Isuzu 6WG1 Engine (KCM 95Z7, 115Z7) Service Repair Manual PDF

Language : English
Pages :396
Downloadable : Yes
File Type : PDF

0 Introduction (All) 6
Introduction 7
safety information 7
14A Service Information Guide (All) 8
Contents included in service information 9
Plastic gauge 11
Recommended liquid gasket 13
Thread locking adhesive agent 15
Term 16
Abbreviations 17
Standard bolts 21
15B Maintenance Information (6WG1) 28
Maintenance precautions 29
Primary specifications 32
Function, Structure, Operation 35
Introduction to the trouble diagnosis 85
15C Functional Inspection (6WG1) 94
Engine compression pressure inspection 95
Fuel system check 97
Air intake system check 98
Exhaust system check 99
DPD control system check100
EGR control system check103
Starting system check104
Glow control system check105
OBD system check107
Inspection of the diagnostic light warning light illumination circuit system108
Inspection of the diagnostic light warning light blinking circuit system109
Inspection of the starter circuit system110
15D Symptom (6WG1)112
Engine start failure113
Engine stalling115
Engine hunching,rough idling117
Excessive white smoke in the exhaust gas118
Excessive black smoke in the exhaust gas119
Abnormal noise120
Large fuel consumption121
Large oil consumption123
Insufficient engine output124
DPD system manual regeneration frequently126
DPD system regeneration long time127
15E DTC Information (6WG1)128
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation131
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit132
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low133
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High134
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance135
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low136
DTC P0092 (Flash Code 217) Fuel Pressure Regulator Control Circuit High137
DTC P0093 (Flash Code 227) Fuel System Leak Detected138
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input139
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input140
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low141
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High142
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low143
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High144
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low145
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High146
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low147
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High148
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low149
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High150
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1151
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2152
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3153
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4154
DTC P0205 (Flash Code 275) Injector Circuit -Cylinder 5155
DTC P0206 (Flash Code 276) Injector Circuit -Cylinder 6156
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition157
DTC P0219 (Flash Code 543) Engine Overspeed Condition158
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition159
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low160
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High161
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit162
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance163
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit164
DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/Performance165
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance166
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit167
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High168
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low169
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1170
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1171
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1172
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2173
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2174
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2175
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low176
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High177
DTC P0560 (Flash Code 155) System Voltage178
DTC P0563 (Flash Code 35) System Voltage High179
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error180
DTC P0602 (Flash Code 154) Control Module Programming Error181
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error182
DTC P0606 (Flash Code 51) ECM/PCM Processor183
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance184
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance185
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit186
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit187
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit188
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open189
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High190
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit191
DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit192
DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit193
DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP)Too Low194
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low195
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High196
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1197
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2198
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low199
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High200
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance201
DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/Performance202
DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit203
DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance204
DTC P1455 (Flash Code 132) PM Over Accumulation205
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration206
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance207
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit208
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit209
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input210
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input211
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input212
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input213
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation214
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit215
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit216
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low217
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High218
DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low219
DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High220
DTC P242F (Flash Code 131) DPD Restriction221
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit222
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance223
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low224
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High225
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position226
DTC P2458 (Flash Code 139) DPD Regeneration Duration227
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)228
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)229
DTC U0101 (Flash Code 85) Lost Communication with TCM230
DTC U0110 (Flash Code 87) Lost Communication with VNT System231
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction232
DTC mapping table233
1A Engine Control (6WG1)238
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation241
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit242
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low244
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High247
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance249
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low251
