Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 99

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 77

This manual is applicable to 2003 year model and later vehicles.

4JH1 ENGINE DRIVEABILITY AND EMISSIONS

6E–1

ENGINE

CONTENTS

4JH1 ENGINE DRIVEABILITY AND EMISSIONS

ABBREVIATION CHARTS . . . . . .

6E-9

ECM CIRCUIT DIAGRAM . . . . . . .

6E-13

GROUND POINT CHART (1/4) . . . . .

6E-14

LOCATION . . . . . . . . . . . .

6E-18

ENGINE CONTROL MODULE (ECM) . ...

6E-20

PARTS LOCATION . . . . . . . . ...

6E-20

. . . . . . . . . . . . . . . . ...

6E-21

PARTS LOCATION . . . . . . . . ...

6E-22

CONNECTOR LIST . . . . . . . . ...

6E-23

RELAY AND FUSE . . . . . . . . .

6E-26

RELAY AND FUSE BOX LOCATION . .

6E-26

RELAY AND FUSE BOX LOCATION . .

6E-27

FUSE AND RELAY LOCATION . . . .

6E-28

ECM WIRING DIAGRAM (1/7) . . . . ..

6E-29

ECM WIRING DIAGRAM (2/7) . . . . ..

6E-30

ECM WIRING DIAGRAM (3/7) . . . . ..

6E-31

ECM WIRING DIAGRAM (4/7) . . . . ..

6E-32

ECM WIRING DIAGRAM (5/7) . . . . ..

6E-33

ECM WIRING DIAGRAM (6/7) . . . . ..

6E-34

ECM WIRING DIAGRAM (7/7) . . . . ..

6E-35

ECM CONNECTOR PIN ASSIGNMENT &

OUTPUT SIGNAL . . . . . . . . .

6E-36

PSG CONNECTOR PIN ASSIGNMENT &

OUTPUT SIGNAL . . . . . . . . .

6E-39

GENERAL DESCRIPTION FOR ECM AND

SENSORS . . . . . . . . . . . ...

6E-40

Engine Control Module (ECM) . . . . ...

6E-40

Pump Control Unit (PSG) & Data Exchange

Between Control Module . . . . . . .

6E-40

Mass Air Flow (MAF) Sensor & Intake Air

Temperature (IAT) Sensor . . . . . ...

6E-41

Throttle Position Sensor (TPS) . . . . ..

6E-41

Crankshaft Position (CKP) Sensor . . .

6E-42

Engine Coolant Temperature (ECT) Sensor

6E-42

Vehicle Speed Sensor (VSS) . . . . .

6E-43

EGR EVRV . . . . . . . . . . . .

6E-43

GENERAL DESCRIPTION FOR INJECTION

PUMP . . . . . . . . . . . . . ..

6E-44

Outline . . . . . . . . . . . . . ...

6E-44

Characteristic of VP44 Injection System ...

6E-44

Cross-section View . . . . . . . . .

6E-45

Low Pressure Fuel Circuit . . . . . . .

6E-46

High Pressure Fuel Circuit . . . . . . .

6E-46

Timing Control . . . . . . . . . . ...

6E-47

Start of Injection . . . . . . . . . . .

6E-47

ISUZU Strategy Based Diagnostics . . . ..

6E-48

Overview . . . . . . . . . . . . .

6E-48

STRATEGY BASED DIAGNOSTICS

CHART . . . . . . . . . . . . .

6E-48

Diagnostic Thought Process . . . . . ..

6E-49

1. Verify the Complaint . . . . . . . ..

6E-49

2. Perform Preliminary Checks . . . . ..

6E-49

3. Check Bulletins and Troubleshooting

Hints . . . . . . . . . . . . . .

6E-50

4. Perform Service Manual Diagnostic

Checks . . . . . . . . . . . . . .

6E-50

5a and 5b. Perform Service Manual Diagnostic

Procedures . . . . . . . . . . . ..

6E-50

5c. Technician Self Diagnoses . . . . ..

6E-50

5d. Intermittent Diagnosis . . . . . . ..

6E-51

5e. Vehicle Operates as Designed . . .

6E-52

6. Re-examine the complaint . . . . . .

6E-53

7. Repair and Verify Fix . . . . . . . .

6E-53

GENERAL SERVICE INFORMATION . ...

