Isuzu N Series 2008 Instruction manual

WORKSHOP MANUAL
ENGINE CONTROL SYSTEM
(4JJ1 model)
No.LG4JJED-WE-0871
WORKSHOP MANUAL
ENGINE CONTROL SYSTEM (4JJ1 model)

This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
2 SUSPENSION 2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D1 Transfer Case (Part Time)
4 BRAKES 4B Brake
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME 11A Frame
51083Maegaki07.11.26 9:58AM ページ1

Engine Control System (4JJ1) 1A-1
ENGINE
Engine Control System
(4JJ1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3
Temperature vs Resistance . . . . . . . . . . . . . . . . 1A-3
Altitude vs Barometric Pressure. . . . . . . . . . . . . 1A-4
Diagnostic Trouble Code (DTC) Type
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . 1A-9
Routing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 1A-11
Fuel System Routing Diagram . . . . . . . . . . . . . 1A-11
Vacuum Hose Routing Diagram. . . . . . . . . . . . 1A-11
Component Locator. . . . . . . . . . . . . . . . . . . . . . . 1A-12
Engine Controls Component Views . . . . . . . . . 1A-12
Engine Control Module (ECM)
Connector End Views . . . . . . . . . . . . . . . . . . . 1A-17
Engine Control Connector End Views . . . . . . . 1A-19
Diagnostic Information and Procedures . . . . . . . 1A-30
Engine Control System Check Sheet. . . . . . . . 1A-30
Diagnostic Starting Point - Engine Controls . . . 1A-31
Diagnostic System Check - Engine Controls . . 1A-32
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-37
Scan Tool Data Definitions . . . . . . . . . . . . . . . . 1A-40
Scan Tool Output Controls . . . . . . . . . . . . . . . . 1A-45
Scan Tool Does Not Power Up. . . . . . . . . . . . . 1A-46
Scan Tool Does Not Communicate with
CAN Device (Euro 4 Specification) . . . . . . . . . 1A-47
Scan Tool Does Not Communicate with
Keyword Device
(Except Euro 4 Specification) . . . . . . . . . . . . . 1A-50
Lost Communication with
The Engine Control Module (ECM)
(Except Euro 4 Specification) . . . . . . . . . . . . . 1A-54
Engine Cranks but Does Not Run . . . . . . . . . . 1A-57
DTC P0016 (Flash Code 16) . . . . . . . . . . . . . . 1A-59
DTC P0045 (Flash Code 33) . . . . . . . . . . . . . . 1A-61
DTC P0079 or P0080 (Flash Code 38) . . . . . . 1A-64
DTC P0087 (Flash Code 225) . . . . . . . . . . . . . 1A-67
DTC P0088 (Flash Code 118) . . . . . . . . . . . . . 1A-72
DTC P0089 (Flash Code 151) . . . . . . . . . . . . . 1A-77
DTC P0091 or P0092 (Flash Code 247) . . . . . 1A-80
DTC P0093 (Flash Code 227) . . . . . . . . . . . . . 1A-83
DTC P0101 (Flash Code 92) . . . . . . . . . . . . . . 1A-89
DTC P0102 or P0103 (Flash Code 91) . . . . . . 1A-92
DTC P0107 or P0108 (Flash Code 32) . . . . . . 1A-96
DTC P0112 or P0113 (Flash Code 22) . . . . .1A-100
DTC P0116 (Flash Code 23) . . . . . . . . . . . . . 1A-104
DTC P0117 or P0118 (Flash Code 23) . . . . .1A-106
DTC P0122 or P0123 (Flash Code 43) . . . . . 1A-110
DTC P0182 or P0183 (Flash Code 211) . . . . 1A-114
DTC P0192 or P0193 (Flash Code 245) . . . . 1A-118
DTC P0201, P0202, P0203 or P0204
(Flash Code 271, 272, 273 or 274) . . . . . . . .1A-122
DTC P0217 (Flash Code 542) . . . . . . . . . . . .1A-130
DTC P0219 (Flash Code 543) . . . . . . . . . . . .1A-132
DTC P0234 (Flash Code 42) . . . . . . . . . . . . .1A-134
DTC P0299 (Flash Code 65) . . . . . . . . . . . . .1A-137
