Isuzu 4JJ1-TC User manual

FOR SERVICE TRAINING
4JJ1-TC ENGINE
-Engine Mechanical Features-
-Engine Control System & Diagnosis-
Applicable Model
Model Year Vehicle Model Main Market
2005 TFR/TFS Thailand
2005 UCR/UCS Thailand & Philippine
ISUZU MOTORS LIMITED
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DAFTAR ISI
Page
PENDAHULUAN & FITUR MEKANIKAL
MESIN ------------------------------------------------------------------------------ 1
DATA UTAMA MESIN & SPESIFIKASI ----------------------------------------------------------------------------- 2
ENGINE CONTROL MODULE (ECM) ------------------------------------------------------------------------------ 4
KOMPONEN ELEKTRIKAL ------------------------------------------------------------------------------ 13
MASS AIR FLOW (MAF) SENSOR & INTAKE
AIR TEMPERATURE (IAT) SENSOR ------------------------------------------------------------------------------ 13
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR ------------------------------------------------------------------------------ 16
FUEL TEMPERATURE (FT) SENSOR ------------------------------------------------------------------------------ 18
CRANKSHAFT POSITION (CKP) SENSOR &
CAMSHAFT POSITION (CMP) SENSOR ------------------------------------------------------------------------------ 20
VEHICLE SPEED (VS) SENSOR ------------------------------------------------------------------------------ 26
BAROMETRIC PRESSURE (BARO) SENSOR ------------------------------------------------------------------------------ 28
ACCELERATOR PEDAL POSITION (APP)
SENSOR ------------------------------------------------------------------------------ 30
SWIRL CONTROL SOLENOID VALVE ------------------------------------------------------------------------------ 35
SYSTEM BAHAN BAKAR ----------------------------------------------------------------------------- 37
FITUR COMMON RAIL SYSTEM ----------------------------------------------------------------------------- 37
FUEL SUPPLY PUMP ------------------------------------------------------------------------------ 38
FUEL RAIL (COMMON RAIL) ------------------------------------------------------------------------------ 45
FUEL RAIL PRESSURE (FRP) SENSOR ------------------------------------------------------------------------------ 47
FUEL INJECTOR ------------------------------------------------------------------------------ 49
FITUR SALURAN BAHAN BAKAR ----------------------------------------------------------------------------- 57
IN-TANK FUEL PUMP & SENDER UNIT ----------------------------------------------------------------------------- 58
BYPASS ONE-WAY VALVE ------------------------------------------------------------------------------ 60
FUEL FILTER & WATER SEPARATOR ------------------------------------------------------------------------------ 60
FUEL INJECTION QUANTITY CONTROL ------------------------------------------------------------------------------ 61
EGR (EXHUAST GAS RE-CIRCULATION)
SYSTEM ------------------------------------------------------------------------------ 69
EGR VALVE ------------------------------------------------------------------------------ 70
INTAKE THROTTLE (IT) VALVE ------------------------------------------------------------------------------ 72
PREHEATING SYSTEM ------------------------------------------------------------------------------ 77
DIAGNOSTIC ------------------------------------------------------------------------------ 79
MALFUNCTION INDICATOR LAMP (MIL) ------------------------------------------------------------------------------ 79
DATA LINK CONNECTOR (DLC) ------------------------------------------------------------------------------ 80
FLASH DIAGNOSTIC TROUBLE CODE ------------------------------------------------------------------------------ 81
TECH 2 SCAN TOOL ------------------------------------------------------------------------------ 81
TECH 2 DATA & DEFINISINYA ------------------------------------------------------------------------------85
