Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual — part 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 . . . . . .
(4JA1-TC LHD) (1/2) . . . . . . . ...
(4JA1-TC LHD) (2/2) . . . . . . . ...
(4JA1-TC RHD) (1/2) . . . . . . . ...
(4JA1-TC RHD) (2/2) . . . . . . . ...
(4JH1-TC RHD M/T) (1/2) . . . . . ...
(4JH1-TC RHD M/T) (2/2) . . . . . ...
(4JH1-TC RHD A/T) (1/2) . . . . . .
(4JH1-TC RHD A/T) (2/2) . . . . . .
GROUND LOCATION . . . . . . . ...
LOCATION (4JA1-TC LHD) . . . . .
6E-22
LOCATION (4JA1-TC RHD) . . . . .
6E-23
LOCATION (4JH1-TC RHD) . . . . .
6E-24
CONNECTOR LIST . . . . . . . . ...
6E-25
RELAY AND FUSE . . . . . . . . .
RELAY AND FUSE BOX LOCATION (LHD)
RELAY AND FUSE BOX LOCATION (RHD)
RELAY & FUSE LOCATION . . . . . .
RELAY & FUSE LOCATION . . . . . .
ECM WIRING DIAGRAM (1/7) . . . . ..
ECM WIRING DIAGRAM (2/7) . . . . ..
ECM WIRING DIAGRAM (3/7) . . . . ..
ECM WIRING DIAGRAM (4/7) . . . . ..
ECM WIRING DIAGRAM (5/7) . . . . ..
ECM WIRING DIAGRAM (6/7) . . . . ..
ECM WIRING DIAGRAM (7/7) . . . . ..
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JA1-TC) . . . . ..
PSG CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JA1-TC) . . . . ..
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JH1-TC) . . . . ..
PSG CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL (4JH1-TC) . . . . ..
GENERAL DESCRIPTION FOR ECM AND
SENSORS . . . . . . . . . . . ...
Engine Control Module (ECM) . . . . ...
Pump Control Unit (PSG) & Data Exchange
Between Control Module . . . . . . .
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor . . . . . ...
Pedal/Throttle Position Sensor (TPS) . .
Crankshaft Position (CKP) Sensor . . .
Engine Coolant Temperature (ECT)
Sensor . . . . . . . . . . . . . .
Vehicle Speed Sensor (VSS) . . . . . .
EGR EVRV (4JA1-TC Only) . . . . . ..
GENERAL DESCRIPTION FOR INJECTION
PUMP . . . . . . . . . . . . . ..
Outline . . . . . . . . . . . . . ...
Characteristic of VP44 Injection System .
Cross-section View . . . . . . . . .
Low Pressure Fuel Circuit . . . . . . ..
High Pressure Fuel Circuit . . . . . . .
Timing Control . . . . . . . . . . ...
Start of Injection . . . . . . . . . . .
ISUZU Strategy Based Diagnostics . . . ..
Overview . . . . . . . . . . . . .
CHART . . . . . . . . . . . . .
Diagnostic Thought Process . . . . . ..
1. Verify the Complaint . . . . . . . ..
2. Perform Preliminary Checks . . . . ..
3. Check Bulletins and Troubleshooting
Hints . . . . . . . . . . . . . .
4. Perform Service Manual Diagnostic
Checks . . . . . . . . . . . . . .
5a and 5b. Perform Service Manual
Diagnostic Procedures . . . . . . . .
5c. Technician Self Diagnoses . . . . ..
5d. Intermittent Diagnosis . . . . . . ..
5e. Vehicle Operates as Designed . . .
6. Re-examine the complaint . . . . . .
6E–2
4JA1-TC/4JH1-TC ENGINE DRIVEABILITY AND EMISSIONS
GENERAL SERVICE INFORMATION . ...
ON-BOARD DIAGNOSTIC (OBD) . . . .
(START UP) . . . . . . . . . . .
TYPICAL SCAN DATA & DEFINITIONS
4JA1-TC (ENGINE DATA) . . . . .
TYPICAL SCAN DATA & DEFINITIONS
4JH1-TC (ENGINE DATA) . . . . ...
MISCELLANEOUS TEST . . . . . . ..
Plotting Snapshot Graph . . . . . . ...
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) . . ..
Flow Chart for Snapshot Replay
(Plotting Graph) . . . . . . . . . ...
SNAPSHOT DISPLAY WITH TIS2000 . ..
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK . . . . . . . . . . . . .
Circuit Description . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . ..
Test Description . . . . . . . . . . .
On-Board Diagnostic (OBD) System Check
NO CHECK ENGINE LAMP (MIL) . . . .
Circuit Description . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . ..
No Check Engine Lamp (MIL) . . . . ...
STEADY . . . . . . . . . . . . ..
Circuit description . . . . . . . . . ..
Diagnostic Aids . . . . . . . . . . ..
Check Engine Lamp (MIL) On Steady . ...
ECM Diagnostic Trouble Codes . . . .
DIAGNOSTIC TROUBLE CODE (DTC) P0100
DIAGNOSTIC TROUBLE CODE (DTC) P0100
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE B) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT LOW INPUT . . . . . . . .
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT . . . . . . .
Circuit Description . . . . . . . . . .
Diagnostic Aids . . . . . . . . . . ..
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage
Supply Circuit High Input . . . . . . .
Diagnostic Trouble Code (DTC) P0100
Diagnostic Trouble Code (DTC) P0100
Diagnostic Trouble Code (DTC) P0100
DIAGNOSTIC TROUBLE CODE (DTC) P0110
(SYMPTOM CODE 1) (FLASH CODE 23)
INTAKE AIR TEMPERATURE (IAT)
SENSOR CIRCUIT HIGH INPUT . . .
DIAGNOSTIC TROUBLE CODE (DTC) P0110
Circuit Description . . . . . . . . . ..
Diagnostic Aids . . . . . . . . . . ..
Diagnostic Trouble Code (DTC) P0110
Diagnostic Trouble Code (DTC) P0110
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 1) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT HIGH INPUT . . .
DIAGNOSTIC TROUBLE CODE (DTC) P0115
(SYMPTOM CODE 2) (FLASH CODE 14)
ENGINE COOLANT TEMPERATURE
SENSOR CIRCUIT LOW INPUT . . . .
Circuit Description . . . . . . . . . ..
Diagnostic Aids . . . . . . . . . . ..
Diagnostic Trouble Code (DTC) P0115
Diagnostic Trouble Code (DTC) P0115
DIAGNOSTIC TROUBLE CODE (DTC) P0180
(SYMPTOM CODE B) (FLASH CODE 15)
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE . . . . . ...
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