DTC P0335 (Flash Code 15) . . . . . . . . . . . . .1A-140
DTC P0336 (Flash Code 15) . . . . . . . . . . . . .1A-143
DTC P0340 (Flash Code 14) . . . . . . . . . . . . .1A-145
DTC P0341 (Flash Code 14) . . . . . . . . . . . . .1A-148
DTC P0380 (Flash Code 66) . . . . . . . . . . . . .1A-150
DTC P0381 (Flash Code 67) . . . . . . . . . . . . .1A-152
DTC P0401 (Flash Code 93) . . . . . . . . . . . . .1A-155
DTC P0404 (Flash Code 45) . . . . . . . . . . . . .1A-158
DTC P0409 (Flash Code 44) . . . . . . . . . . . . .1A-161
DTC P0426 (Flash Code 143) . . . . . . . . . . . .1A-164
DTC P0427 or P0428 (Flash Code 48) . . . . .1A-166
DTC P042B (Flash Code 145) . . . . . . . . . . . .1A-171
DTC P042C or P042D (Flash Code 49). . . . .1A-173
DTC P0477 or P0478 (Flash Code 46) . . . . .1A-178
DTC P0500 (Flash Code 25) . . . . . . . . . . . . .1A-181
DTC P0502 or P0503 (Flash Code 25) . . . . .1A-184
DTC P0560 (Flash Code 155) . . . . . . . . . . . .1A-190
DTC P0563 (Flash Code 35) . . . . . . . . . . . . .1A-193
DTC P0601 (Flash Code 53) . . . . . . . . . . . . .1A-194
DTC P0602 (Flash Code 154) . . . . . . . . . . . .1A-195
DTC P0604, P0606 or P060B
(Flash Code 153, 51 or 36) . . . . . . . . . . . . . .1A-197
DTC P0633 (Flash Code 176) . . . . . . . . . . . .1A-198
DTC P0638 (Flash Code 61) . . . . . . . . . . . . .1A-199
DTC P0641 (Flash Code 55) . . . . . . . . . . . . .1A-202
DTC P0650 (Flash Code 77) . . . . . . . . . . . . .1A-205
DTC P0651 (Flash Code 56) . . . . . . . . . . . . .1A-208
DTC P0685 or P0687 (Flash Code 416) . . . . 1A-211
DTC P0697 (Flash Code 57) . . . . . . . . . . . . .1A-214
DTC P1093 (Flash Code 227) . . . . . . . . . . . .1A-217
DTC P1261 or P1262 (Flash Code 34) . . . . .1A-222
DTC P1404 (Flash Code 45) . . . . . . . . . . . . .1A-223
DTC P1455 (Flash Code 132) . . . . . . . . . . . .1A-225
DTC P1471 (Flash Code 149) . . . . . . . . . . . .1A-227
DTC P161B (Flash Code 179) . . . . . . . . . . . .1A-230
DTC P1621 (Flash Code 54) . . . . . . . . . . . . .1A-232
DTC P1664 (Flash Code 76) . . . . . . . . . . . . .1A-233
DTC P1669 (Flash Code 75) . . . . . . . . . . . . .1A-236
DTC P2122 or P2123 (Flash Code 121) . . . .1A-241
DTC P2127 or P2128 (Flash Code 122) . . . .1A-245
DTC P2138 (Flash Code 124) . . . . . . . . . . . .1A-249
DTC P2146 or P2149
(Flash Code 158 or 159) . . . . . . . . . . . . . . . . 1A-251
DTC P2227 (Flash Code 71) . . . . . . . . . . . . .1A-256
LG4JJED-WE-0871.book 1 ページ ２００８年４月４日 金曜日 午前９時６分

1A-2 Engine Control System (4JJ1)
DTC P2228 or P2229 (Flash Code 71) . . . . . 1A-259
DTC P242F (Flash Code 131) . . . . . . . . . . . . 1A-263
DTC P2452 (Flash Code 142) . . . . . . . . . . . . 1A-265
DTC P2453 (Flash Code 141) . . . . . . . . . . . . 1A-268
DTC P2454 or P2455 (Flash Code 47) . . . . . 1A-271
DTC P2456 (Flash Code 47) . . . . . . . . . . . . . 1A-276
DTC P2458 (Flash Code 139) . . . . . . . . . . . . 1A-278
DTC P2527 or P2528 (Flash Code 233) . . . . 1A-281
DTC P253A (Flash Code 28) . . . . . . . . . . . . . 1A-286
DTC P256A (Flash Code 31) . . . . . . . . . . . . . 1A-289
DTC U0073 (Flash Code 84) . . . . . . . . . . . . . 1A-293
DTC U0101 (Flash Code 85) . . . . . . . . . . . . . 1A-296
DTC U0167 (Flash Code 177) . . . . . . . . . . . . 1A-298
EGR Control System Check. . . . . . . . . . . . . . 1A-299
Glow Control System Check . . . . . . . . . . . . . 1A-303