BREAKER BOX ------------------------------------------------------------------------------ 91
DIAGNOSTIC SYSTEM CHECK ------------------------------------------------------------------------------ 92
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MESIN BERPUTAR TETAPI TIDAK HIDUP ----------------------------------------------------------------------------- 95
ECM DIAGNOSTIC TROUBLE CODE (DTC)
LIST ------------------------------------------------------------------------------ 99
HASIL DIAGNOSA GEJALA ------------------------------------------------------------------------------ 111
CHECK SHEET ENGINE CONTROL SYSTEM ----------------------------------------------------------------------------- 113
WIRING DIAGRAM ELEKTRIKAL ------------------------------------------------------------------------------ 134
DISTRIBUSI POWER (1 of 2) ----------------------------------------------------------------------------- 134
DISTRIBUSI POWER (2 of 2) ----------------------------------------------------------------------------- 135
STARTING & CHARGING SYSTEM ------------------------------------------------------------------------------ 136
ECM POWER ------------------------------------------------------------------------------ 137
ECM GROUND ------------------------------------------------------------------------------ 138
GAUGES & WARNING LAMPS ------------------------------------------------------------------------------ 139
A/C CONTROL, GLOW CONTROL &
NEUTRAL SWITCH ------------------------------------------------------------------------------ 140
RELAY, FUSE & SLOW BLOW FUSE
LOCATION (ENGINE ROOM) ------------------------------------------------------------------------------ 141
FUSE LOCATION (CABIN) ------------------------------------------------------------------------------ 142
LOKASI GROUND ----------------------------------------------------------------------------- 143
PETUNJUK PERBAIKAN ----------------------------------------------------------------------------- 144
ENGINE CONTROL MODULE (ECM)
PENGGANTIAN/ FUEL INJECTOR ID CODE &
IMMOBILIZER PROGRAMMING
------------------------------------------------------------------------------ 144
PENGGANTIAN FUEL INJECTOR / FUEL
INJECTOR ID CODE PROGRAMMING ------------------------------------------------------------------------------ 151
PENGGANTIAN FUEL SUPPLY PUMP ----------------------------------------------------------------------------- 153
SERVICE SPECIAL TOOL (SST) ------------------------------------------------------------------------------ 161
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4JJ1-TC Engine-1
INTRODUCTION & ENGINE MECHANICAL FEATURES
Truck pick-up TFR/ TFS dan UCR/UCS tahun 2007
memakai mesisn 4JK1-TC pengganti mesin 4JA1-T
dan mesin 4JJ1-TC pengganti mesin 4JH1- T. Kedua
mesin telah dikembangkan sebagai mesin generasi terbaru
dengan tambahan fitur utama yaitu penggunaan common
rail fuel injection system yang menghasilkan maksimum
kenaikan pada output dan torque, dan juga masuk dalam
standar regulasi emisi Euro 3.Berikut adalah garis besar
dari dari item tersebut dibawah ini:
Sistem common rail multi fuel injection type high-
pressure system dan dibuat oleh Denso.
Double overhead camshaft (DOHC) dengan 4 valves per
cylinder yang dioperasikan oleh roller rocker arm.
Chain driven intake dan exhaust camshaft.
Electrical control EGR valve, water-cooled EGR
cooler.
Electrical control intake throttle.
Variable swirl control system.
Turbocharger dengan intercooler.
Aluminum cylinder head.
Induction hardening cylinder liner.
Cylinder block menyatu dengan oil cooler.
Gear driven vacuum pump, power steering oil pump
dan oil pump mesin.
Engine Type Maximum Output Maximum Toruque
4JK1-TC 85kw/ 3600RPM 280Nm/ 1800 - 2200RPM
4JJ1-TC (A/T) 107kw/ 3600RPM 294Nm/ 1400 - 3400RPM
4JJ1-TC (M/T) 103kw/ 3600RPM 280Nm/ 1200 - 3400RPM
Transmisi yang dipakai model Isuzu MUA5H manual untuk
4JK1-TC, MUA5G manual untuk 4JJ1-TC. JATCO JR405E
automatic transmission untuk 4JJ1-TC berikut optionalnya.
