the fuel pressure regulator. 2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator.
Page 291: Fuel System Diagnosis
DRIVEABILITY AND EMISSIONS 6E1-121 Fuel System Diagnosis (Cont'd) Step Action Value(s) Locate and correct the restriction in the fuel return line. Is the action complete? Verify repair Visually and physically inspect the fuel rail outlet passages for a restriction. Was a restriction found? Verify repair Go to Step 11 Is the fuel pressure indicated by the fuel pressure gauge...
Page 292 6E1-122 DRIVEABILITY AND EMISSIONS...
Page 293 DRIVEABILITY AND EMISSIONS 6E1-123 Manifold Absolute Pressure (MAP) Sensor Throttle Position Sensor 0.75 0.75 Intake Air Temperature Sensor YEL/ Engine Sensor MAP Sensor 5 Volt Control Ground Input Reference Module Signal (ECM) MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK The number(s) below refer to the step number(s) on Circuit Description the Diagnostic Chart.
Page 294 6E1-124 DRIVEABILITY AND EMISSIONS Manifold Absolute Pressure (MAP) Output Check Step Action Value(s) 1. Turn the ignition OFF and leave it OFF for 15 seconds. 2. Ignition ON. Do not crank engine. 3. The Scan Tool should indicate a manifold absolute pressure (MAP) sensor voltage.
Page 295 DRIVEABILITY AND EMISSIONS 6E1-125 EVAPORATIVE EMISSIONS (EVAP) CANISTER PURGE CONTROL SOLENOID VALVE CHECK (IF APPLICABLE) Circuit Description Diagnostic Aids • Make a visual check of vacuum hoses. Canister purge is controlled by a solenoid valve that • Check the throttle body for possible cracked or allows manifold vacuum to purge the canister.
Page 296 6E1-126 DRIVEABILITY AND EMISSIONS Evaporative Emissions (EVAP) Canister Purge Valve Solenoid Check Step Action Value(s) 1. Ignition OFF. 2. Ignition ON, engine OFF. 3. At the intake manifold, disconnect the hose that goes to the pump solenoid. 4. Using a hand vacuum purge with an attached vacuum gauge 5-8840-0279-0, apply vacuum (10”...
Page 297: Verify Repair
DRIVEABILITY AND EMISSIONS 6E1-127 Evaporative Emissions (EVAP) Canister Purge Valve Solenoid Check (Cont'd) Step Action Value(s) Probe each terminal of the solenoid valve electrical connector with a test lamp to ground. Does the test lamp light on both terminals? Go to Step 11 Go to Step 12 Repair the short to voltage in the wire between the solenoid and the ECM.
Page 298 6E1-128 DRIVEABILITY AND EMISSIONS...
Page 299 DRIVEABILITY AND EMISSIONS 6E1-129 Throttle Position (TP) Sensor Engine Manifold Coolant Absolute Temperature Pressure Sensor Sensor 0.75 0.75 Engine Sensor Throttle 5 Volt Sensor Control Ground Position Reference Ground Module (TP) Signal (ECM) Sensor Input THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM •...
Page 300 6E1-130 DRIVEABILITY AND EMISSIONS TP Sensor Circuit Range/Performance Problem Step Action Value(s) Was the "On-Board Diagnostic (OBD) System Check " Go to OBD performed? System Go to Step 2 Check 1. Ignition ON, engine OFF. 2. Monitor the TP value on the Scan Tool While moving the throttle between 0% and 100%.
Page 301: Replace The Tp Sensor
DRIVEABILITY AND EMISSIONS 6E1-131 TP Sensor Circuit Range/Performance Problem (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Place a Digital Multimeter (DVM), set to measure voltage between the ground circuit and the 5 volt signal circuit, both at the wiring harness' TP sensor about 5 volts connector.
Page 302 6E1-132 DRIVEABILITY AND EMISSIONS...
Page 303 DRIVEABILITY AND EMISSIONS 6E1-133 Throttle Position (TP) Sensor Engine Manifold Coolant Absolute Temperature Pressure Sensor Sensor 0.75 0.75 Engine Sensor Throttle 5 Volt Sensor Control Ground Position Reference Ground Module (TP) Signal (ECM) Sensor Input DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 22) THROTTLE POSITION (TP) SENSOR CIRCUIT LOW INPUT Circuit Description Action Taken When the DTC Sets...
Page 304: Check For The Following Conditions
6E1-134 DRIVEABILITY AND EMISSIONS • Damaged harness - Inspect the wiring harness for Diagnostic Aids damage. If the harness appears to be OK, observe Check for the following conditions: the throttle position display on the Scan Tool while • Poor connection at ECM - Inspect harness moving connectors and wiring harnesses related to connectors for backed-out terminals, improper the throttle Position sensor.
Page 305 DRIVEABILITY AND EMISSIONS 6E1-135 DTC (Flash DTC = 22) Throttle Position (TP) Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the ECM and check the 5 volt reference circuit for an open or short to ground. 3.
Page 306 6E1-136 DRIVEABILITY AND EMISSIONS...
Page 307 DRIVEABILITY AND EMISSIONS 6E1-137 Throttle Position (TP) Sensor Engine Manifold Coolant Absolute Temperature Pressure Sensor Sensor 0.75 0.75 Engine Sensor Throttle 5 Volt Sensor Control Ground Position Reference Ground Module (TP) Signal (ECM) Sensor Input DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 21) THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT Circuit Description Action Taken When the DTC Sets...
Page 308 6E1-138 DRIVEABILITY AND EMISSIONS • Faulty Throttle Position sensor - With the ignition Test Description key ON engine OFF observe the Throttle Position Number(s) below refer to the step number(s) on the sensor display on the Scan Tool while slowly Diagnostic Chart.
Page 309 DRIVEABILITY AND EMISSIONS 6E1-139 DTC (Flash DTC = 21) Throttle Position (TP) Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Ignition OFF disconnect the ECM. 2. Ignition ON, engine OFF. 3. Check for a short to voltage on the Throttle Position sensor signal circuit.
Page 310 6E1-140 DRIVEABILITY AND EMISSIONS...
Page 311 DRIVEABILITY AND EMISSIONS 6E1-141 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 13) O2 SENSOR CIRCUIT NOT READY DETECTED (IF APPLICABLE) • HO2S signal voltage remains between 343mV and Circuit Description 540mV. • The engine control module (ECM) supplies a bias •...
Page 312 6E1-142 DRIVEABILITY AND EMISSIONS HO2S and connect a test light between the HO2S Diagnostic Aids battery feed and heater ground circuits. If the test Check for the following conditions: light does not light for 2 seconds when the ignition • Poor connection or damaged harness - Inspect the is turned on, repair the open battery feed or sensor harness connectors for backed-out terminals, ground circuit as necessary.
Page 313 DRIVEABILITY AND EMISSIONS 6E1-143 DTC (Flash DTC = 13) O2 Sensor Circuit Not Ready (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. With the ECM disconnected, check continuity of the HO2S high circuit. 3. If the HO2S high circuit measures over 0.5 ohms, repair open or poor connection as necessary.
Page 314 6E1-144 DRIVEABILITY AND EMISSIONS...
Page 315 DRIVEABILITY AND EMISSIONS 6E1-145 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 44) O2 SENSOR TOO LEAN (IF APPLICABLE) Circuit Description All above conditions met and the following condition is met: The engine control module (ECM) supplies a bias • HO2S signal voltage remains less than 274mV. voltage of about 450mV between the heated oxygen sensor (HO2S) signal and low circuits.
Page 316: Fuel System Diagnosis
6E1-146 DRIVEABILITY AND EMISSIONS • Exhaust leaks - An exhaust leak may cause outside Diagnostic Aids air to be pulled into the exhaust gas stream past the Check for the following conditions: HO2S, causing the system to appear lean. Check •...
Page 317: Specified Value
DRIVEABILITY AND EMISSIONS 6E1-147 DTC (Flash DTC = 44) O2 Sensor Too Lean (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Reconnect the ECM, leave the sensor disconnected. 3. Ignition ON. Refer to Does the Scan Tool indicate HO2S voltage near the Diagnostic specified value? 430-450mV...
Page 318 6E1-148 DRIVEABILITY AND EMISSIONS...