Engine Warm Up Control System Check . . . . 1A-306
Exhaust Brake Control System Check. . . . . . 1A-309
Diesel Particulate Defuser (DPD)
Control System Check . . . . . . . . . . . . . . . . .1A-315
Symptoms - Engine Controls . . . . . . . . . . . . . .1A-321
Symptoms - Engine Controls . . . . . . . . . . . . . 1A-321
Intermittent Conditions . . . . . . . . . . . . . . . . . . 1A-323
Hard Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-326
Rough, Unstable, or
Incorrect Idle and Stalling . . . . . . . . . . . . . . .1A-328
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . 1A-330
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-331
Surges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-332
Lack of Power, Sluggishness or Sponginess . 1A-334
Hesitation, Sag or Stumble. . . . . . . . . . . . . . . 1A-336
Abnormal Combustion Noise . . . . . . . . . . . . .1A-338
Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . 1A-339
Excessive Smoke (Black Smoke) . . . . . . . . . 1A-341
Excessive Smoke (White Smoke) . . . . . . . . . 1A-343
DPD System Manual Regeneration
Frequently . . . . . . . . . . . . . . . . . . . . . . . . . . .1A-345
DPD System Regeneration Long Time . . . . . 1A-347
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-349
Engine Control Module (ECM) Replacement . 1A-349
Service Programming System (SPS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . .1A-351
Service Programming System
(SPS) (Remote Procedure) . . . . . . . . . . . . . . 1A-352
Service Programming System (SPS)
(Pass-Thru Procedure) . . . . . . . . . . . . . . . . .1A-353
Description and Operation . . . . . . . . . . . . . . . . 1A-355
Engine Control Module (ECM) Description . .1A-355
Engine Control Component Description. . . . . 1A-358
Fuel System Description . . . . . . . . . . . . . . . . 1A-362
Fuel System Component Description. . . . . . .1A-363
Fuel Injection System Description . . . . . . . . . 1A-367
Exhaust Gas Recirculation (EGR)
System Description . . . . . . . . . . . . . . . . . . . . 1A-368
Turbocharger Description. . . . . . . . . . . . . . . .1A-369
Diesel Particulate Defuser (DPD)
System Description . . . . . . . . . . . . . . . . . . . . 1A-372
Special Tools and Equipment . . . . . . . . . . . . . .1A-375
Special Tools and Equipment . . . . . . . . . . . . . 1A-375
LG4JJED-WE-0871.book 2 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-3
Specifications
Temperature vs Resistance
Engine Coolant Temperature vs. Resistance
Exhaust Temperature vs. Resistance
Fuel Temperature vs. Resistance
Intake Air Temperature vs. Resistance (Euro 4
Specification)
°C°FOhms
Temperature vs. Resistance Value (Approximately)
120 248 115
110 230 150
100 212 190
90 194 250
80 176 330
70 158 450
60 140 610
50 122 840
40 104 1200
30 86 1730
20 68 2560
10 50 3870
0 32 6000
-10 14 9200
-20 -4 15700
-30 -22 26500
°C°FOhms
Temperature vs. Resistance Value (Approximately)
1000 1832 120
950 1742 135
900 1652 155
850 1562 180
800 1472 205
750 1382 240
700 1292 290
650 1202 345
600 1112 425
550 1022 530
500 932 675
450 842 885
400 752 1200
350 662 1710
300 572 2580
250 482 4300
200 392 6900
150 302 13900
100 212 33600
50 122 106000
°C°FOhms
Temperature vs. Resistance Value (Approximately)
110 230 140
100 212 180
90 194 240
80 176 310
70 158 420
60 140 580
50 122 810
40 104 1150
30 86 1660
