Isuzu 4HL1 User Manual

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WORKSHOP MANUAL

727 (N SERIES)

ENGINE CONTROL SYSTEM

(4HL1 ENGINE)

SECTION 1A

International Service & Parts

Tokyo, Japan

Table of Contents

Table of Contents3
Engine3
Engine Control System3
Engine Control System4
- Circuit Test Tools4
- Damage by Electrostatic Discharge4
- Wire Color4
Precautions on Service4
- ECM Description5
- Function of ECM5
- Electronic Control System5
Function and Operation5
- Calculation of Desired Injection Quantity7
- Injector Control7
- SCV Control (Pump Control)7
- Intake Throttle Control8
- EGR Control9
- Idle Stop Control Working Conditions10
- Exhaust Brake Control10
- QWS Working Conditions10
- QWS Control10
- Component Layout - Vehicle Side11
Powertrain System Components11
- Component Layout - Engine Side12
- ECT Sensor12
- EGR Valve and EGR Valve Position Sensor13
- Intake Throttle Valve and ITP Sensor13
- CMP Sensor13
- CKP Sensor14
- Scv14
- FT Sensor14
- Common Rail Pressure Sensor14
- AP Sensor15
- Clutch Switch15
- Idle Position Switch15
- IAT Sensor15
- Atmospheric Pressure Sensor16
- VS Sensor16
- Neutral Switch16
- Exhaust Brake Solenoid Valve16
- VIM17
- CHECK ENGINE Lamp (MIL)17
- Dlc17
- Fuse Layout18
- Spare Fuse18
- Relay Layout20
- ECM Circuit Diagram22
- VIM Circuit Diagram23
- ECM/VIM Circuit Diagram24
- Connector List31
- ECM Pinouts35
- H-835
- H-735
- 81-Way Connector (Engine Side)36
- 40-Way Connector (Vehicle Side)37
- VIM Pinouts38
- 26-Way Connector39
- 16-Way Connector39
- 12-Way Connector40
- 22-Way Connector40
- Strategy-Based System Diagnostics40
Strategy-Based Diagnostics40
- DTC Stored41
- No DTC41
- No Matching Symptom41
- Intermittents41
- Non-OEM Parts42
- Poor Vehicle Maintenance42
- Visual/Physical Engine Compartment Inspection42
- Basic Knowledge of Tools Required42
- Diagnostic Executive43
- Diagnostic Information43
- Input Components43
- Comprehensive Component Monitor Diagnostic Operation43
- Verifying Vehicle Repair44
- Diagnostic Trouble Code (DTC)44
- Reading Diagnostic Trouble Codes44
- Diagnostic Trouble Codes Not Stored44
- Diagnostic Trouble Codes Stored45
- Clearing Diagnostic Trouble Codes45
- ECM Voltage and Continuity Test/Measurement46
- Key Points on Hearing46
Functional Check List46
Hearing Diagnostic46
- Engine Control System Diagnostic Chart47
- Circuit Description49
- Diagnostic Aids49
- Test Description49
On-Board Diagnostic (OBD) System Check . 1A-4749
Inactive CHECK ENGINE Lamp Check52
Unblinking CHECK ENGINE Lamp Check56
- ECM Power Supply and Grounding System Circuit Check58
- Tech 2 Scan Tool61
- Features of Tech 261
Diagnosis with Tech 2 Scan Tool61
- Data Display64
- Snapshot64
- Diagnostic Trouble Codes64
- Menu Breakdown64
- Replaying Recorded Data Graph65
- Snapshot after Data Indication65
- Snapshot after Determination of Trigger Type65
- Actuator Test66
- ECM Date69
- ECM Data78
Diagnostic Chart90
- Conditions for Setting the DTC95
- Action Taken When the DTC Sets95
- Major Faulty Event95
DTC14 - CMP Sensor System Fault95
Conditions for Clearing MIL/DTC99
DTC15 - CKP Sensor System Fault99
DTC18 - Starter Degradation (for Only Vehicles Equipped with Idle Stop Function)103
DTC22 - IAT Sensor System Fault105
Characteristics of IAT Sensor (Reference)108