Page 319 DRIVEABILITY AND EMISSIONS 6E1-149 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 45) O2 SENSOR TOO RICH (IF APPLICABLE) • Throttle angle is greater than 5%. Circuit Description • Following Diagnostic Trouble Codes are not set: The engine control module (ECM) supplies a bias Malfunction DTC: 21, 22, 33, 24 voltage of about 450mV between the heated oxygen •...
Page 320 6E1-150 DRIVEABILITY AND EMISSIONS • An intermittent TP sensor output will cause the Diagnostic Aids system to go rich due to a false indication of the Check the following items: engine accelerating. • Fuel pressure - The system will go rich if pressure •...
Page 321 DRIVEABILITY AND EMISSIONS 6E1-151 DTC (Flash DTC = 45) 02 Sensor Too Rich (Cont’d) Step Action Value(s) 1. Ignition ON, engine OFF. 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...
Page 322 6E1-152 DRIVEABILITY AND EMISSIONS...
Page 323 DRIVEABILITY AND EMISSIONS 6E1-153 Engine Coolant Temperature (ECT) Sensor 0.75 0.75 Engine Sensor Control Ground Sensor Module Input (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 14) ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT Circuit Description Action Taken When the DTC Sets The engine coolant temperature (ECT) sensor is a •...
Page 324 6E1-154 DRIVEABILITY AND EMISSIONS above or below a certain temperature. If this is the Diagnostic Aids case, replace the ECT sensor. If the ECT sensor Check for the following conditions: appears to be OK, the fault is intermittent; refer to •...
Page 325 DRIVEABILITY AND EMISSIONS 6E1-155 DTC (Flash DTC = 14) ECT Sensor Circuit High Input (Cont'd) Step Action Value(s) 1. Jumper the ECT signal circuit at the ECT sensor harness connector to chassis ground. 2. Observe the "Eng Coolant Temp" displayed on the Scan Tool.
Page 326 6E1-156 DRIVEABILITY AND EMISSIONS...
Page 327 DRIVEABILITY AND EMISSIONS 6E1-157 Engine Coolant Temperature (ECT) Sensor 0.75 0.75 Engine Sensor Control Ground Sensor Module Input (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 15) ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT Circuit Description Action Taken When the DTC Sets The ECT sensor is a thermistor mounted in the engine •...
Page 328 6E1-158 DRIVEABILITY AND EMISSIONS above or below a certain temperature. If this is the Diagnostic Aids case, replace the ECT sensor. If the ECT sensor Check for the following conditions: appears to be OK, the fault is intermittent; refer to •...
Page 329 DRIVEABILITY AND EMISSIONS 6E1-159 DTC (Flash DTC = 15) Engine Coolant Temperature (ECT) Sensor Circuit Low Input (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the ECM and check the ECT circuit for a an open or a short to battery in the sensor circuit. 3.
Page 330 6E1-160 DRIVEABILITY AND EMISSIONS...
Page 331 DRIVEABILITY AND EMISSIONS 6E1-161 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 16) KNOCK SENSOR (KS) DISCONNECTED MALFUNCTION Circuit Description Conditions for Clearing the MIL/DTC The knock sensor (KS) system is used to detect Once the ECM determines that a fault(s) has been engine detonation.
Page 332: Obd System Check
6E1-162 DRIVEABILITY AND EMISSIONS block, the knock sensor may be responding to the poor terminal to wiring connections or physical noise. damage to the wiring harness. 6. Any circuitry, that is suspected as causing the 8. Checking the internal resistance of the knock complaint, should be thoroughly checked for sensor verifies if the knock sensor or the wiring to backed out terminals, improper mating, broken...
Page 333 DRIVEABILITY AND EMISSIONS 6E1-163 DTC (Flash DTC = 16) KS Sensor Disconnected Malfunction (Cont'd) Step Action Value(s) 1. Using the Scan Tool, clear the Diagnostic Trouble Codes. 2. Start the engine and idle at normal operating temperature. 3. Operate the vehicle within the conditions for setting this Diagnostic Trouble Code as specified in the supporting text.
Page 334 6E1-164 DRIVEABILITY AND EMISSIONS...
Page 335 DRIVEABILITY AND EMISSIONS 6E1-165 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 18) DIGITALLY CONTROLED SIGNAL TO NOISE ENHANCEMENT FILTER FAILURE Circuit Description Conditions for Clearing the MIL/DTC The knock sensor (KS) system is used to detect Once the ECM determines that a fault(s) has been engine detonation.
Page 336: Obd System Check
6E1-166 DRIVEABILITY AND EMISSIONS 5. Any circuitry, that is suspected as causing the 9. If the KS module was previously replaced and the complaint, should be thoroughly checked for Diagnostic Trouble Code resets, a malfunctioning backed out terminals, improper mating, broken ECM is indicated.
Page 337 DRIVEABILITY AND EMISSIONS 6E1-167 DTC (Flash DTC = 18) Digitally Controlled Signal To Noise Enhancement Filter Failure (Cont’d) Step Action Value(s) 1. Re-Connect the KS Sensor in order to monitor the voltage between the KS sensor terminal and the engine ground.
Page 338 6E1-168 DRIVEABILITY AND EMISSIONS...
Page 339 DRIVEABILITY AND EMISSIONS 6E1-169 Crankshaft Position (CKP) Sensor Engine Sensor Control Sensor Ground Module Input (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 19) CRANKSHAFT POSITION (CKP) SENSOR SIGNAL INCORRECT Circuit Description Conditions for Clearing the MIL/DTC The 58X reference signal is produced by the Once the ECM determines that a fault(s) has been crankshaft position...
Page 340 6E1-170 DRIVEABILITY AND EMISSIONS • Damaged harness - Inspect the wiring harness for while moving connectors and wiring harnesses damage; shorts to Ground, shorts to Battery related to the ECM. A change in voltage will indicate Positive, and Open circuits. If the harness appears the location of the fault.
Page 341 DRIVEABILITY AND EMISSIONS 6E1-171 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 24) VEHICLE SPEED SENSOR (VSS) FAULT • Following malfunctions are not set: DTC 21, 22, 33, Circuit Description 34 are not set. The vehicle speed sensor has a magnet rotated by the When the above conditions are met, one of the transmission output shaft.
Page 342 6E1-172 DRIVEABILITY AND EMISSIONS • Damaged harness: Inspect the wiring harness to Diagnostic Aids the Speedometer, Tachometer and check Engine • Poor connection at the ECM: Inspect harness Lamp for an intermittent open or intermittent short connectors for backed out terminals, improper circuit.
Page 343 DRIVEABILITY AND EMISSIONS 6E1-173 Manifold Absolute Pressure (MAP) Sensor Throttle Position Sensor 0.75 0.75 Intake Air Temperature Sensor YEL/ Engine Sensor MAP Sensor 5 Volt Control Ground Input Reference Module Signal (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 33) MANIFOLD ABSOLUTE PRESSURE (MAP) TOO HIGH •...
Page 344 6E1-174 DRIVEABILITY AND EMISSIONS • Damaged harness - Inspect the wiring harness for Diagnostic Aids damage, shorts to Ground, shorts to Battery Check for the following conditions: positive, and Open circuits. If the harness appears • Poor connection at ECM - Inspect harness to be OK, observe the MAP display on the Scan connectors for backed-out terminals, improper Tool while moving connectors and wiring harnesses...
Page 345 DRIVEABILITY AND EMISSIONS 6E1-175 DTC (Flash DTC = 33) Manifold Absolute Pressure (MAP) Too High (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Place a fused jumper between the MAP sensor circuit and the 5 volt signal circuit, both at the wiring harness' MAP sensor connector.
Page 346 6E1-176 DRIVEABILITY AND EMISSIONS...
Page 347 DRIVEABILITY AND EMISSIONS 6E1-177 Manifold Absolute Pressure (MAP) Sensor Throttle Position Sensor 0.75 0.75 Intake Air Temperature Sensor YEL/ Engine Sensor MAP Sensor 5 Volt Control Ground Input Reference Module Signal (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 34) MANIFOLD ABSOLUTE PRESSURE (MAP) TOO LOW Circuit Description Conditions for Setting the DTC...
Page 348 6E1-178 DRIVEABILITY AND EMISSIONS • Damaged harness - Inspect the wiring harness for 1. They are cleared by disconnecting the Battery for more than 30 seconds. damage, shorts to Ground, shorts to Battery 2. A service tool such as Tech 2 is used to clear them. positive, and Open circuits.