20 68 2450
10 50 3700
0325740
-10 14 9160
-20 -4 15000
-30 -22 25400
°C°FOhms
Temperature vs. Resistance Value (Approximately)
100 212 190
90 194 240
80 176 320
70 158 430
60 140 590
50 122 810
40 104 1150
30 86 1650
20 68 2430
10 50 3660
0325550
-10 14 8970
-20 -4 14700
°C°FOhms
Temperature vs. Resistance Value (Approximately)
LG4JJED-WE-0871.book 3 ページ ２００８年４月４日 金曜日 午前９時６分

1A-4 Engine Control System (4JJ1)
Intake Air Temperature vs. Resistance (Except Euro
4 Specification)
Altitude vs Barometric Pressure
°C°FOhms
Temperature vs. Resistance Value (Approximately)
100 212 180
90 194 240
80 176 330
70 158 470
60 140 670
50 122 980
40 104 1460
30 86 2240
20 68 3510
10 50 5660
0 32 9400
-10 14 16200
-20 -4 28590
Altitude Measured
in Meters (m)
Altitude Measured
in Feet (ft)
Barometric
Pressure
Measured in
Kilopascals (kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
4267 14000 56-64
3962 13000 58-66
3658 12000 61-69
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105
LG4JJED-WE-0871.book 4 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-5
Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC
Action Taken When the DTC Sets - Type A
• The ECM illuminates the malfunction indicator
lamp (MIL) when the diagnostic runs and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Freeze Frame/ Failure Records.
(Euro 4 specification)
Action Taken When the DTC Sets - Type B
• The ECM illuminates the MIL on the second
consecutive driving cycle when the diagnostic runs
and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the ECM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive driving cycle, the
ECM records the operating conditions at the time
of failure and stores this information in the Freeze
Frame and updates the Failure Records.
Conditions for Clearing the MIL/ DTC - Type A or
Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail. (Euro 4 specification)
• The ECM turns OFF the MIL after 1 ignition cycle
when the diagnostic runs and does not fail. (Except
Euro 4 specification)
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported. (Euro 4
specification)
• A history DTC clears after 20 consecutive driving
cycles, if no failures are reported. (Except Euro 4
specification)
• Use a scan tool to clear the MIL and the DTC.
Non-Emissions Related DTCs
Action Taken When the DTC Sets - Type C
• The ECM illuminates the Service Vehicle Soon
(SVS) lamp when the diagnostic runs and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Failure Records.
Conditions for Clearing the SVS Lamp/ DTC - Type
C
• The ECM turns OFF the SVS lamp after 1 driving
cycle when the diagnostic runs and does not fail.
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported.
• Use a scan tool to clear the SVS lamp and the
DTC.
Action Taken When the DTC Sets - Type D
• The ECM will not illuminate the MIL or SVS lamp.
• The ECM records the operating conditions at the
time the diagnostic fails. The ECM stores this
information in the Failure Records. (Euro 4
specification)
Conditions for Clearing the DTC - Type D
• A current DTC clears when the diagnostic runs and
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported. (Euro 4
specification)
• A history DTC clears after 20 consecutive driving
cycles, if no failures are reported. (Except Euro 4
specification)
• Use a scan tool to clear the DTC.
