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Isuzu Diesel Engine 4HK1 & 6HK1 Troubleshooting Manual – PDF DOWNLOAD
Isuzu Diesel Engine 4HK1 & 6HK1 Troubleshooting Manual – PDF DOWNLOAD
FILE DETAILS:
Isuzu Diesel Engine 4HK1 & 6HK1 Troubleshooting Manual – PDF DOWNLOAD
Language : English
Pages : 827
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Isuzu Diesel Engine 4HK1 & 6HK1 Troubleshooting Manual – PDF DOWNLOAD
Introduction...................................................................................................................................... 1 Control System.................................................................................................................................... 3 4/6HK1 Electronic Control Fuel Injection System (Common Rail Type)............................................................................ 3 How to Use This Manual.................................................................................................................... 6 How to use this manual................................................................................................................ 6 Table of abbreviation................................................................................................................. 7 Conversion formula.................................................................................................................... 8 About colors of wirings............................................................................................................... 9 About wiring diagrams................................................................................................................. 10 How to read trouble diagnosis section................................................................................................. 11 Precautions on Service Work............................................................................................................... 13 Electrical system..................................................................................................................... 13 Fuel injection system................................................................................................................. 13 Procedure of Trouble Diagnosis............................................................................................................ 15 About trouble diagnosis............................................................................................................... 15 Trouble diagnostic procedure.......................................................................................................... 16 Interview............................................................................................................................. 17 Pre-inspection........................................................................................................................ 19 Trouble diagnosis..................................................................................................................... 19 How to read DTC....................................................................................................................... 20 Confirmation after repair............................................................................................................. 22 List of final check items............................................................................................................. 22 How to clear DTC...................................................................................................................... 23 Trouble diagnosis with scan tool...................................................................................................... 24 How to Use Trouble Diagnosis-Related Tool................................................................................................. 30 Function of service tools............................................................................................................. 30 Tech2................................................................................................................................. 30 Tech2 data reference value............................................................................................................ 53 Rewriting of Q adjust correction data by Tech2........................................................................................ 73 Injector ID code (No. 1 cylinder - No. 6 cylinder or No. 4 cylinder) registration setting using Tech2................................. 80 ID code upload (Tech2)................................................................................................................ 88 ID code download (ECM)................................................................................................................ 92 TIS2000............................................................................................................................... 98 How to Inspect Injector...................................................................................................................108 How to use injector checker...........................................................................................................108 Method to identify using non-contact infrared thermometer.............................................................................112 Injector balance test (Tech2, EMPSIII)................................................................................................118 Trouble Diagnostic Tools (EMPS) for Industrial Engine.....................................................................................119 Introduction..........................................................................................................................119 List of functions of EMPS.............................................................................................................119 Cautions..............................................................................................................................120 EMPS Component Parts..................................................................................................................122 ECM (hardware) compatibility..........................................................................................................123 ECM Variation.........................................................................................................................123 System Requirements for EMPS Software (Recommended)...................................................................................123 EMPS (software) Setup Procedure.......................................................................................................124 EMPSIII...................................................................................................................................127 EMPSIII connection....................................................................................................................127 EMPSIII screen display................................................................................................................130 EMPS Operation Procedure..................................................................................................................133 1. Preparation........................................................................................................................133 2. ECM Reflash........................................................................................................................136 