Page 349 DRIVEABILITY AND EMISSIONS 6E1-179 DTC (Flash DTC = 34) Manifold Absolute Pressure (MAP) Too Low (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the ECM and check the 5 volt reference circuit for an open or short to ground. 3.
Page 350 6E1-180 DRIVEABILITY AND EMISSIONS...
Page 351: Ecm Fuse
DRIVEABILITY AND EMISSIONS 6E1-181 HOT AT ALL TIMES HOT AT ALL TIMES Ignition Coil FUSE Fuse FUSE Fuse BLOCK BLOCK Fuse Ignition Coil Relay Fuel Pump F/Pump 1.25 1.25 Fuse RED/ RED/ 1.25 1.25 1.25 1.25 Ignition Feeds Batt+ Engine Control Module (ECM)
Page 352 6E1-182 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 49) System Voltage High Step Action Value(s) Was the "On-Board Diagnostic (OBD) System Check" Go to OBD performed? Go to Step 2 System Check 1. Ignition OFF, engine OFF. 2. Using a Digital Voltmeter (DVM), measure the battery voltage at the battery.
Page 353 DRIVEABILITY AND EMISSIONS 6E1-183 Intake Air Temperature (IAT) Sensor Sensor YEL/ Engine Sensor Control Ground Sensor Module Input (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 69) INTAKE AIR TEMPERATURE (IAT) SENSOR TOO HIGH Circuit Description Action Taken When the DTC Sets The intake air temperature (IAT) sensor is a thermistor •...
Page 354: Diagnostic Aids
6E1-184 DRIVEABILITY AND EMISSIONS mating, broken locks, improperly formed at various temperatures to evaluate the possibility damaged terminals, and poor terminal-to-wire of a "shifted" sensor that may be open above or connection. below a certain temperature. If this is the case, •...
Page 355 DRIVEABILITY AND EMISSIONS 6E1-185 DTC (Flash DTC = 69) Intake Air Temperature (IAT) Sensor Too High (cont'd) Step Action Value(s) 1. Jumper the IAT signal circuit at the IAT sensor harness connector to chassis ground. 2. Observe the "Intake Air Temp" display on the Scan Tool.
Page 356 6E1-186 DRIVEABILITY AND EMISSIONS...
Page 357 DRIVEABILITY AND EMISSIONS 6E1-187 Intake Air Temperature (IAT) Sensor Sensor YEL/ Engine Sensor Control Ground Sensor Module Input (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 71) INTAKE AIR TEMPERATURE (IAT) SENSOR TOO LOW Circuit Description Action Taken When the DTC Sets •...
Page 358 6E1-188 DRIVEABILITY AND EMISSIONS refer to the Temperature vs. Resistance Value Diagnostic Aids table. The table may be used to test the IAT sensor Check for the following conditions: at various temperatures to evaluate the possibility • Poor connection at ECM - Inspect harness of a "shifted"...
Page 359 DRIVEABILITY AND EMISSIONS 6E1-189 DTC (Flash DTC = 71) Intake Air Temperature (IAT) Sensor Too Low (Cont'd) Step Action Value(s) 1. Ignition OFF. 2. Disconnect the IAT sensor electrical connector. 3. Ignition ON. −36°C 4. Observe the intake air temperature on the Scan Tool. Is the intake air temperature below the specified value? (−32.8°F) Go to Step 6...
Page 360 6E1-190 DRIVEABILITY AND EMISSIONS...
Page 361 DRIVEABILITY AND EMISSIONS 6E1-191 HOT AT ALL TIMES HOT IN RUN AND START Engine Injector Fuse Fuse Fuse 2B/R Canister 0.85G/W Purge Solenoid Fuel Pump 0.85G/R 0.85G/B 1.25 1.25 0.85 0.85G Engine Fuel Control Injector Module Control (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 17) INJECTOR CIRCUIT MALFUNCTION •...
Page 362 6E1-192 DRIVEABILITY AND EMISSIONS set. It will also cause a misfire due to an inoperative 4. This steps tests the harness wiring and ECM injector. control of the injectors. 6. Because the test light was ON steady, voltage to Long term and short term fuel trims that are the injector is OK, but the driver circuit is grounded excessively high or low are a good indication that an at all times.
Page 363 DRIVEABILITY AND EMISSIONS 6E1-193 DTC (Flash DTC = 17) Injector Circuit Malfunction (Cont'd) Step Action Value(s) Does the engine Idle Condition change? Note the detected faulty injector. Go to Step 6 Go to Step 8 1. Ignition off. 2. Disconnect the ECM connector for the affected injectors.
Page 364 6E1-194 DRIVEABILITY AND EMISSIONS...
Page 365 DRIVEABILITY AND EMISSIONS 6E1-195 HOT IN START AND RUN Coil FUSE Fuse BLOCK Ignition Ignition Coil Coil 1.25 1.25 1.25 1.25 Engine Electronic Spark Control Timing Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 41) IGNITION COIL DRIVER "B" SHORT TO BATTERY •...
Page 366: Ignition System
6E1-196 DRIVEABILITY AND EMISSIONS to Voltage. If the harness appears to be OK, Diagnostic Aids observe the Scan Tool display related to DTC 41 Check for the following conditions: while moving the connector and wiring related to the • Poor connection at the ECM - Inspect the harness ignition system.
Page 367 DRIVEABILITY AND EMISSIONS 6E1-197 HOT IN START AND RUN Coil FUSE Fuse BLOCK Ignition Ignition Coil Coil 1.25 1.25 1.25 1.25 Engine Electronic Spark Control Timing Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 42) IGNITION COIL DRIVER "A" SHORT TO BATTERY •...
Page 368: Ignition System
6E1-198 DRIVEABILITY AND EMISSIONS damaged terminals, and poor terminal-to-wire ignition system. A change in the display will indicate connections. the location of the fault. • Damaged harness - Inspect the wiring harness for • This code detects a short to battery on the damage;...
Page 369: Circuit Description
DRIVEABILITY AND EMISSIONS 6E1-199 HOT IN START AND RUN Coil FUSE Fuse BLOCK Ignition Ignition Coil Coil 1.25 1.25 1.25 1.25 Engine Electronic Spark Control Timing Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 63) IGNITION COIL DRIVER "B" SHORT TO GROUND •...
Page 370 6E1-200 DRIVEABILITY AND EMISSIONS to Voltage. If the harness appears to be OK, Diagnostic Aids observe the Scan Tool display related to DTC 63 Check for the following conditions: while moving the connector and wiring related to the • Poor connection at the ECM - Inspect the harness ignition system.
Page 371 DRIVEABILITY AND EMISSIONS 6E1-201 HOT IN START AND RUN Coil FUSE Fuse BLOCK Ignition Ignition Coil Coil 1.25 1.25 1.25 1.25 Engine Electronic Spark Control Timing Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 64) IGNITION COIL DRIVER "A" SHORT TO GROUND •...
Page 372 6E1-202 DRIVEABILITY AND EMISSIONS damaged terminals, and poor terminal-to-wire ignition system. A change in the display will indicate connections. the location of the fault. • Damaged harness - Inspect the wiring harness for • This code detects a short to ground on the damage;...
Page 373 DRIVEABILITY AND EMISSIONS 6E1-203 Idle Air Control (IAC) Valve Engine Control Module High High (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 35) IDLE AIR CONTROL (IAC) ERROR This malfunction detects an error in the IAC control Circuit Description logic, then DTC 35 will set. The engine control module (ECM) controls engine idle speed with the idle air control (IAC) valve.
Page 374 6E1-204 DRIVEABILITY AND EMISSIONS • Rich heated oxygen sensor signal (low air/fuel ratio) Action Taken when the DTC sets - The idle speed will be too low. Scan Tool IAC • The ECM will illuminate the malfunction indicator counts will usually be above 80. The system is lamp (MIL).
Page 375 DRIVEABILITY AND EMISSIONS 6E1-205 DTC (Flash DTC = 35) Idle Air Control (IAC) Error Step Action Value(s) 1. Ignition OFF.. 2. Connect the IAC motor analyzer 5-8840-2312-0 to the IAC valve. 3. Set the parking brake. 4. Block the wheels. 5.
Page 376 6E1-206 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 35) Idle Air Control (IAC) Error (Cont’d) Step Action Value(s) If the circuits did not test green and red, check the following: • Faulty connector terminal contacts. • Open circuits, including connections. •...
Page 377 DRIVEABILITY AND EMISSIONS 6E1-207 HOT AT ALL TIMES HOT IN START AND RUN Meter Fuse FUSE Fuse FUSE BLOCK BLOCK 0.85 Instrument Panel(I/P) TACHO Cluster Malfuntion Indicator Lamp 1.25 1.25 RED/ RED/ BR/Y Engine Batt+ Malfunction Control Indicator Module Lamp (ECM) Control DIAGNOSTIC TROUBLE CODE (DTC) 56 (Flash DTC = 56)