LG4JJED-WE-0871.book 5 ページ ２００８年４月４日 金曜日 午前９時６分

1A-6 Engine Control System (4JJ1)
Diagnostic Trouble Code (DTC) List
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi-
cation
Except
Euro 4
Specifi-
cation
P0016 16 A A Crankshaft Position - Camshaft Position Correlation
P0045 33 A – Turbocharger Boost Control Solenoid Circuit
P0079 38 A – Exhaust Valve Control Solenoid Circuit Low
P0080 38 A – Exhaust Valve Control Solenoid Circuit High
P0087 225 A A Fuel Rail/ System Pressure Too Low
P0088 118 D A Fuel Rail/ System Pressure Too High (First Stage)
P0088 118 A A Fuel Rail/ System Pressure Too High (Second Stage)
P0089 151 A A Fuel Pressure Regulator Performance
P0091 247 A A Fuel Pressure Regulator Control Circuit Low
P0092 247 A A Fuel Pressure Regulator Control Circuit High
P0093 227 A A Fuel System Leak Detected
P0101 92 B – Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A – Mass Air Flow Sensor Circuit Low Input
P0103 91 A – Mass Air Flow Sensor Circuit High Input
P0107 32 A A Manifold Absolute Pressure Sensor Circuit Low Input
P0108 32 A A Manifold Absolute Pressure Sensor Circuit High Input
P0112 22 A A Intake Air Temperature Sensor Circuit Low
P0113 22 A A Intake Air Temperature Sensor Circuit High
P0116 23 B – Engine Coolant Temperature Sensor Circuit Range/ Performance
P0117 23 A A Engine Coolant Temperature Sensor Circuit Low
P0118 23 A A Engine Coolant Temperature Sensor Circuit High
P0122 43 A – Throttle Position Sensor Circuit Low
P0123 43 A – Throttle Position Sensor Circuit High
P0182 211 A A Fuel Temperature Sensor Circuit Low
P0183 211 A A Fuel Temperature Sensor Circuit High
P0192 245 A A Fuel Rail Pressure Sensor Circuit Low
P0193 245 A A Fuel Rail Pressure Sensor Circuit High
P0201 271 A A Injector Circuit Open - Cylinder 1
P0202 272 A A Injector Circuit Open - Cylinder 2
P0203 273 A A Injector Circuit Open - Cylinder 3
P0204 274 A A Injector Circuit Open - Cylinder 4
P0217 542 D D Engine Coolant Over Temperature Condition
P0219 543 D A Engine Overspeed Condition
P0234 42 A A Turbocharger Overboost Condition
P0299 65 B – Turbocharger Underboost
P0335 15 A A Crankshaft Position Sensor Circuit
VN53-sec1A(secid3566)print.fm 6 ページ ２００８年４月２日 水曜日 午後９時２５分

Engine Control System (4JJ1) 1A-7
P0336 15 A A Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 A A Camshaft Position Sensor Circuit
P0341 14 A – Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C A Glow Plug Circuit
P0381 67 C A Glow Plug Indicator Circuit
P0401 93 A – EGR Flow Insufficient Detected
P0404 45 A A EGR Control Circuit Range/ Performance
P0409 44 A A EGR Position Sensor Circuit
P0426 143 C – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1
P0427 48 A – Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 48 A – Catalyst Temperature Sensor Circuit High Sensor 1
P042B 145 C – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2
P042C 49 C – Catalyst Temperature Sensor Circuit Low Sensor 2
P042D 49 C – Catalyst Temperature Sensor Circuit High Sensor 2
P0477 46 – A Exhaust Pressure Control Valve Low
P0478 46 – A Exhaust Pressure Control Valve High
P0500 25 B A Vehicle Speed Sensor
P0502 25 A A Vehicle Speed Sensor Circuit Low Input
P0503 25 A A Vehicle Speed Sensor Circuit High Input
P0560 155 A – System Voltage
P0563 35 C A System Voltage High
P0601 53 A A Internal Control Module Memory Check Sum Error
P0602 154 C A Control Module Programming Error