DTC P0092 (Flash Code 217) Fuel Pressure Regulator Control Circuit High252
DTC P0093 (Flash Code 227) Fuel System Leak Detected253
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input255
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input256
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low257
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High258
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low259
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High260
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low261
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High262
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low263
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High264
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low265
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High266
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1267
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2268
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3269
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4270
DTC P0205 (Flash Code 275) Injector Circuit -Cylinder 5272
DTC P0206 (Flash Code 276) Injector Circuit -Cylinder 6273
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition274
DTC P0219 (Flash Code 543) Engine Overspeed Condition275
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition276
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low277
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High278
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit279
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance281
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit282
DTC P0341 (Flash Code 14) Camshaft Position Sensor Circuit Range/Performance283
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance284
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit285
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High286
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low287
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1288
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1289
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1290
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2291
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2292
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2293
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low294
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High295
DTC P0560 (Flash Code 155) System Voltage296
DTC P0563 (Flash Code 35) System Voltage High297
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error298
DTC P0602 (Flash Code 154) Control Module Programming Error299
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error300
DTC P0606 (Flash Code 51) ECM/PCM Processor301
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance302
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance303
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit304
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit306
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit307
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open308
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High309
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit310
DTC P1062 (Flash Code 257) Fuel Pressure Regulator 1 Solenoid Control Circuit311
DTC P1063 (Flash Code 258) Fuel Pressure Regulator 2 Solenoid Control Circuit312
DTC P1093 (Flash Code 226) Fuel Rail Pressure (FRP)Too Low313
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low315
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High316
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1317
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2318
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low319
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High320
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance321
DTC P140A (Flash Code 345) Exhaust Gas Recirculation 2 Control Circuit Range/Performance322
DTC P140B (Flash Code 344) Exhaust Gas Recirculation 2 Sensor Circuit323
DTC P140C (Flash Code 345) Exhaust Gas Recirculation 2 Closed Position Performance325
DTC P1455 (Flash Code 132) PM Over Accumulation326
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration327
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance329
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit330
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit332
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input333
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input334
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input335
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input336
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation337
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit338
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit340
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low342
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High343
DTC P2295 (Flash Code 248) Fuel Pressure Regulator 2 Solenoid Control Circuit Low344
DTC P2296 (Flash Code 218) Fuel Pressure Regulator 2 Solenoid Control Circuit High345
DTC P242F (Flash Code 131) DPD Restriction346
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit347
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance349
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low351
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High352
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position353
DTC P2458 (Flash Code 139) DPD Regeneration Duration354
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)356
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)357
DTC U0101 (Flash Code 85) Lost Communication with TCM359
DTC U0110 (Flash Code 87) Lost Communication with VNT System360
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction361
Wiring Diagram362
Using the Wiring Diagram364
Structure and Content of This Document365
1Wiring Diagram366
2Location Diagram369
3Connector Information369
4Terminal Name369
5Circuit Symbols370
6Abbreviations371
Engine372
Engine Control373
Location Diagram378
Connector Location Diagram379
Connector List382
T …（Connector List ）383
H …（Connector List ）385
S …（Connector List ）386
Terminal Name388
Terminal Name389

This manual describes the service procedures for the 6WG1 diesel engine (Interim Tier 4 compatible). The contents of this manual are current at the date of issue, but may differ slightly from your engine due to specification changes or other modifications made there after.

safety information:
1. Repair work safety information
1. Use an engine stand when demounting the engine from the equipment.
Be sure not to place the engine directly on the
ground or allow the oil pan to come into contact with the ground.
2. When performing a procedure with two or more people, make sure to ensure each other’s safety.
3. When repairing the electrical system, make sure to disconnect the cable from the negative (-) battery terminal before working. Keep fire away when removing the battery cover.
HICWXSHO01001
4. Do not leave the engine running for an extended period of time or perform painting in a poorly ventilated working environment
5. Make sure to use only the special tools if the procedure requires them for the work. Performing the procedure using other tools may cause damage to parts or personal injury.
6. Inspect the tools, instruments, and special tools regularly, and prepare them before working. Do not use tools such as a wrench that has lost its edges, a hammer with frayed edges, or a chipped chisel.
7. When performing work using a device such as a grinder, crane or welder, make sure to pay sufficient attention to the handling precautions.
Wear work clothes and safety equipments in the other operations as well.
8. Be sure to check that there is no fuel leaks when performing maintenance on fuel systems.