Page 378: Connection, Rubbed-Through Wire Insulation Or A Wire
6E1-208 DRIVEABILITY AND EMISSIONS Test Description Diagnostic Aids Number(s) below refer to the step number(s) on the An intermittent MIL may be caused by a poor Diagnostic Chart. connection, rubbed-through wire insulation, or a wire 2. A “No MIL” condition accompanied by a no-start broken inside the insulation.
Page 379 DRIVEABILITY AND EMISSIONS 6E1-209 DTC (Flash DTC = 56) Check Engine Lamp Low Error (Cont’d) Step Action Value(s) Locate and repair the open ECM battery feed circuit. Is the action complete? Verify repair Locate and repair the short to ground in the ECM battery feed circuit.
Page 380 6E1-210 DRIVEABILITY AND EMISSIONS...
Page 381 DRIVEABILITY AND EMISSIONS 6E1-211 HOT AT ALL TIMES HOT IN START AND RUN Meter Fuse FUSE Fuse FUSE BLOCK BLOCK 0.85 Instrument Panel(I/P) TACHO Cluster Malfuntion Indicator Lamp 1.25 1.25 RED/ RED/ BR/Y Engine Batt+ Malfunction Control Indicator Module Lamp (ECM) Control DIAGNOSTIC TROUBLE CODE (DTC) 57 (Flash DTC = 57)
Page 382: Poor Connection Or Damaged Harness - Inspect The Ecm Harness And Connectors For Improper Mating
6E1-212 DRIVEABILITY AND EMISSIONS Diagnostic Aids Test Description An intermittent may be caused by a poor connection, Number(s) below refer to the step number(s) on the rubbed-through wire insulation, or a wire broken inside Diagnostic Chart. the insulation. Check for the following items: 2.
Page 383 DRIVEABILITY AND EMISSION 6E1-213 Purge Control 0.5 R/L DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 61) EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CANISTER PURGE CONTROL VALVE CIRCUIT LOW ERROR (IF APPLICABLE) Circuit Description Conditions for Clearing the MIL/DTC The engine control Module (ECM) controls the Once the ECM determines that a fault(s) has been Evaporative Emission (EVAP) Canister Purge control rectified then the CEL will switch OFF, although the...
Page 384: Value(S) Yes No
6E1-214 DRIVEABILITY AND EMISSIONS • This malfunction detects a low impedance short to ground or open contact on the purge control solenoid output. DTC (Flash DTC = 61) Evaporative Emission (EVAP) Control System Canister Purge Control Valve Circuit Low Error Step Action Value(s)
Page 385 DRIVEABILITY AND EMISSIONS 6E1-215 Purge Control 0.5 R/L DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 62) EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM CANISTER PURGE CONTROL VALVE CIRCUIT HIGH ERROR (IF APPLICABLE) Circuit Description Action Taken When the DTC Sets • The ECM will illuminate the Malfunction Indicator The engine control Module (ECM) controls the Evaporative Emission...
Page 386 6E1-216 DRIVEABILITY AND EMISSIONS for open circuits, shorts to ground, and shorts to voltage. • This malfunction detects a high impedance short to ground or open contact on the purge control solenoid output. DTC (Flash DTC = 62) Evaporative Emission (EVAP) Control System Canister Purge Control Valve Circuit High Error Step Action...
Page 387 DRIVEABILITY AND EMISSIONS 6E1-217 HOT IN START AND RUN Joint To HA09 Relay:A/C Relay Compressor Thermo Clutch (Compressor) GR/R Engine Control Compressor Module Relay (ECM) Control DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 87) A/C COMPRESSOR CLUTCH RELAY LOW ERROR 1.
Page 388 6E1-218 DRIVEABILITY AND EMISSIONS • Damaged harness-Inspect the wiring harness for A/C Clutch Diagnosis damage; shorts to Ground, shorts to Battery This chart should be used for diagnosing the electrical Voltage, and Open circuits. If the harness appears portion of the A/C compressor clutch circuit. A Scan to be OK, observe the A/C clutch while moving Tool will be used in diagnosing the system.
Page 389 DRIVEABILITY AND EMISSIONS 6E1-219 DTC (Flash DTC = 87) A/C Compressor Clutch Relay Low Error (Cont'd) Step Action Value(s) 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.
Page 390 6E1-220 DRIVEABILITY AND EMISSIONS...
Page 391 DRIVEABILITY AND EMISSIONS 6E1-221 A/C Switch 0.5G/W 0.5G/W 0.5G/W Thermo Switch GR/Y Pressure Switch Engine Control Compressor Module Relay (ECM) Control DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 88) A/C COMPRESSOR CLUTCH RELAY HIGH ERROR 1. They are cleared by disconnecting the Battery for Circuit Description more than 30 seconds.
Page 392 6E1-222 DRIVEABILITY AND EMISSIONS malfunction will indicate source Tool has the ability to read the A/C request input to the intermittent fault. ECM. The Scan Tool can display when the ECM has commanded the A/C clutch ON. The Scan Tool should A/C Clutch Diagnosis have the ability to override the A/C request signal and This chart should be used for diagnosing the electrical...
Page 393 DRIVEABILITY AND EMISSIONS 6E1-223 DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 93) QUAD DRIVER SUB MODULE Circuit Description Conditions for Clearing the DTC Quad Driver Sub Module (QDSM) are used by the Once the ECM determines that a fault(s) has been engine control module (ECM) to turn ON many of the rectified then the CEL will switch OFF, although the current-driven devices that are needed to control...
Page 394 6E1-224 DRIVEABILITY AND EMISSIONS observe a voltmeter connected to the MIL driver This malfunction detects a: circuit at the ECM harness connector while moving Short to battery or Open Load or Short to ground at connectors and rewiring harnesses relates to the QDSM output.
Page 395 DRIVEABILITY AND EMISSIONS 6E1-225 DIAGNOSTIC TROUBLE CODE DTC (Flash DTC=51) ELECTRICALLY PROGRAMMABLE READ-ONLY MEMORY (EPROM) ERROR Circuit Description Conditions for Clearing the MIL/DTC • Once the ECM determines that a fault(s) has been The Engine control module (ECM) used in this vehicle utilizes an electrically programmable read- only rectified then the CEL will switch OFF, although the memory (EPROM).
Page 396 6E1-226 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 51) Electrically Programmable Read-Only Memory (EPROM) Error Action Value(s) Was the "On-Board Diagnostic (OBD) System Check" performed? Go to OBD System Go to step 2 Check Refer to Service Bulletins. Is there still a problem? Go to step 3 Verify Repair Replace the EPROM or ECM.
Page 397 DRIVEABILITY AND EMISSIONS 6E1-227 DIAGNOSTIC TROUBLE CODE DTC (Flash DTC = 55) ELECTRICALLY ERASABLE PROGRAMMABLE READ-ONLY MEMORY (EEPROM) ERROR Circuit Description Conditions for Clearing the MIL/DTC • Once the ECM determines that a fault(s) has been The Engine control module (ECM) used in this vehicle utilizes an electrically erasable programmable read- rectified then the CEL will switch OFF, although the only memory (EEPROM).
Page 398 6E1-228 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 55) Electrically Erasable Programmable Read-Only Memory Error Action Value(s) Was the "On-Board Diagnostic (OBD) System Check" performed? Go to OBD System Go to step 2 Check Refer to Service Bulletins. Is there still a problem? Go to step 3 Verify Repair Replace the EPROM or ECM.
Page 399 DRIVEABILITY AND EMISSIONS 6E1-229 Meter Fuse Tacho Meter Crank Angle Sensor Engine Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 91) TACHO OUT LOW ERROR Circuit Description Action Taken When the DTC Sets • The ECM will turn ON the Malfunction Indicator Based on the information from the Crank Position Sensor (CKP), X58 reference signal is generated at Lamp...
Page 400: Verify Repair Go To Step
6E1-230 DRIVEABILITY AND EMISSIONS • This malfunction detects a low impedance short to ground or open contact on the ECM out put circuit. DTC (Flash DTC = 91) Tacho Out Low Error Step Action Value(s) Was the "On-Board Diagnostic (OBD) System Check" Go to OBD performed? Go to Step 2...
Page 401 DRIVEABILITY AND EMISSIONS 6E1-231 Meter Fuse Tacho Meter Crank Angle Sensor Engine Control Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC =92) TACHO OUT HIGH ERROR Circuit Description Action Taken When the DTC Sets • The ECM will turn ON the Malfunction Indicator Based on the information from the Crank Position Sensor (CKP), X58 reference signal is generated at Lamp...