P0604 153 A A Internal Control Module RAM Error
P0606 51 A A ECM Processor
P060B 36 A A Internal Control Module A/D Processing Performance
P0633 176 C A Immobilizer Not Programmed
P0638 61 B A Throttle Actuator Control Range/ Performance
P0641 55 A A Sensor Reference Voltage 1 Circuit
P0650 77 A D Malfunction Indicator Lamp (MIL) Control Circuit
P0651 56 A A Sensor Reference Voltage 2 Circuit
P0685 416 C A ECM Power Relay Control Circuit Open
P0687 416 C A ECM Power Relay Control Circuit High
P0697 57 A A Sensor Reference Voltage 3 Circuit
P1093 227 A A Fuel Rail Pressure Too Low
P1261 34 A A Injector Positive Voltage Control Circuit Group 1
P1262 34 A A Injector Positive Voltage Control Circuit Group 2
P1404 45 A – EGR Position Fault (Closed Position Error)
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi-
cation
Except
Euro 4
Specifi-
cation
LG4JJED-WE-0871.book 7 ページ ２００８年４月４日 金曜日 午前９時６分

1A-8 Engine Control System (4JJ1)
P1404 45 A A EGR Position Fault (Learned Position Error)
P1455 132 A – PM Over Accumulation
P1471 149 A – DPD Insufficient Regeneration
P161B 179 C A Immobilizer Wrong Response
P1621 54 A A Control Module Long Tern Memory Performance
P1664 76 C – Service Vehicle Soon Lamp Control Circuit
P1669 75 C – DPD Lamp Control Circuit
P2122 121 B A Pedal Position Sensor 1 Circuit Low Input
P2123 121 B A Pedal Position Sensor 1 Circuit High Input
P2127 122 B A Pedal Position Sensor 2 Circuit Low Input
P2128 122 B A Pedal Position Sensor 2 Circuit High Input
P2138 124 B A Pedal Position Sensor 1-2 Voltage Correlation
P2146 158 A A Fuel Injector Group 1 Supply Voltage Circuit
P2149 159 A A Fuel Injector Group 2 Supply Voltage Circuit
P2227 71 B – Barometric Pressure Sensor Circuit Range/ Performance
P2228 71 A A Barometric Pressure Sensor Circuit Low
P2229 71 A A Barometric Pressure Sensor Circuit High
P242F 131 A – DPD Restriction
P2452 142 A – DPD Differential Pressure Sensor Circuit
P2453 141 A – DPD Differential Pressure Sensor Circuit Range/ Performance
P2454 47 A – DPD Differential Pressure Sensor Circuit Low
P2455 47 A – DPD Differential Pressure Sensor Circuit High
P2456 47 A – DPD Differential Pressure Sensor Learned Position
P2458 139 A – DPD Regeneration Duration
P2527 233 A – Vacuum Pressure Sensor Circuit Low
P2528 233 A – Vacuum Pressure Sensor Circuit High
P253A 28 C A PTO Sensor Circuit
P256A 31 C A Engine Idle Speed Selector Sensor
U0073 84 B A Control Module Communication Bus Off
U0101 85 C A Lost Communication with TCM
U0167 177 C A Lost Communication With Vehicle Immobilizer Control Module
DTC Flash
Code
DTC Type
DTC Descriptor
Euro 4
Specifi-
cation
Except
Euro 4
Specifi-
cation
LG4JJED-WE-0871.book 8 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-9
Overview Wirings
Overview Wirings
1/2
LNW71AXF001801
13245768
9 10111213141516
PTO throttle sensor
Accel pedal position sensor 1
Accel pedal position sensor 2
BARO sensor
Mass air flow sensor
Intake air temperature sensor
Exhaust differential pressure sensor
Vehicle speed sensor or EHCU
Exhaust temperature sensor 2
Exhaust temperature sensor 1
Clutch switch
Exhaust brake switch
DPD switch
Water separator switch
A/C switch
Engine warm up switch
Condenser
fan relay
Heater & A/C
relay Refrigerant
pressure switch
A/C unit
Neutral switch
Parking brake switch
PTO switch
Oil level switch
Ignition switch (on)
Ignition switch (start)
Main relay
Dropping
resistor
Case ground