6E-54

ON-BOARD DIAGNOSTIC (OBD) . . . .

6E-54

TECH 2 OPERATING FLOW CART

(START UP) . . . . . . . . . . . .

6E-58

TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) . . . . . . . . ...

6E-60

MISCELLANEOUS TEST . . . . . . ..

6E-62

Plotting Snapshot Graph . . . . . . .

6E-63

Plotting Graph Flow Chart (Plotting graph

after obtaining vehicle information) . . ..

6E-64

Flow Chart for Snapshot Replay

(Plotting Graph) . . . . . . . . . ...

6E-65

SNAPSHOT DISPLAY WITH TIS2000 . ..

6E-66

ON-BOARD DIAGNOSTIC (OBD) SYSTEM

CHECK . . . . . . . . . . . . .

6E-75

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

6E-75

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

6E-75

Test Description . . . . . . . . . . .

6E-75

On-Board Diagnostic (OBD) System Check

6E-76

NO CHECK ENGINE LAMP (MIL) . . . .

6E-79

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

6E-79

6E–2

4JH1 ENGINE DRIVEABILITY AND EMISSIONS

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

6E-79

No Check Engine Lamp (MIL) . . . . ...

6E-80

CHECK ENGINE LAMP (MIL) “ON”

STEADY . . . . . . . . . . . . ..

6E-82

Circuit description . . . . . . . . . ..

6E-82

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

6E-82

Check Engine Lamp (MIL) On Steady . ...

6E-83

ECM Diagnostic Trouble Codes . . . .

6E-84

DIAGNOSTIC TROUBLE CODE (DTC) P0100

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

6E-95

DIAGNOSTIC TROUBLE CODE (DTC) P0100

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

6E-95

DIAGNOSTIC TROUBLE CODE (DTC) P0100

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

6E-95

DIAGNOSTIC TROUBLE CODE (DTC) P0100

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

6E-95

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

6E-96

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

6E-96

Diagnostic Trouble Code (DTC) P0100

(Symptom Code 7) (Flash Code 65) Mass Air
Flow (MAF) Sensor Voltage Supply Circuit
High Input . . . . . . . . . . . .

6E-96

Diagnostic Trouble Code (DTC) P0100

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

6E-99

Diagnostic Trouble Code (DTC) P0100

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

6E-101

Diagnostic Trouble Code (DTC) P0100

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

6E-104

DIAGNOSTIC TROUBLE CODE (DTC) P0110

(SYMPTOM CODE 1) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT) SENSOR
CIRCUIT HIGH INPUT . . . . . . .

6E-107

DIAGNOSTIC TROUBLE CODE (DTC) P0110

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

6E-107

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

6E-107

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

6E-108

Diagnostic Trouble Code (DTC) P0110

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

6E-108

Diagnostic Trouble Code (DTC) P0110

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

6E-112

DIAGNOSTIC TROUBLE CODE (DTC) P0115

(SYMPTOM CODE 1) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT HIGH INPUT . . .

6E-115

DIAGNOSTIC TROUBLE CODE (DTC) P0115

(SYMPTOM CODE 2) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT . . . .

6E-115

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

6E-115

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

6E-116

Diagnostic Trouble Code (DTC) P0115 (Symptom

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

6E-116

Diagnostic Trouble Code (DTC) P0115 (Symptom

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

6E-120

DIAGNOSTIC TROUBLE CODE (DTC) P0180

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

6E-123

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

6E-123

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

6E-123

Diagnostic Trouble Code (DTC) P0180

(Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/
Performance . . . . . . . . . . .

6E-124

DIAGNOSTIC TROUBLE CODE (DTC) P0215

(SYMPTOM CODE A) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION . . . . . . . . . ...

6E-125

DIAGNOSTIC TROUBLE CODE (DTC) P0215

(SYMPTOM CODE B) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
CIRCUIT HIGH INPUT . . . . . . .

6E-125

DIAGNOSTIC TROUBLE CODE (DTC) P0215

(SYMPTOM CODE C) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE ALWAYS
ACTIVE . . . . . . . . . . . . .

6E-125

DIAGNOSTIC TROUBLE CODE (DTC) P0215

(SYMPTOM CODE D) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION . . . . . . . . . ...