Page 402 6E1-232 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 92) Tacho Out High Error Step Action Value(s) Was the "On-Board Diagnostic (OBD) System Check" Go to OBD performed? System Go to Step 2 Check 1. Ignition OFF. 2. Check for a faulty connection or damaged terminals at the tacho meter connector.
Page 403 DRIVEABILITY AND EMISSIONS 6E1-233 Battery Joint Cable Fuse 0.85W Relay Fuel Pump Fuel Pump Fuse Fuel Injectors Engine Fuel Control Pump Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 29) FUEL PUMP RELAY SHORTED TO GROUND Circuit Description Conditions for Setting the DTC When the ignition switch is first turned ON, the engine •...
Page 404: Go To Obd System
6E1-234 DRIVEABILITY AND EMISSIONS 2. If the fuel pump is operating but incorrect pressure Action Taken When the DTC sets is noted, the fuel pump wiring is OK and the “Fuel • The ECM will turn ON the Malfunction Indicator System Pressure Test”...
Page 405 DRIVEABILITY AND EMISSIONS 6E1-235 DTC (Flash DTC = 29) Fuel Pump Relay Shorted To Ground (Cont’d) Step Action Value(s) 1. Verify that the pump is not running by removing the fuel filler cap and listening. 2. Check the fuel pump relay connector is loosely fitting or disconnected.
Page 406 6E1-236 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 29) Fuel Pump Relay Shorted To Ground (Cont’d) Step Action Value(s) Repair the open circuit in the fuel pump ground wire. Is the action complete? Verify repair 1. Re-connect the horn relay in its proper location. 2.
Page 407 DRIVEABILITY AND EMISSIONS 6E1-237 Battery Joint Cable Fuse 0.85W Relay Fuel Pump Fuel Pump Fuse Fuel Injectors Engine Fuel Control Pump Module (ECM) DIAGNOSTIC TROUBLE CODE (DTC) (Flash DTC = 32) FUEL PUMP RELAY SHORTED TO BATTERY Circuit Description Conditions for Setting the DTC When the ignition switch is first turned ON, the engine •...
Page 408 6E1-238 DRIVEABILITY AND EMISSIONS Caution: To reduce the risk of fire and Diagnostic Aids personal injury: An intermittent may be caused by a poor connection, • It is necessary to relieve fuel system rubbed-through wire insulation, or a wire broken inside pressure before connecting a fuel pressure the insulation.
Page 409 DRIVEABILITY AND EMISSIONS 6E1-239 DTC (Flash DTC = 32) Fuel Pump Relay Shorted To Battery (Cont’d) Step Action Value(s) Repair short or open battery feed to fuel pump relay. Is the action complete? Verify repair 1. Connect a test light between the two wires that connect to the fuel pump relay pull-in coil.
Page 410 6E1-240 DRIVEABILITY AND EMISSIONS DTC (Flash DTC = 32) Fuel Pump Relay Shorted To Battery (Cont’d) Step Action Value(s) 1. With the fuel pump electrical connector at the fuel tank disconnected, connect a test light between the feed wire and the ground wire (harness side). 2.
Page 411 • The engine does not start. of the fault. Condition for Clearing the MIL/DTC • Use clear DTC information with Tech2. (Refer to the immobilizer workshop manual.) (ISUZU TF Immobilizer system) Diagnostic Aids Check for the following conditions: • Poor connection at ECM and Immobilizer-Inspect...
Page 412 6E1-242 DRIVEABILITY AND EMISSIONS DTC (Flash DTC=83) Received Response Was Not Correct Step Action Value(s) Was the "On-Board Diagnostic (OBD) system Check" Go to OBD performed? Go to Step 2 system check Replace the ECM. IMPORTANT: The replacement ECM must be programmed.
Page 413 MIL. A change in voltage will indicate the location of the fault. Condition for Clearing the MIL/DTC • Use clear DTC information with Tech2. (Refer to the immobilizer workshop manual.) (ISUZU TF Immobilizer system) Diagnostic Aids Check for the following conditions: •...
Page 414 6E1-244 DRIVEABILITY AND EMISSIONS DTC (Flash DTC=84) No Response From Immobilizer Step Action Value(s) Was the "On-Board Diagnostic (OBD) system Check" Go to OBD performed? system Go to Step 2 check Using the Tech2 system selection menu, select Body Refer to function.
Page 415 • Use clear DTC information with Tech2. (Refer to connectors and wiring harnesses relates to the MIL. the immobilizer workshop manual.) (ISUZU TF A change in voltage will indicate the location of the Immobilizer system) fault.
Page 416 6E1-246 DRIVEABILITY AND EMISSIONS DTC (Flash DTC=85) Security Code & Secret Key Not Programmed Step Action Value(s) Was the "On-Board Diagnostic (OBD) system Check" Go to OBD performed? system Go to Step 2 check Using the Tech2 system selection menu, select Body Refer to function.
Page 417 MIL. A change in voltage will indicate the location of the Condition for Clearing the MIL/DTC fault. • Use clear DTC information with Tech2. (Refer to the immobilizer workshop manual.) (ISUZU TF Immobilizer system)
Page 418 6E1-248 DRIVEABILITY AND EMISSIONS DTC (Flash DTC=86) Received Incorrect Security Code Step Action Value(s) Was the "On-Board Diagnostic (OBD) system Check" Go to OBD performed? system Go to Step 2 check Recheck the security code. Is the action complete? Verify repair...
Page 419 DRIVEABILITY AND EMISSIONS 6E1-249 ON-VEHICLE SERVICE PROCEDURE ECM AND SENSORS CRANKSHAFT POSITION (CKP) SENSOR Removal Disconnect the negative battery cable. Remove the drive belt. Refer to Engine Mechanical Section. Remove the A/C compressor from engine. Refer to Engine Mechanical Section. Disconnect electrical connector from the sensor.
Page 420 6E1-250 DRIVEABILITY AND EMISSIONS ENGINE COOLANT TEMPERATURE (ECT) SENSOR Removal Disconnect the negative battery cable. Drain enough engine coolant so that the coolant level will be below the ECT sensor. Remove electrical connector from the sensor located on the thermostat housing. Unscrew the sensor from the thermostat housing.
Page 421 DRIVEABILITY AND EMISSIONS 6E1-251 Installation Note: If HO2S is reinstalled after removal. Install HO2S on the exhaust pipe. Tighten the sensor to 55 Nm(7.6kgf⋅m). Connect the pigtail to the wiring harness. Connect the negative battery cable. INTAKE AIR TEMPERATURE (IAT) SENSOR Removal Disconnect the negative battery cable.
Page 422 6E1-252 DRIVEABILITY AND EMISSIONS MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR Removal Disconnect the negative battery cable. Disconnect the electrical connector from the sensor. (The MAP sensor is located on the intake manifold behind throttle body.) Connect electrical connector. Connect the negative battery cable. Installation Push MAP sensor into the manifold.
Page 423 DRIVEABILITY AND EMISSIONS 6E1-253 Notice: To prevent possible Electrostatic Discharge damage, follow these guidelines: • Do not touch the control module connector pins or soldered components on the control module circuit board. • Do not open the replacement part package until the part is ready to be installed.
Page 424 6E1-254 DRIVEABILITY AND EMISSIONS Connect both red and tan connectors. Replace the ECM to the original position by tightening the screws. Attach the center cover assembly. POWER STEERING PRESSURE (PSP) SWITCH Removal Disconnect the battery negative cable. Disconnect the PSP switch pigtail from the wiring harness.
Page 425: Throttle Position Sensor
DRIVEABILITY AND EMISSIONS 6E1-255 THROTTLE POSITION SENSOR (TPS) Removal Disconnect the negative battery cable. Disconnect the TPS electrical connector. Remove the two screws and TP sensor from the throttle body. Notice: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result.
Page 426 6E1-256 DRIVEABILITY AND EMISSIONS Inspection Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn.
Page 427: Air Filter
DRIVEABILITY AND EMISSIONS 6E1-257 AIR INDUCTION SYSTEM AIR FILTER Removal Disconnect electrical connector at the IAT sensor. Release the four latches securing the lid to the air cleaner housing. Remove the air cleaner lid. Remove the air filter element. Installation Install the air filter element in the air cleaner housing.