Signal ground
Signal ground
Power ground
Power ground
Power ground
Key position
Battery 24V
MIL
Glow lamp
DPD lamp
Oil pressure lamp
Water separator lamp
Oil pressure switch
Glow relay
Glow plug
Starter cut relay
Starter relay
Exhaust brake solenoid valve
Tacho meter
ECM
70
41
Idle up sensor 66
20
63
42
24
46
21
40
2
5
35
81
43
62
1
3
4
6
11
16
Exhaust brake lamp
7
SVS lamp
17
9
10
31
14
15
8
38
52
18
37
64
60
71
23
69
22
72
39
73
79
67
80
74
19
28
47
Refrigerator switch 33
26
45
51
34
50
48
44
53
61
BCM or DRMIP clusterTCMEHCU
EURO 2
EURO 4
EURO 4
EURO 4
EURO 4
EURO 4
EURO 4
EURO 3
Intake air temperature sensor
EURO 2
EURO 3
B
A
C
A
A
C
B
A
C
B
LG4JJED-WE-0871.book 9 ページ ２００８年４月４日 金曜日 午前９時６分

1A-10 Engine Control System (4JJ1)
2/2
LNW71AXF001901
EURO 4
EURO 4
EURO 4
EURO 3
EURO 4
Crank shaft position sensor
Boost pressure sensor
Intake throttle position sensor
Engine coolant temperature sensor
Fuel temperature sensor
EGR motor
U
V
W
U
V
W
EGR position sensor
Fuel rail pressure sensor
Camshaft position sensor
Fuel injector 1
Intake throttle solenoid
Fuel injector 3
Fuel injector 2
Fuel injector 4
Fuel rail pressure regulator
Exhaust throttle solenoid valve
ECM
121
119
117
112
104
116
120
118
105
113
89
97
102
Turbocharger control solenoid valve
96
68
95
107
109
108
91
VNT vacuum pressure sensor 92
85
87
98
101
100
82
90
84
83
111
103
110
94
93
99
MM+
M-
M
Immobilizer
control unit
(ICU)
CAN Resistor
58
78
Cylinder #1
Cylinder #4
Cylinder #3
Cylinder #2
Ground
13245768
9 10111213141516
B
LG4JJED-WE-0871.book 10 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-11
Routing Diagrams
Fuel System Routing Diagram
Legend
1. Fuel rail
2. Pressure limiter valve
3. Leak off pipe
4. Fuel injector
5. Fuel return pipe
6. Fuel feed pipe
7. Fuel tank
8. Vent valve
9. Priming pump
10. Fuel filter with water separator
11. Return fuel flow back valve
12. Fuel supply pump
Vacuum Hose Routing Diagram
Legend
1. Vacuum pressure sensor
2. Turbocharger nozzle control solenoid valve
3. Vacuum pipe
4. Brake booster
5. Vacuum pump
6. Actuator control vacuum hose
7. Turbocharger nozzle control actuator
LNW76ESF001801
11 10 9
8
12
5
6
123
47
LNW76ESF000201
2
43
5
7
6
1
LG4JJED-WE-0871.book 11 ページ ２００８年４月４日 金曜日 午前９時６分

1A-12 Engine Control System (4JJ1)
Component Locator
Engine Controls Component Views
Legend
1. Barometric pressure (BARO) sensor 2. Accelerator pedal position (APP) sensor
Legend
1. Fuel injector No.1 cylinder
2. Fuel injector No.2 cylinder
3. Fuel injector No.3 cylinder
4. Fuel injector No.4 cylinder
5. Exhaust gas recirculation (EGR) valve
6. Intake throttle valve
7. Turbocharger nozzle control solenoid valve (Euro 4
specification)
8. Boost pressure sensor
LNW81ASF001201
1
2
LNW81ASF001401
1234 5
876
LG4JJED-WE-0871.book 12 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-13
Legend
1. Variable nozzle turbocharger (VNT) vacuum pressure
sensor (Euro 4 specification)
2. Engine coolant temperature (ECT) sensor
3. Camshaft position (CMP) sensor
Legend
1. Fuel rail pressure (FRP) regulator
2. Fuel temperature (FT) sensor
3. Pressure limiter valve
4. Fuel rail pressure (FRP) sensor
5. Engine oil pressure switch
6. Crankshaft position (CKP) sensor
7. Engine oil level switch
LNW81ASF001501
12
3
LNW81ASF001601
76
12 3 4 5
LG4JJED-WE-0871.book 13 ページ ２００８年４月４日 金曜日 午前９時６分

1A-14 Engine Control System (4JJ1)
Legend
1. Exhaust brake valve
2. Exhaust temperature sensor 2 (in front of oxygen