DTC23 - ECT Sensor System Fault109
DTC24 - Accelerator Sensor System Fault114
Fault115
- DTC25 - Vehicle Speed Sensor System Fault118
- DTC28 - PTO Accelerator Sensor System Fault122
DTC31 - Idle up Volume System Fault125
Idle up Volume Switch Description128
DTC33 - VIM Internal Fault (EEPROM Write Error)129
DTC34 - ECM Internal Fault (Charge Circuit Fault)131
Fault)132
DTC35 - VIM Internal Fault (A/D Conversion Fault)134
DTC43 - ITP Sensor System Fault136
Intake Throttle Valve Description140
DTC44 - EGR Valve Position Sensor System Fault141
DTC45 - EGR Valve System Fault146
DTC46 - Exhaust Brake System Fault149
DTC51 - ECM Internal Fault (CPU Error / CPU History Error)152
DTC52 - ECM Internal Fault (Sub CPU Error)154
- DTC61 - Intake Throttle Valve System Fault156
- DTC71 - Barometric Pressure Sensor Fault159
DTC81 - Clutch Switch System Fault161
- Second but Not more than 3 Seconds. (Press the Accelerator Pedal.) 2. Turn on the Idle Position Switch for Not Less than161
- Second but Not more than 3 Seconds. (Release the Accelerator Pedal.)161
- Second but Not more than 3 Seconds. (Release the Accelerator Pedal.) 3. Turn off the Idle Position Switch for Not Less than161
- If the DTC Is Not Detected, the Possible Cause Is Intermittent (Intermittent Fault)162
- Refer to OBD System Check162
- Second but Not more than 3 Seconds. (Press the Accelerator Pedal.) 6. after the above Operations Are Properly Completed, the CHECK ENGINE Lamp (MIL) I162
- Turn off the Starter Switch. Wait for 5 Seconds and Turn on the Starter Switch Again162
DTC82 - Neutral Switch System Fault165
DTC84 - CAN Communication Fault (CAN Bus Error)168
- Go to Step169
DTC86 - CAN Communication Fault (CAN Timeout Error)171
- Go to Step172
DTC115 - Common Rail Pressure Sensor Fixed Output Fault174
- DTC118 - Common Rail Pressure Fault (Control System)179
- DTC158 - Injector Power Supply System Short (Common 1)184
- DTC159 - Injector Power Supply System Short (Common 2)188
- Fault188
  - DTC211 - Fuel Temperature Sensor System Fault192
  - Characteristics of FT Sensor (Reference)196
- DTC217 - SCV Drive System Short197
- DTC227 - no Pump Pressure Feed (Fuel Leak)200
  - DTC241 - Idle Position Switch Circuit Open Wiring205
  - DTC242 - Idle Position Switch Circuit Short208
- DTC245 - Common Rail Pressure Sensor System Fault211
- DTC247 - SCV Drive System Fault217
- DTC277 - Injector Power Supply System Open Wiring Fault (Common 1)237
- DTC278 - Injector Power Supply System Open Wiring Fault (Common 2)241
- DTC416 - Main Relay System Fault245
- DTC417 - Starter Switch System Fault248
- DTC543 - High Engine Speed Error251
- Default Matrix Table252
- Special Tools258
Wiring Harness Repair: Shielded Cable259
- Removal Procedure259
- Installation Procedure259
Twisted Leads260
- Removal Procedure260
- Installation Procedure260
Weather-Pack Connector262
- Removal Procedure262
- Installation Procedure262
- Special Tools263
Com-Pack III264
- General Information264
Metri-Pack265
- Removal Procedure265
- Installation Procedure265
- Special Tools265

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Isuzu 4HL1 Specifications

General

Brand	Isuzu
Model	4HL1
Category	Control Systems
Language	English

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