6E-125

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

6E-126

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

6E-126

Diagnostic Trouble Code (DTC) P0215

(Symptom Code A) (Flash Code 52)

4JH1 ENGINE DRIVEABILITY AND EMISSIONS

6E–3

Fuel Cutoff Solenoid Valve Malfunction ...

6E-126

Diagnostic Trouble Code (DTC) P0215

(Symptom Code B) (Flash Code 52)
Fuel Cutoff Solenoid Valve Circuit
High Input . . . . . . . . . . . .

6E-128

Diagnostic Trouble Code (DTC) P0215

(Symptom Code C) (Flash Code 52)
Fuel Cutoff Solenoid Valve Always Active

6E-130

Diagnostic Trouble Code (DTC) P0215

(Symptom Code D) (Flash Code 52)
Fuel Cutoff Solenoid Valve Malfunction ...

6E-132

DIAGNOSTIC TROUBLE CODE (DTC) P0216

(SYMPTOM CODE A) (FLASH CODE 54)
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION (TIMER DEVIATION) .

6E-133

DIAGNOSTIC TROUBLE CODE (DTC) P0216

(SYMPTOM CODE B) (FLASH CODE 54)
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION (TIMER FLUCTUATION)

6E-133

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

6E-134

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

6E-134

Diagnostic Trouble Code (DTC) P0216

(Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit
Malfunction (Timer Deviation) . . . . ..

6E-134

Diagnostic Trouble Code (DTC) P0216

(Symptom Code B) (Flash Code 54)
Injection Timing Control Circuit
Malfunction (Timer Fluctuation) . . . ...

6E-135

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 6) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 7) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE 9) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE A) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE B) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE D) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

DIAGNOSTIC TROUBLE CODE (DTC) P0251

(SYMPTOM CODE E) (FLASH CODE 53)
INJECTION PUMP MALFUNCTION . ...

6E-137

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

6E-138

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

6E-138

Diagnostic Trouble Code (DTC) P0251

(Symptom Code 6) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-138

Diagnostic Trouble Code (DTC) P0251

(Symptom Code 7) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-140

Diagnostic Trouble Code (DTC) P0251

(Symptom Code 9) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-144

Diagnostic Trouble Code (DTC) P0251

(Symptom Code A) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-145

Diagnostic Trouble Code (DTC) P0251

(Symptom Code B) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-146

Diagnostic Trouble Code (DTC) P0251

(Symptom Code D) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-147

Diagnostic Trouble Code (DTC) P0251

(Symptom Code E) (Flash Code 53)
Injection Pump Malfunction . . . . . ..

6E-148

DIAGNOSTIC TROUBLE CODE (DTC) P0335

(SYMPTOM CODE B) (FLASH CODE
43)CRANKSHAFT POSITION SENSOR
CIRCUIT MALFUNCTION . . . . . ...

6E-149

DIAGNOSTIC TROUBLE CODE (DTC) P0335

(SYMPTOM CODE D) (FLASH CODE 43)
CRANKSHAFT POSITION SENSOR
MALFUNCTION . . . . . . . . . ...

6E-149

DIAGNOSTIC TROUBLE CODE (DTC) P0335

(SYMPTOM CODE E) (FLASH CODE 43)
ENGINE SPEED INPUT CIRCUIT RANGE/
PERFORMANCE . . . . . . . . . .

6E-149

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

6E-150

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

6E-150

Diagnostic Trouble Code (DTC) P0335

(Symptom Code B) (Flash Code 43)
Crankshaft Position Sensor Circuit
Malfunction . . . . . . . . . . . ..

6E-150

Diagnostic Trouble Code (DTC) P0335

(Symptom Code D) (Flash Code 43)
Crankshaft Position Sensor Malfunction ..

6E-150

Diagnostic Trouble Code (DTC) P0335

(Symptom Code E) (Flash Code 43)
Engine Speed Input Circuit Range/
Performance . . . . . . . . . . .

6E-155

DIAGNOSTIC TROUBLE CODE (DTC) P0380

(SYMPTOM CODE 4) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE LOW

6E-158

DIAGNOSTIC TROUBLE CODE (DTC) P0380

(SYMPTOM CODE 8) (FLASH CODE 66)
GLOW RELAY CIRCUIT VOLTAGE HIGH

6E-158

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

6E-158

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

6E-158