catalyst)
3. Exhaust temperature sensor 1 (in front of filter)
4. Exhaust differential pressure sensor
5. Exhaust throttle valve
6. DPD assembly
Legend
1. Mass air flow (MAF) sensor/ intake air temperature
(IAT) sensor (Euro 4 specification)
2. Intake air temperature (IAT) sensor (except Euro 4
specification)
LNW76ESF000901
1
2
3
4
5
6
LNW81ASF001701
12
LG4JJED-WE-0871.book 14 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-15
Legend
1. Vehicle speed sensor (VSS) (without ABS model)
Legend
1. CAN resistor (LHD) (with immobilizer model) 2. CAN resistor (RHD) (with immobilizer model)
LNW76ESF001101
1
LNW81ASF001801
2
1
LG4JJED-WE-0871.book 15 ページ ２００８年４月４日 金曜日 午前９時６分

1A-16 Engine Control System (4JJ1)
NHR, NLR, NMR model
Legend
1. Engine control module (ECM) 2. Dropping resistor (Euro 4 specification)
NNR, NPR model
Legend
1. Engine control module (ECM) 2. Dropping resistor (Euro 4 specification)
SF
LNW81ASF001001
1
2
LNW81ASF000101
12
LG4JJED-WE-0871.book 16 ページ ２００８年４月４日 金曜日 午前９時６分

Engine Control System (4JJ1) 1A-17
Engine Control Module (ECM) Connector
End Views
Engine Control Module (ECM)
Connector No. J14
Connector color Black
Test adapter No. J-35616-64A
Pin No. Wire color Pin function
1 BLK ECM power ground
2 WHT/ RED Battery voltage
3 BLK ECM power ground
4 BLK ECM power ground
5 WHT/ RED Battery voltage
6 YEL/ BLK MIL control
7 BRN/ WHT Exhaust brake lamp control
8 LT GRN Engine speed signal output
9LT GRN/
BLK
DPD amber lamp control (Euro 4
specification)
10 WHT/ GRN Glow relay control
11 ORN/ BLU Glow plug lamp control
12 – Not used
13 – Not used
14 BLK/ RED Starter cut relay control
15 WHT/ RED Exhaust brake solenoid valve
control
16 BLU/ YEL Engine oil level lamp control
17 BRN/ GRN SVS lamp control (Euro 4
specification)
18 BLU/ WHT CAN high signal
LNW76ESH001501
54
17
55
74
18
56
75
19
57
76
20
58
77
21
59
78
22
60
79
23
61
80
24
62
81
9
47
66
10
48
67
11
49
68
6
44
63
7
45
64
8
46
65
12
50
69
13
51
70
14
52
71
15
53
72
16
36 37 38 39 40 41 42 4328 29 3025 26 27 31 32 33 34 35
54
73 21
3
19 YEL/ GRN
VSS signal (without ABS) or
vehicle speed signal from EHCU
(with ABS)
20 BLU/ WHT APP sensor 1 shield ground
21 BLU/ YEL ECM main relay control
22 BLK MAF sensor low reference (Euro 4
specification)
23 RED/ BLU MAF sensor 12 volts reference
(Euro 4 specification)
24 BLK/ BLU Ignition voltage
25 – Not used
26 WHT/ BLK Clutch pedal switch signal
(Manual transmission)
27 – Not used
28 ORN/ GRN Water separator switch signal
29 – Not used
30 – Not used
31 BRN/ WHT Water separator lamp control
32 – Not used
33 BLU/ BLK Refrigerator switch signal
34 BRN/ YEL A/C signal
35 GRN Dropping resistor (Euro 4
specification)
36 – Not used
37 BLU CAN low signal
38 LT BLU Keyword 2000 serial data (except
Euro 4 specification)
39 BLK/ WHT APP sensor 2 and MAF sensor
shield ground
40 BLU/ YEL ECM main relay control
41 BLU/ RED APP sensor 1, idle up sensor and
PTO throttle sensor low reference
42 BLU
APP sensor 1, idle up sensor and
PTO throttle sensor 5 volts
reference
43 BLK ECM signal ground
44 VIO/ WHT PTO switch signal
45 LT GRN/
RED Exhaust brake switch signal
46 BLK/ WHT Ignition switch signal
47 BLU/ WHT DPD regeneration switch signal
(Euro 4 specification)
48 YEL Parking brake switch signal
Connector No. J14
Connector color Black
Test adapter No. J-35616-64A
Pin No. Wire color Pin function
LG4JJED-WE-0871.book 17 ページ ２００８年４月４日 金曜日 午前９時６分