Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Instruction - page 1
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WORKSHOP MANUAL
TF SERIES
ENGINE DRIVEABILITY AND EMISSIONS
4JA1-TC/4JH1-TC ENGINE WITH BOSCH VP44 SYSTEM
SECTION 6E
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 - 0A 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.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model : TFR/S 54/77
This manual is applicable to 2002 year model and later vehicles.
4JA1-TC/4JH1-TC ENGINE DRIVEABILITY AND EMISSIONS
6E–1
ENGINE
CONTENTS
4JH1 ENGINE DRIVEABILITY AND EMISSIONS
ABBREVIATION CHARTS ........................
6E-9
ECM CIRCUIT DIAGRAM
(4JA1-TC LHD) (1/2) ...............................
6E-13
ECM CIRCUIT DIAGRAM
(4JA1-TC LHD) (2/2) ...............................
6E-14
ECM CIRCUIT DIAGRAM
(4JA1-TC RHD) (1/2) ...............................
6E-15
ECM CIRCUIT DIAGRAM
(4JA1-TC RHD) (2/2) ...............................
6E-16
ECM CIRCUIT DIAGRAM
(4JH1-TC RHD M/T) (1/2) .......................
6E-17
ECM CIRCUIT DIAGRAM
(4JH1-TC RHD M/T) (2/2) .......................
6E-18
ECM CIRCUIT DIAGRAM
(4JH1-TC RHD A/T) (1/2) ........................
6E-19
ECM CIRCUIT DIAGRAM
(4JH1-TC RHD A/T) (2/2) ........................
6E-20
GROUND LOCATION ...............................
6E-21
CABLE HARNESS & CONNECTOR
LOCATION (4JA1-TC LHD) ....................
6E-22
CABLE HARNESS & CONNECTOR
LOCATION (4JA1-TC RHD) ....................
6E-23
CABLE HARNESS & CONNECTOR
LOCATION (4JH1-TC RHD) ....................
6E-24
CONNECTOR LIST ...................................
6E-25
RELAY AND FUSE ....................................
6E-28
RELAY AND FUSE BOX LOCATION (LHD)
6E-28
RELAY AND FUSE BOX LOCATION (RHD)
6E-28
RELAY & FUSE LOCATION .....................
6E-29
RELAY & FUSE LOCATION .....................
6E-30
ECM WIRING DIAGRAM (1/7) ..................
6E-31
ECM WIRING DIAGRAM (2/7) ..................
6E-32
ECM WIRING DIAGRAM (3/7) ..................
6E-33
ECM WIRING DIAGRAM (4/7) ..................
6E-34
ECM WIRING DIAGRAM (5/7) ..................
6E-35
ECM WIRING DIAGRAM (6/7) ..................
6E-36
ECM WIRING DIAGRAM (7/7) ..................
6E-37
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JA1-TC) ..................
6E-38
PSG CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JA1-TC) ..................
6E-41
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JH1-TC) ..................
6E-42
PSG CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JH1-TC) ..................
6E-45
GENERAL DESCRIPTION FOR ECM AND
SENSORS ...............................................
6E-46
Engine Control Module (ECM) ...................
6E-46
Pump Control Unit (PSG) & Data Exchange
Between Control Module .........................
6E-46
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor .......................
6E-47
Pedal/Throttle Position Sensor (TPS) ........
6E-47
Crankshaft Position (CKP) Sensor ............
6E-48
Engine Coolant Temperature (ECT)
Sensor .....................................................
6E-48
Vehicle Speed Sensor (VSS) .....................
6E-49
EGR EVRV (4JA1-TC Only) ......................
6E-49
GENERAL DESCRIPTION FOR INJECTION
PUMP ......................................................
6E-50
Outline .......................................................
6E-50
Characteristic of VP44 Injection System ....
6E-50
Cross-section View ....................................
6E-51
Low Pressure Fuel Circuit ..........................
6E-52
High Pressure Fuel Circuit .........................
6E-52
Timing Control ...........................................
6E-53
Start of Injection .........................................