Page 428 6E1-258 DRIVEABILITY AND EMISSIONS Measurement 28mm max. • In order to install a new IAC valve, measure the distance between the tip of the pintle and the mounting flange. If that measurement is 28 mm or less, the valve needs no adjustment.
Page 429 DRIVEABILITY AND EMISSIONS 6E1-259 Installation Connect the intake air duct at the throttle body and at the air filter box. Make sure retaining hole is inserted to the intake air duct bracket. Tighten retaining clamp at the throttle body and at the air filter box.
Page 430: Oil Pressure Switch
6E1-260 DRIVEABILITY AND EMISSIONS OIL PRESSURE SWITCH Removal Disconnect battery negative cable. Disconnect electrical connector at Oil Pressure Switch. Unscrew Oil Pressure Switch from Oil Filter Mounting Housing. Installation Install Oil Pressure Switch into Oil Filter Mounting Housing and tighten. Tighten the screws to 30 -50Nm (3.1 -5.1kgf⋅m).
Page 431 DRIVEABILITY AND EMISSIONS 6E1-261 FUEL METERING SYSTEM ACCELERATOR CABLE ASSEMBLY Removal Loosen the adjusting nut on the cable bracket mounting on the throttle body. Remove the cable clip from holding bracket. Remove accelerator control cable (on the throttle valve end). Remove the accelerator control cable (on the accelerator pedal end).
Page 432 6E1-262 DRIVEABILITY AND EMISSIONS ACCELERATOR CABLE ADJUSTMENT Adjustment Loosen the adjusting nut. Loosen the jam nut. Pull the outer cable while fully closing the throttle valve. Tighten the adjusting nut. Tighten the jam nut. Loosen the adjusting nut and adjust clearance between adjusting nut and bracket to 2∼3.5mm.
Page 433 DRIVEABILITY AND EMISSIONS 6E1-263 FUEL FILLER CAP The Fuel Filler Cap includes a vacuum valve. If high vacuum occurs in the fuel tank, the vacuum valve works to adjust the pressure in order to prevent damage to the tank. Inspection Notice: Replace the fuel filler cap with the same type of filler cap that was originally installed on the vehicle.
Page 434: Fuel Injectors
6E1-264 DRIVEABILITY AND EMISSIONS Installation Install the fuel filter in the correct direction. Install the bolt on the fuel filter holder. Connect the fuel line on the engine side. Connect the fuel line on the fuel tank side. Install the fuel filler cap. Connect the negative battery cable.
Page 435 DRIVEABILITY AND EMISSIONS 6E1-265 Install fuel rail assembly. Tighten the nuts to 19 N⋅m (1.9 kgf⋅m). Refer to Fuel Rail Installation Procedure. Tighten the flare nut to 27 - 33 N⋅m (2.8 - 3.4 kgf⋅m). Connect the negative battery cable. FUEL PRESSURE REGULATOR Removal Caution: To reduce the risk of fire and personal injury, it is...
Page 436 6E1-266 DRIVEABILITY AND EMISSIONS Remove the fuel pressure regulator retaining screw. Remove the fuel pressure regulator from fuel rail. Installation Insert the fuel pressure regulator into the fuel rail. Install the fuel pressure regulator retaining bracket and tighten with a screw. Connect vacuum line onto the fuel pressure regulator.
Page 437: Fuel Pressure Relief
DRIVEABILITY AND EMISSIONS 6E1-267 FUEL PRESSURE RELIEF Caution: To reduce the risk of fire and personal injury, it is necessary to relieve the fuel system pressure before servicing the fuel system components. Caution: After relieving the fuel system pressure, a small amount of fuel may be released when servicing fuel lines or connections.
Page 438 6E1-268 DRIVEABILITY AND EMISSIONS Lift fuel pump to remove from fuel tank. Inspection Inspect in-tank fuel filter for tears, damage of evidence of dirt derbris or water in the fuel. If any of these condition exist, replace the in-tank fuel filter. Installation Insert the fuel pump assembly into fuel tank and place them in their position.
Page 439 DRIVEABILITY AND EMISSIONS 6E1-269 FUEL PUMP RELAY Removal Remove the fuse and relay box cover located right side of engine room. Determine correct relay by referring to the diagram on the cover. Insert a small screwdriver or use thumb pressure to release the retainer of the relay.
Page 440 6E1-270 DRIVEABILITY AND EMISSIONS If removal of fuel pressure regulator is necessary, Refer to Fuel Pressure Regulator Removal Procedure. If removal of fuel injector is necessary, Refer to Fuel Injectors Removal Procedure. Installation Install the fuel injectors if necessary. Refer to Fuel Injector Installation Procedure.
Page 441 DRIVEABILITY AND EMISSIONS 6E1-271 FUEL TANK Removal Disconnect the negative battery cable. Remove fuel filler cap. Drain the fuel from fuel filler neck. Disconnect the fuel filler hose at the fuel tank. Disconnect the air breather hose at the fuel tank. Disconnect the evaporator hose at the fuel tank.
Page 442 6E1-272 DRIVEABILITY AND EMISSIONS Connect fuel supply and return lines. Connect the fuel filler hose, the air breather hose and EVAP hose onto fuel tank and secure them with clamps. Pour fuel into fuel tank. Install fuel filler cap securely. Connect the battery negative cable.
Page 443 DRIVEABILITY AND EMISSIONS 6E1-273 Remove the gaskets from the intake manifolds. Remove the IAC. Refer to Idle Air Control Valve Solenoid Removal Procedure. Remove TPS. Refer to Throttle Position Sensor Removal Procedure. Inspection Notice: Do not use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly.
Page 444 6E1-274 DRIVEABILITY AND EMISSIONS ELECTRONIC IGNITION SYSTEM IGNITION COIL Removal Disconnect the negative battery cable. Disconnect the all connector from the ignition control module. Remove the three attaching screws. Remove the ignition control module from the engine block. Installation Fasten the module to the engine block with three screws. Reconnect the all connector.
Page 445 DRIVEABILITY AND EMISSIONS 6E1-275 SPARK PLUGS Type: RN9YC4 Spark Gap: 1.0-1.1 mm (0.039" - 0.043") Spark Plug Torque: 25N⋅m (2.5kgf⋅m) Removal Disconnect the negative battery cable. Remove the spark plug cable. Remove the spark plug. Inspection Check the insulator for cracks. Replace the spark plug if cracks are present.
Page 446 6E1-276 DRIVEABILITY AND EMISSIONS Installation Tighten the spark plug to the 25N⋅m (2.5kgf⋅m). Push the spark plug cable in until it snaps in. SPARK PLUG CABLES The cable contains a synthetic conductor which is easily damaged. Never stretch or kink the cable. Disconnect the cable from spark plug and the ignition coil.
Page 447: Ignition Timing Adjustment
DRIVEABILITY AND EMISSIONS 6E1-277 EMISSIONS CATALYTIC CONVERTER (IF APPLICABLE) Refer to Engine Exhaust. AIR CONDITIONING RELAY Removal Remove the fuse and relay box cover at right side of engine room. Refer to the diagram on the cover to determine which is the correct relay.
Page 448 6E1-278 DRIVEABILITY AND EMISSIONS EVAP CANISTER (IF APPLICABLE) Removal Disconnect all hoses. Remove EVAP canister. Inspection Inspect the hoses for cracks, damage and leaks. Inspect the canister for damages. Installation Install EVAP canister. Connect all hoses and secure them with clamps. EVAP CANISTER PURGE VALVE SOLENOID (IF APPLICABLE) Removal...
Page 449: Wiring Harness Service
DRIVEABILITY AND EMISSIONS 6E1-279 WIRING AND CONNECTORS WIRING HARNESS SERVICE The control module harness electrically connects the control module to the various solenoids, switches and sensors in the vehicle engine compartment and passenger compartment. Replace wire harnesses with the proper part number replacement.
Page 450 6E1-280 DRIVEABILITY AND EMISSIONS WIRE HARNESS REPAIR: TWISTED SHIELDED CABLE Removal Remove the outer jacket. Unwrap the aluminum/mylar tape. Do not remove the mylar. Untwist the conductors. Strip the insulation as necessary. Installation Splice the wires using splice clips and rosin core solder. Wrap each splice to insulate.
Page 451 DRIVEABILITY AND EMISSIONS 6E1-281 TWISTED LEADS Removal Locate the damaged wire. Remove the insulation as required. Installation Use splice clips and rosin core solder in order to splice the two wires together. Cover the splice with tape in order to insulate it from the other wires.
