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Isuzu Diesel Engine 4JJ1 Troubleshooting Manual – PDF
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Description
Isuzu Diesel Engine 4JJ1 Troubleshooting Manual – PDF DOWNLOAD
FILE DETAILS:
Isuzu Diesel Engine 4JJ1 Troubleshooting Manual – PDF DOWNLOAD
Language : English
Pages : 713
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Isuzu Diesel Engine 4JJ1 Troubleshooting Manual – PDF DOWNLOAD
Introduction...................................................................................................................................... 1 Control System.................................................................................................................................... 3 4JJ1 Electronic Control Fuel Injection System (Common Rail Type).............................................................................. 3 How to Use This Manual.................................................................................................................... 6 How to use this manual................................................................................................................ 6 Table of abbreviation................................................................................................................. 7 Conversion formula.................................................................................................................... 8 About colors of wirings............................................................................................................... 9 About wiring diagrams................................................................................................................. 10 How to read trouble diagnosis section................................................................................................. 11 Precautions on Service Work............................................................................................................... 13 Electrical system..................................................................................................................... 13 Fuel injection system................................................................................................................. 13 Procedure of Trouble Diagnosis............................................................................................................ 15 About trouble diagnosis............................................................................................................... 15 Trouble diagnostic procedure.......................................................................................................... 16 Interview............................................................................................................................. 17 Pre-inspection........................................................................................................................ 19 Trouble diagnosis..................................................................................................................... 19 How to read DTC....................................................................................................................... 20 Confirmation after repair............................................................................................................. 22 List of final check items............................................................................................................. 22 How to clear DTC...................................................................................................................... 23 Trouble diagnosis with scan tool...................................................................................................... 24 How to Use Trouble Diagnosis-Related Tool................................................................................................. 29 Function of service tools............................................................................................................. 29 Tech2................................................................................................................................. 29 Tech2 data reference value............................................................................................................ 52 Rewriting of Q adjust correction data by Tech2........................................................................................ 65 Injector ID code (No. 1 cylinder - No. 6 cylinder or No. 4 cylinder) registration setting using Tech2................................. 72 ID code upload (Tech2)................................................................................................................ 80 ID code download (ECM)................................................................................................................ 84 TIS2000............................................................................................................................... 90 How to Inspect Injector...................................................................................................................100 Injector balance test (Tech2, EMPSIII)................................................................................................100 Trouble Diagnostic Tools (EMPS) for Industrial Engine.....................................................................................101 Introduction..........................................................................................................................101 List of functions of EMPS.............................................................................................................101 Cautions..............................................................................................................................102 EMPS Component Parts..................................................................................................................104 ECM (hardware) compatibility..........................................................................................................105 ECM Variation.........................................................................................................................105 System Requirements for EMPS Software (Recommended)...................................................................................105 EMPS (software) Setup Procedure.......................................................................................................106 EMPSIII...................................................................................................................................109 EMPSIII connection....................................................................................................................109 EMPSIII screen display................................................................................................................112 EMPS Operation Procedure..................................................................................................................115 1. Preparation........................................................................................................................115 2. ECM Reflash........................................................................................................................118 3. Injector Replacement...............................................................................................................137 4. Replace ECM (Same Model)...........................................................................................................151 5. Factory Setting....................................................................................................................176 6. Recover Point......................................................................................................................187 7. Error Messages.....................................................................................................................189 8. Error Code List....................................................................................................................196 How to Use Breaker Box....................................................................................................................206 Breaker box inspection procedure......................................................................................................206 Engine Control System.....................................................................................................................209 Description of function and operation for engine control (common rail) system.........................................................209 Engine control module (ECM)...........................................................................................................224 Engine component location diagram.....................................................................................................226 Wiring diagram of engine control module (ECM).........................................................................................239 Pin arrangement of engine control module (ECM)........................................................................................244 Circuit diagram.......................................................................................................................258 Engine harness location...............................................................................................................272 Connector list........................................................................................................................276 List of Function Checks...................................................................................................................279 List of function checks...............................................................................................................279 OBD system check......................................................................................................................280 Diagnosis lamp illumination circuit system check......................................................................................282 Diagnosis lamp blinking circuit system check..........................................................................................284 Scan tool power supply circuit system check (Tech2)...................................................................................287 Scan tool power supply circuit system check (EMPSIII).................................................................................289 