3. Injector Replacement...............................................................................................................155 4. Replace ECM (Same Model)...........................................................................................................169 5. Factory Setting....................................................................................................................196 6. Recover Point......................................................................................................................207 7. Error Messages.....................................................................................................................209 8. Error Code List....................................................................................................................216 How to Use Breaker Box....................................................................................................................226 Breaker box inspection procedure......................................................................................................226 Engine Control System.....................................................................................................................229 Description of function and operation for engine control (common rail) system.........................................................229 Engine control module (ECM)...........................................................................................................243 Engine component location diagram.....................................................................................................245 Wiring diagram of engine control module (ECM).........................................................................................262 Pin arrangement of engine control module (ECM)........................................................................................276 Circuit diagram.......................................................................................................................310 Engine harness location...............................................................................................................326 Connector list........................................................................................................................337 List of Function Checks...................................................................................................................340 List of function checks...............................................................................................................340 OBD system check......................................................................................................................341 Diagnosis lamp illumination circuit system check......................................................................................343 Diagnosis lamp blinking circuit system check..........................................................................................345 Scan tool power supply circuit system check (Tech2)...................................................................................348 Scan tool power supply circuit system check (EMPSIII).................................................................................350 Scan tool communication circuit system check..........................................................................................352 Starting circuit system check.........................................................................................................355 Starting system check.................................................................................................................360 Fuel system check.....................................................................................................................363 Intake system check...................................................................................................................367 Exhaust system check..................................................................................................................368 EGR control system check..............................................................................................................369 QOS system check......................................................................................................................372 List of Diagnostic Trouble Codes..........................................................................................................377 List of diagnostic trouble codes......................................................................................................377 DTC: P0087 (Flash code 227) Common rail low pressure fault (No pressure feed in supply pump)..........................................424 DTC: P0088 (Flash code 118) Common rail pressure is abnormally high (1st or 2nd stage)................................................434 DTC: P0089 (Flash code 151) Common rail pressure fault (Excessive pressure feed in supply pump).......................................440 DTC: P0090 (Flash code 247) SCV drive system open circuit, +B short or ground short...................................................445 DTC: P0107 (Flash code 71) Barometric pressure sensor circuit input is low (open circuit or ground short).............................451 DTC: P0108 (Flash code 71) Barometric pressure sensor circuit input is high (+5V short)...............................................458 DTC: P0112 (Flash code 22) Intake air temperature sensor fault (low voltage fault, GND short, short circuit)..........................465 DTC: P0113 (Flash code 22) Intake air temperature sensor fault (high voltage fault, open circuit or short to power supply circuit)....471 DTC: P0117 (Flash code 23) Engine coolant temperature sensor fault (low voltage fault, GND short, short circuit)......................478 DTC: P0118 (Flash code 23) Engine coolant temperature sensor input is high (open circuit or short to power supply)....................484 DTC: P0182 (Flash code 211) Fuel temperature sensor fault (low voltage fault, GND short)..............................................492 DTC: P0183 (Flash code 211) Fuel temperature sensor fault (high voltage fault, open circuit or short to power supply circuit).........498 DTC: P0192 (Flash code 245) Common rail pressure sensor fault (low voltage fault, short circuit)......................................506 DTC: P0193 (Flash code 245) Common rail pressure sensor fault (high voltage fault)....................................................512 DTC: P0201 (Flash code 271) Open circuit in injection nozzle #1 drive system..........................................................518 DTC: P0202 (Flash code 272) Open circuit in injection nozzle #2 drive system..........................................................525 DTC: P0203 (Flash code 273) Open circuit in injection nozzle #3 drive system..........................................................532 DTC: P0204 (Flash code 274) Open circuit in injection nozzle #4 drive system..........................................................539 DTC: P0205 (Flash code 275) Open circuit in injection nozzle #5 drive system..........................................................546 DTC: P0206 (Flash code 276) Open circuit in injection nozzle #6 drive system..........................................................551 DTC: P0219 (Flash code 543) Overrun...................................................................................................556 DTC: P0237 (Flash code 32) Boost pressure sensor fault (low voltage fault, open circuit)..............................................558 DTC: P0238 (Flash code 32) Boost pressure sensor fault (high voltage fault, short to power supply circuit, ground open circuit).......565 DTC: P0335 (Flash code 15) Crank sensor fault (no signal).............................................................................572 DTC: P0336 (Flash code 15) Crank sensor fault (signal fault)..........................................................................579 DTC: P0340 (Flash code 14) Cam sensor fault (no signal)...............................................................................585 DTC: P0341 (Flash code 14) Cam sensor fault (signal fault)............................................................................592 DTC: P0380 (Flash code 66) Glow relay circuit fault...................................................................................599 DTC: P0381 (Flash code 67) Glow plug lamp circuit fault...............................................................................604 DTC: P0487 (Flash code 44) EGR position sensor fault..................................................................................609 DTC: P0488 (Flash code 45) EGR valve control fault....................................................................................615 DTC: P0522 (Flash code 294) Engine oil pressure sensor fault (low voltage fault, open circuit, ground short)..........................621 DTC: P0523 (Flash code 294) Engine oil pressure sensor fault (high voltage fault, short to power supply, ground short)................627 DTC: P0601 (Flash code 53) ROM fault..................................................................................................635 DTC: P0603 (Flash code 54) EEPROM fault...............................................................................................637 DTC: P0606 (Flash code 51) CPU fault..................................................................................................639 DTC: P0606 (Flash code 52) CPU monitoring IC fault....................................................................................641 DTC: P0611 (Flash code 34) Charge circuit fault (bank 1)..............................................................................643 DTC: P0612 (Flash code 34) Charge circuit fault (bank 2)..............................................................................646 DTC: P0650 (Flash code 77) Diagnosis lamp circuit fault...............................................................................649 DTC: P1093 (Flash code 227) No pump pressure feed.....................................................................................654 DTC: P1095 (Flash code 225) Pressure limiter open.....................................................................................665 DTC: P1112 (Flash code 295) Boost temperature sensor fault (low voltage fault, ground short)..........................................676 DTC: P1113 (Flash code 295) Boost temperature sensor fault (high voltage fault, open circuit, short to power supply circuit)..........683 DTC: P1173 (Flash code 542) Overheat..................................................................................................690 DTC: P1225 (Flash code 31) Idle UP/DOWN switch fault..................................................................................695 DTC: P1261 (Flash code 158) Injection nozzle common 1 drive system fault..............................................................699 DTC: P1262 (Flash code 159) Injection nozzle common 2 drive system fault..............................................................710 DTC: P1271 (Flash code 24) Accelerator sensor 1-2 comparison fault....................................................................721 DTC: P1277 (Flash code 24) Accelerator sensor 1 fault (low voltage fault).............................................................727 DTC: P1278 (Flash code 24) Accelerator sensor 1 fault (high voltage fault)............................................................732 DTC: P1282 (Flash code 24) Accelerator sensor 2 fault (low voltage fault).............................................................737 DTC: P1283 (Flash code 24) Accelerator sensor 2 fault (high voltage fault)............................................................742 DTC: P1345 (Flash code 16) Cam sensor out of phase....................................................................................747 DTC: P1625 (Flash code 416) Main relay fault..........................................................................................752 DTC: P1630 (Flash code 36) A/D conversion fault.......................................................................................758 DTC: P1631 (Flash code 55) Voltage fault in 5-V power supply 1........................................................................760 DTC: P1632 (Flash code 55) Voltage fault in 5-V power supply 2........................................................................764 DTC: P1633 (Flash code 55) Voltage fault in 5-V power supply 3........................................................................768 DTC: P1634 (Flash code 55) Voltage fault in 5-V power supply 4........................................................................772 DTC: P1635 (Flash code 55) Voltage fault in 5-V power supply 5........................................................................776 DTC: U2104 (Flash code 84) CAN Bus fault..............................................................................................780 DTC: U2106 (Flash code 85) CAN timeout fault..........................................................................................785 List of Trouble Symptom...................................................................................................................790 List of trouble symptom...............................................................................................................790 Engine start failure..................................................................................................................791 Engine stall..........................................................................................................................799 Engine hunting, rough idling..........................................................................................................804 Engine output shortage................................................................................................................809 Exhaust gas contains a lot of white smoke.............................................................................................813 Exhaust gas contains a lot of black smoke.............................................................................................816 Noise.................................................................................................................................819 Fuel consumption deteriorates.........................................................................................................821 Oil consumption deteriorates..........................................................................................................824 Special Tool..............................................................................................................................826 List of special tool..................................................................................................................826
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