Page 452: Tools Required
6E1-282 DRIVEABILITY AND EMISSIONS Tape the wires with electrical tape. WEATHER-PACK CONNECTOR Tools Required 5-8840-0388-0 Weather-Pack II Terminal Remover Removal A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This engine room connector protects against moisture and dirt, which could form oxidation and deposits on the terminals.
Page 453 DRIVEABILITY AND EMISSIONS 6E1-283 Installation Make certain the connectors are properly seated and all of the sealing rings are in place when you reconnect the leads. The secondary lock hinge provides a backup locking feature for the connector. The secondary lock hinge is used for added reliability.
Page 454 6E1-284 DRIVEABILITY AND EMISSIONS Installation Metri-Pack terminals are also referred to as "pull-to-seat" terminals. In order to install a terminal on a wire, the wire must be inserted through the seal (2) and through the connector (3). The terminal (1) is then crimped onto the wire. Then the terminal is pulled back into the connector to seat it in place.
Page 455 DRIVEABILITY AND EMISSIONS 6E1-285 GENERAL DESCRIPTION ECM AND SENSORS 58X REFERENCE ECM INPUT The engine control module (ECM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The ECM also uses the pulses on this circuit to initiate injector pulses.
Page 456 6E1-286 DRIVEABILITY AND EMISSIONS ENGINE COOLANT TEMPERATURE (ECT) SENSOR The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of about 100,000 ohms at −40°C (−40°F).
Page 457 DRIVEABILITY AND EMISSIONS 6E1-287 INTAKE AIR TEMPERATURE (IAT) SENSOR The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high resistance of about 100,000 ohms at −40°C (−40°F). High temperature causes low resistance of about 70 ohms at 130°C (266°F).
Page 458 6E1-288 DRIVEABILITY AND EMISSIONS ECM FUNCTION The ECM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistors in the ECM which are so high in value that a test light will not light when connected to the circuit.
Page 459 DRIVEABILITY AND EMISSIONS 6E1-289 ECM INPUTS/OUTPUTS Inputs - Operating Conditions Read • Air Conditioning Compressor Clutch ON or OFF • Engine Coolant Temperature • Crankshaft Position • Exhaust Oxygen Content (If equipped) • Manifold Absolute Pressure • Battery Voltage • Throttle Position •...
Page 460 6E1-290 DRIVEABILITY AND EMISSIONS THROTTLE POSITION SENSOR (TPS) The throttle position sensor (TPS) is a potentiometer connected to the throttle shaft on the throttle body. The ECM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TPS signal also changes.
Page 461 DRIVEABILITY AND EMISSIONS 6E1-291 AFTERMARKET ELECTRICAL AND VACUUM EQUIPMENT Aftermarket (add-on) electrical and vacuum equipment is defined as any equipment which connects to the vehicle's electrical or vacuum systems that is installed on a vehicle after it leaves the factory. No allowances have been made in the vehicle design for this type of equipment.
Page 462 6E1-292 DRIVEABILITY AND EMISSIONS Notice: To prevent possible electrostatic discharge damage, follow these guidelines: • Do not touch the ECM connector pins or soldered components on the ECM circuit board. • Do not touch any electronic module component leads. • Do not open the replacement part package until the part is ready to be installed.
Page 463 DRIVEABILITY AND EMISSIONS 6E1-293 BATTERY VOLTAGE CORRECTION MODE When battery voltage is low, the ECM will compensate for the weak spark by increasing the following: • The amount of fuel delivered. • The idle RPM. CLEAR FLOOD MODE Clear a flooded engine by pushing the accelerator pedal down all the way.
Page 464 6E1-294 DRIVEABILITY AND EMISSIONS FUEL METERING SYSTEM COMPONENTS The fuel metering system is made up of the following parts: • The fuel injectors. • The throttle body. • The fuel rail. • The fuel pressure regulator. • The ECM. • The crankshaft position (CKP) sensor. •...
Page 465 DRIVEABILITY AND EMISSIONS 6E1-295 FUEL PRESSURE REGULATOR The fuel pressure regulator is a diaphragm-operated relief valve mounted on the fuel rail with fuel pump pressure on one side and manifold pressure on the other side. The fuel pressure regulator maintains the fuel pressure available to the injector at three times barometric pressure adjusted for engine load.
Page 466 6E1-296 DRIVEABILITY AND EMISSIONS IDLE AIR CONTROL (IAC) VALVE The purpose of the idle air control (IAC) valve is to control engine idle speed, while preventing stalls due to changes in engine load. The IAC valve, mounted in the throttle body, controls bypass air around the throttle plate.
Page 467 DRIVEABILITY AND EMISSIONS 6E1-297 STARTING MODE When the ignition is first turned ON, the ECM energizes the fuel pump relay for two seconds to allow the fuel pump to build up pressure. The ECM then checks the engine coolant temperature (ECT) sensor and the throttle position (TP) sensor to determine the proper air/fuel ratio for starting.
Page 468 6E1-298 DRIVEABILITY AND EMISSIONS IGNITION COILS The all engines use 2 ignition coils, 1 per 2 cylinders. A two- wire connector provides a 12-volt primary supply through the 15-amp ignition coil fuse. IGNITION CONTROL The ignition control (IC) spark timing is the ECM's method of controlling the spark advance and the ignition dwell.
Page 469 DRIVEABILITY AND EMISSIONS 6E1-299 SPARK PLUG Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequently fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance.
Page 470 6E1-300 DRIVEABILITY AND EMISSIONS Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This may be due to improper gap adjustment or to excessive wear of the electrode during use. A check of the gap size and comparison to the gap specified for the vehicle in Maintenance and Lubrication will tell if the gap is too wide.
Page 471 DRIVEABILITY AND EMISSIONS 6E1-301 A/C CLUTCH DIAGNOSIS A/C CLUTCH CIRCUIT OPERATION A 12-volt signal is supplied to the A/C request input of the ECM when the A/C is selected through the A/C control switch. The A/C compressor clutch relay is controlled through the ECM.
Page 472 6E1-302 DRIVEABILITY AND EMISSIONS EVAPORATIVE EMISSION (EVAP) SYSTEM (IF APPLICABLE) EVAP EMISSION CONTROL SYSTEM PURPOSE The basic evaporative emission (EVAP) control system used on all vehicles is the charcoal canister storage method. Gasoline vapors from the fuel tank flow into the canister through the inlet labeled "TANK."...
Page 473 DRIVEABILITY AND EMISSIONS 6E1-303 SYSTEM FAULT DETECTION The EVAP leak detection strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. At an appropriate time, the EVAP purge solenoid is turned "ON," allowing the engine vacuum to draw a small vacuum on the entire evaporative emission system.
Page 474 6E1-304 DRIVEABILITY AND EMISSIONS POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM CRANKCASE VENTILATION SYSTEM PURPOSE The crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to the atmosphere. Fresh air from the throttle body is supplied to the crankcase and mixed with blow-by gases.
Page 475 DRIVEABILITY AND EMISSIONS 6E1-305 SPECIAL SERVICE TOOLS Legend (1) Tech 2 Scan Tool (4) Tech 2 DLC Interface Cable (2) Tech 2 AC/DC Power Adapter (5) Tech 2 RS232 Connector Port (3) Tech 2 OBD DLC Interface Connector (6) Tech 2 10 Meg Memory Card...
Page 476 6E1-306 DRIVEABILITY AND EMISSIONS SPECIAL SERVICE TOOLS (Cont'd) ITEM NO. ILLUSTRATION PART NO. PART NAME High Impedance 5-8840-2392-0 Multimeter (Digital Voltmeter -DVM) IAC Motor Analyzer 5-8840-2312-0 5-8840-2618-0 Fuel Injector Tester 5-8840-0385-0 Connector Test AdapterKit Vacuum Pump 5-8840-0279-0 with Gauge Terminal Remover 5-8840-0632-0 Weather Pack 5-8840-0388-0...