Scan tool communication circuit system check..........................................................................................291 Starting circuit system check.........................................................................................................294 Starting system check.................................................................................................................299 Fuel system check.....................................................................................................................302 Intake system check...................................................................................................................306 Exhaust system check..................................................................................................................306 EGR control system check..............................................................................................................307 QOS system check......................................................................................................................310 List of Diagnostic Trouble Codes..........................................................................................................315 List of diagnostic trouble codes......................................................................................................315 DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump)..........................................334 DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)................................................344 DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump).......................................350 DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short...................................................355 DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short).............................361 DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)...............................................367 DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit)..........................373 DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)....379 DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)......................386 DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)....................392 DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)..............................................400 DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit).........406 DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)......................................414 DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)....................................................420 DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system..........................................................426 DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system..........................................................431 DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system..........................................................436 DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system..........................................................441 DTC: P0219 (Flash code 543) Overrun...................................................................................................446 DTC: P0237 (Flash code 32) Boost pressure sensor fault (low voltage fault, open circuit)..............................................448 DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit).......455 DTC: P0335 (Flash code 15) Crank sensor fault (no signal).............................................................................462 DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)..........................................................................469 DTC: P0340 (Flash code 14) Cam sensor fault (no signal)...............................................................................475 DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)............................................................................482 DTC: P0380 (Flash code 66) Glow relay circuit fault...................................................................................488 DTC: P0381 (Flash code 67) Glow plug lamp circuit fault...............................................................................493 DTC: P0487 (Flash code 44) EGR position sensor fault..................................................................................498 DTC: P0488 (Flash code 45) EGR valve control fault....................................................................................504 DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)..........................510 DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)................516 DTC: P0601 (Flash code 53) ROM fault..................................................................................................524 DTC: P0603 (Flash code 54) EEPROM fault...............................................................................................526 DTC: P0606 (Flash code 51) CPU fault..................................................................................................528 DTC: P0606 (Flash code 52) CPU monitoring IC fault....................................................................................530 DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)..............................................................................532 DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)..............................................................................535 DTC: P0615 (Flash code 19) Starter cut relay circuit fault............................................................................538 DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault...............................................................................543 DTC: P1093 (Flash code 227) No pump pressure feed.....................................................................................548 DTC: P1095 (Flash code 225) Pressure limiter open.....................................................................................559 DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)..........................................570 DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)..........577 DTC: P1173 (Flash code 542) Overheat..................................................................................................584 DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault..................................................................................589 DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault..............................................................593 DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault..............................................................600 DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault....................................................................607 DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault).............................................................613 DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)............................................................618 DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault).............................................................623 DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)............................................................628 DTC: P1345 (Flash code 16) Cam sensor out of phase....................................................................................633 DTC: P1625 (Flash code 416) Main relay fault..........................................................................................638 DTC: P1630 (Flash code 36) A/D conversion fault.......................................................................................644 DTC: P1631 (Flash code 55) Voltage fault in 5V power supply 1.........................................................................646 DTC: P1632 (Flash code 55) Voltage fault in 5V power supply 2.........................................................................650 DTC: P1633 (Flash code 55) Voltage fault in 5V power supply 3.........................................................................654 DTC: P1634 (Flash code 55) Voltage fault in 5V power supply 4.........................................................................658 DTC: P1635 (Flash code 55) Voltage fault in 5V power supply 5.........................................................................662 DTC: U2104 (Flash code 84) CAN Bus fault..............................................................................................666 DTC: U2106 (Flash code 85) CAN timeout fault..........................................................................................671 List of Trouble Symptom...................................................................................................................676 List of trouble symptom...............................................................................................................676 Engine start failure..................................................................................................................677 Engine stall..........................................................................................................................685 Engine hunting, rough idling..........................................................................................................690 Engine output shortage................................................................................................................695 Exhaust gas contains a lot of white smoke.............................................................................................699 Exhaust gas contains a lot of black smoke.............................................................................................702 Noise.................................................................................................................................705 Fuel consumption deteriorates.........................................................................................................707 Oil consumption deteriorates..........................................................................................................710 Special Tool..............................................................................................................................712 List of special tool..................................................................................................................712
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