Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Instruction - page 1

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

(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR VOLTAGE
SUPPLY CIRCUIT HIGH INPUT .............

6E-104

DIAGNOSTIC TROUBLE CODE (DTC) P0100

(SYMPTOM CODE 9) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT ..............

6E-104

DIAGNOSTIC TROUBLE CODE (DTC) P0100

(SYMPTOM CODE B) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT LOW INPUT .............................

6E-104

DIAGNOSTIC TROUBLE CODE (DTC) P0100

(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................

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

(Symptom Code 9) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage
Supply Circuit Low Input ..........................

6E-108

Diagnostic Trouble Code (DTC) P0100

(Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output
Circuit Low Input ......................................

6E-110

Diagnostic Trouble Code (DTC) P0100

(Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output
Circuit High Input .....................................

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

(SYMPTOM CODE 2) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT) SENSOR
CIRCUIT LOW INPUT .............................

6E-116

Circuit Description ......................................

6E-116

Diagnostic Aids ..........................................

6E-117

Diagnostic Trouble Code (DTC) P0110

(Symptom Code 1) (Flash Code 23)
Intake Air Temperature (IAT) Sensor
Circuit High Input .....................................

6E-117

Diagnostic Trouble Code (DTC) P0110

(Symptom Code 2) (Flash Code 23)
Intake Air Temperature (IAT) Sensor
Circuit Low Input ......................................

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

(Symptom Code 1) (Flash Code 14)
Engine Coolant Temperature Sensor
Circuit High Input .....................................

6E-125

Diagnostic Trouble Code (DTC) P0115

(Symptom Code 2) (Flash Code 14)
Engine Coolant Temperature Sensor
Circuit Low Input ......................................

6E-129

DIAGNOSTIC TROUBLE CODE (DTC) P0180

(SYMPTOM CODE B) (FLASH CODE 15)
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE .......................

6E-132

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