Page 477 DRIVEABILITY AND EMISSIONS 6E1-307 SPECIAL SERVICE TOOLS (Cont'd) ITEM NO. ILLUSTRATION PART NO. PART NAME Ultrasonic Leak 5-8840-2608-0 Detector 5-8840-2589-0 Injector Adapter Cable 5-8840-2608-0 EVAP Pressure/Purge Diagnostic Station is a multipurpose tool which is used to perform several diagnostic procedures for enhanced emission testing. The station will accommodate a nitrogen gas filled cylinder which is used to pressurize the vehicle EVAP system for a leakdown test and leak location test when a vehicle is repaired for leakage in the enhanced evaporative emission control system.
Page 478: Engine Exhaust
INDEX ENGINE EXHAUST 6F-1 SECTION 6F ENGINE EXHAUST CONTENTS PAGE General Description......................6F- 3 Service Precaution ......................6F- 5 Exhaust Pipe ........................6F- 6 Exhaust pipe and Associated parts................6F- 6 Removal ........................6F- 6 Installation ........................6F- 6 Inspection ........................6F- 7 Front Exhaust Pipe ......................
Page 479 6F-2 ENGINE EXHAUST PAGE Main Data and Specifications ..................6F-18 Torque Specification....................6F-19...
Page 480: General Description
ENGINE EXHAUST 6F-3 General Description This illustration is based on the 4×4 with TWC model.
Page 481 6F-4 ENGINE EXHAUST When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating the floor pan and possible damage to the passenger compartment insulation and trim materials. Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep...
Page 482: Service Precaution
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 483: Exhaust Pipe
6F-6 ENGINE EXHAUST Exhaust Pipe Exhaust Pipe and Associated parts Removal 1. Front exhaust pipe flange nut and 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.
Page 484: Inspection
ENGINE EXHAUST 6F-7 Important - Installation 1. Front Exhaust Pipe Flange Nut Connect the exhaust pipe to the exhaust manifold. Front exhaust pipe to manifold nut. Torque N⋅m (kgf⋅m) 28 (2.9) Inspection Make the necessary adjustments, and part replacements if excessive wear or damage is discover during inspection.
Page 485: Front Exhaust Pipe
6F-8 ENGINE EXHAUST Front Exhaust Pipe Front Exhaust Pipe and Associated Parts Legend 1 Front Exhaust Pipe Fixing Nuts 3 Front Exhaust Pipe Sensor (If applicable) 4 Front Exhaust Pipe Fixing Bolts and Nuts Removal 1. Disconnect battery ground cable. 2.
Page 486: Installation
ENGINE EXHAUST 6F-9 Installation 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 O sensor and reconnect O sensor harness connector. (If applicable) Torque:55 N⋅m (5.6 kgf⋅m)
Page 487: Mid Pipe
6F-10 ENGINE EXHAUST Mid Pipe Mid Pipe and Associated Parts Legend 1. Front Exhaust Pipe Fixing Bolts and Nuts 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.
Page 488: Installation
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...
Page 489: Catalytic Converter (If Applicable)
6F-12 ENGINE EXHAUST Catalytic Converter (If applicable) Catalytic Converter and Associated Parts Legend 1. Catalytic Converter 2. Grakets Removal 1. Disconnect battery ground cable. 2. Raise the vehicle and support with suitable safety stands. 3. Remove center exhaust pipe fixing bolts. 4.
Page 490: Way Catalytic Converter System
ENGINE EXHAUST 6F-13 3 WAY CATALYTIC CONVERTER SYSTEM (If applicable) Inspection Make the necessary adjustments, and part replacements if excessive or damage is discovered during inspection. 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.
Page 491 6F-14 ENGINE EXHAUST Installation 1. Place new gaskets 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 torque. 3.
Page 492: Exhaust Silencer
ENGINE EXHAUST 6F-15 Exhaust Silencer Exhaust Silencer and Associated Parts Legend 1. Exhaust Silencer Fixing Bolts 2. Exhaust Silencer Removal 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 disconnect rear exhaust silencer from rear exhaust pipe 4.
Page 493: Installation
6F-16 ENGINE EXHAUST 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: Bolts: 43 N⋅m (4.4 kgf⋅m)
Page 494: Rear Exhaust Pipe
ENGINE EXHAUST 6F-17 Rear Exhaust pipe Rear Exhaust pipe and Associated Parts Legend 1 Gasket 2 Mounting 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 rear exhaust pipe (3) from exhaust silencer.
Page 495: Installation
6F-18 ENGINE EXHAUST Installation 1. Install the mounting rubber (2). 2. Install the exhaust pipe (3) and tighten two bolts and nuts on exhaust silencer to specified torque. Torque: Nuts: 43 N.m (4.4 kgf.m) Main Data and Specifications Exhaust system Pipe outside diameter thickness Front pipe...
Page 496 ENGINE EXHAUST 6F-19 Main Data and Specifications Torque Specification m (kgf...
Page 497: Engine Lubrication
INDEX ENGINE LUBRICATION 6G-1 SECTION 6G ENGINE LUBRICATION CONTENTS PAGE General 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 ........................
Page 498: General Description
6G-2 ENGINE LUBRICATION General Description Legend 9 Connecting Rod Bearing 1 Oil Strainer 10 Connecting Rod 2 Oil Pump 11 Piston 3 Relief Valve 12 Oil Gallery; Cylinder Head 4 Oil Filter 13 Camshaft 5 Safety Valve 14 Camshaft Journal 6 Oil Gallery 15 HLV 7 Crankshaft Bearing...
Page 499: Service Precaution
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 500: Oil Pump
6G-4 ENGINE LUBRICATION Oil Pump Oil Pump and Associated Parts Legend 1 Oil Pump Assembly 3 Gasket 2 Oil Pressure Switch 4 Sleeve Disassembly 1. Remove crankshaft timing pulley. 2. Remove oil pan. 3. Remove oil strainer. 4. Remove oil pump assembly. 5.
Page 501: Inspection And Repair
ENGINE LUBRICATION 6G-5 Inspection and Repair CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Body and Gears The pump assembly must be replaced if one or more of the conditions below is discovered during inspection: Indentation of gear pair - Use feeler strip and straight edge.
Page 502: Oil Pan
6G-6 ENGINE LUBRICATION Oil Pan Oil Pan and Associated Parts Legend 1 Drain Plug 4 Oil Pan Gasket 2 Bolts 3.Oil Pan Important Disassembly 1. Loosen a drain plug to drain oil. 2. Remove engine hood. 3. Remove engine rear mounting. 4.
Page 503: Inspection And Repair
ENGINE LUBRICATION 6G-7 Inspection and Repair CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found through inspection. Reassembly 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 bolted to block.
Page 504: Engine Speed Control System
INDEX ENGINE SPEED CONTROL SYSTEM 6H-1 SECTION 6H ENGINE SPEED 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..............
Page 505: Service Precaution
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 506: Accelerator Pedal
ENGINE SPEED CONTROL SYSTEM 6H-3 Accelerator Pedal Accelerator Pedal and Associated Parts Legend 1 Accelerator Pedal Control Cable 2 Accelerator Pedal Assembly Removal 1. Accelerator pedal control cable (1). 2. Accelerator pedal assembly (2). Installation 1. Accelerator pedal assembly (2). 2.
Page 507 INDEX 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...
Page 508 Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant.
Page 509 This manual is applicable 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 LIMITED. Issued by ISUZU MOTORS LIMITED INTERNATIONAL SERVICE DEPARTMENT Tokyo, Japan First edition May., 1998...
Page 510 No. TFHEC-WE-981 PRINTED IN JAPAN...

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Isuzu C22NE Workshop Manual

Section 6 Engine Diagnosis

Section 6A Engine Mechanical

General Description

Main Data and Specification

Operations on Engine Aggregates

Operations on Installed Engine

Component Parts

Operations on Cylinder Head and Camshaft Housing

Operations on Crank Drive

Operations on Removed Engine

Operations on Oil Circulation

Operations on Cooling Sysytem

Engine External Parts

Fuel Injection System

Fuel Injector

Technical Data

Section 6B Engine Cooling

Section 6C Engine Fuel

Section 6D1 Engine Electrical

Section 6D2 Ignition System

Section 6D3 Starting and Charging System

Section 6E Driveability and Emissions

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