6E-53
ISUZU Strategy Based Diagnostics ..............
6E-54
Overview ....................................................
6E-54
STRATEGY BASED DIAGNOSTICS
CHART ....................................................
6E-54
Diagnostic Thought Process ......................
6E-55
1. Verify the Complaint ..............................
6E-55
2. Perform Preliminary Checks ..................
6E-55
3. Check Bulletins and Troubleshooting
Hints ........................................................
6E-56
4. Perform Service Manual Diagnostic
Checks .....................................................
6E-56
5a and 5b. Perform Service Manual
Diagnostic Procedures .............................
6E-56
5c. Technician Self Diagnoses ..................
6E-56
5d. Intermittent Diagnosis ..........................
6E-57
5e. Vehicle Operates as Designed ............
6E-58
6. Re-examine the complaint .....................
6E-59
7. Repair and Verify Fix .............................
6E-59
6E–2
4JA1-TC/4JH1-TC ENGINE DRIVEABILITY AND EMISSIONS
GENERAL SERVICE INFORMATION .......
6E-60
ON-BOARD DIAGNOSTIC (OBD) .............
6E-60
TECH 2 OPERATING FLOW CART
(START UP) ............................................
6E-64
TYPICAL SCAN DATA & DEFINITIONS
4JA1-TC (ENGINE DATA) ....................
6E-66
TYPICAL SCAN DATA & DEFINITIONS
4JH1-TC (ENGINE DATA) ...................
6E-68
MISCELLANEOUS TEST ..........................
6E-70
Plotting Snapshot Graph ...........................
6E-71
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) ..........
6E-72
Flow Chart for Snapshot Replay
(Plotting Graph) .......................................
6E-73
SNAPSHOT DISPLAY WITH TIS2000 ......
6E-74
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK ....................................................
6E-83
Circuit Description .....................................
6E-83
Diagnostic Aids ..........................................
6E-83
Test Description .........................................
6E-83
On-Board Diagnostic (OBD) System Check
6E-84
NO CHECK ENGINE LAMP (MIL) .............
6E-87
Circuit Description .....................................
6E-87
Diagnostic Aids ..........................................
6E-87
No Check Engine Lamp (MIL) ...................
6E-88
CHECK ENGINE LAMP (MIL) “ON”
STEADY ..................................................
6E-90
Circuit description ......................................
6E-90
Diagnostic Aids ..........................................
6E-90
Check Engine Lamp (MIL) On Steady .......
6E-91
ECM Diagnostic Trouble Codes ................
6E-93
DIAGNOSTIC TROUBLE CODE (DTC) P0100
6E-104
DIAGNOSTIC TROUBLE CODE (DTC) P0100
6E-104
DIAGNOSTIC TROUBLE CODE (DTC) P0100
6E-104
DIAGNOSTIC TROUBLE CODE (DTC) P0100
6E-104
Circuit Description .....................................
6E-105
Diagnostic Aids ..........................................
6E-105
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage
Supply Circuit High Input .........................
6E-105
Diagnostic Trouble Code (DTC) P0100
6E-108
Diagnostic Trouble Code (DTC) P0100
6E-110
Diagnostic Trouble Code (DTC) P0100
6E-113
DIAGNOSTIC TROUBLE CODE (DTC) P0110
(SYMPTOM CODE 1) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT)
SENSOR CIRCUIT HIGH INPUT ............
6E-116
DIAGNOSTIC TROUBLE CODE (DTC) P0110
6E-116
Circuit Description ......................................
6E-116
Diagnostic Aids ..........................................
6E-117
Diagnostic Trouble Code (DTC) P0110
6E-117
Diagnostic Trouble Code (DTC) P0110
6E-121
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 1) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT HIGH INPUT ............
6E-124
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 2) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT .............
6E-124
Circuit Description ......................................
6E-124
Diagnostic Aids ..........................................
6E-125
Diagnostic Trouble Code (DTC) P0115
6E-125
Diagnostic Trouble Code (DTC) P0115
6E-129
DIAGNOSTIC TROUBLE CODE (DTC) P0180
6E-132
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