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4JJ1-TC Engine-2
1. Fuel Rail
2. Leak Off Pipe
3. Fuel Injector
4. Return Pipe
5. Fuel Feed Pipe
6. Fuel Tank
7. Fuel Pump & Sender
Assembly
8. Fuel Filler Cap
9. Check Valve
10.Fuel Filter with Water
Separator
11.Bypass One-way
Valve
12.Fuel Supply Pump
DATA UTAMA MESIN & SPESIFIKASI
Engine Model 4JK1-TC 4JJ1-TC
Engine Type Diesel, Four Cycle
Cylinder Layout - Number of Cylinders Inline-Four Cylinders
Fuel Injection Order 1-3-4-2
Bore x Stroke (mm) 95.4 x 87.4 95.4 x 104.9
Total Displacement (cc) 2499 2999
Compression Ratio 17.5 18.3
Compression Pressure at Cranking More than 3Mpa
Combustion Camber Type Direct Injection
Cylinder Liner Liner Less
Engine Idle Speed (RPM) 700 ±25
Fast Engine Idle Speed (RPM) 750 ±25
No Load Maximum Engine Speed (RPM) 4700 ±50 4400 ±50
Fuel System Common Rail System
Injection Pump Type DENSO (HP3) Supply Pump
Injection Nozzle Type Electrical Controlled Injector
Number of Injection Hole 6
Diameter of Injection Hole (mm) 0.13 0.14
Injection Nozzle Operating Pressure (MPa) Electrically Controlled
Fuel Filter Type Cartridge Paper Element & Water Separator
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4JJ1-TC Engine-3
Valve System
Valve Layout Double Overhead Camshaft
Drive Type Gear & Chain Drive
Intake Valve Open At BTDC (°CA) 13.0
Intake Valve Close At ABDC (°CA) 41.0
Exhaust Valve Open At BBDC (°CA) 52.0
Exhaust Valve Close At ATDC (°CA) 6.0
Intake Valve Clearance At Cold (mm) 0.15 (Between roller and camshaft)
Exhaust Valve Clearance At Cold (mm) 0.15 (Between roller and camshaft)
Cooling System
Cooling Method Water Cooled
Water Capacity (litter/gal) 14
Water Pump Type Centrifugal Impeller Type
Thermostat Type Wax Pellet
Thermostat Opening Temperature (°C / °F) 85 /185
Lubricating System
Lubricating Method Full Flow Pressure Circulation
Oil Pump Type Gear
Oil Capacity (litter) 8
Oil Filter Type Cartridge Paper Element
Air Cleaner Type Dry Paper Element
EGR System W/Cooler & Electrical Control EGR Valve
PCV System Closed Type
Preheating System Glow Plug
Starting System
Starter Motor Output (V-kW) 12 – 2.3
Charge System
Alternator Output (V-A) 12 – 90
Regulator Type IC
Battery Size 65D31L
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4JJ1-TC Engine-4
ENGINE CONTROL MODULE (ECM)
ECM ditempatkan didalam ruangan mesin memakai
mounting bracket dan dekat dengan rumah air cleaner
ECM mempunyai kemampuan 32 bits dan dibuat oleh
Delphi. Fungsi utama ECM adalah mengontrol
sebagai berikut.
Mengontrol Fuel injection
Mengontrol Fuel Injection timing
Mengontrol Exhaust gas recirculation (EGR) system
Mengontrol Preheating system
Mengontrol kerja A/C compressor
Mengontrol kerja Fuel pump
Mengontrol Immobilizer (jika dilengkapi)
Mengatur system On-board diagnostics untuk mesin.
ECM secara konstan mengawasi informasi dari
beberapa sensor. ECM mengontrol system yang
mempengaruhi performance kendaraan. ECM meng
atur fungsi diagnosa pada system. ECM dapat
rmelakukan rekonsiliasi masalah, mengingatkan penge-
mudi dengan malfunction indicator lamp (MIL),
dan menyimpan diagnostic trouble code (DTCs).
untuk diidentifikasi oleh teknisi saat melakukan perbaikan.
1. Isuzu Parts Number
2. Delphi Parts Number
3. Transmission Type
4. 1st & last digit of Isuzu Parts Number
5. Broadcast Code
6. Assembled Factory Code
7. Engineering Revision Level
8. Product Date
9. Product Sequential Number
Diaggnostic dikerjakan didalam microprocessor yang
terintegrasi didalam ECM. Electronically erasable pro -
grammable read only memory (EEPROM) menyimpan
data-data seperti, data VIN, data immobilizer dan data
kode ID injector untuk pengontrolan mesin dan komunikasi
dengan control module yang lainnya.
Catatan!Jika ECM akan diganti maka program
yang sesuai HARUS diinstal / diprogram kedalam
ECM yang baru.
Data Kode ID Fuel Injector (24, 0-9 atau A-F
character untuk setiap fuel injector)
Immobilizer (jika dilengkapi)
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4JJ1-TC Engine-5
ECM Connector Pin Assignment
Pin No. Fungsi Pin Pin No. Fungsi Pin Pin No. Fungsi Pin
J1-1 Blank J1-26 Engine Coolant Temperature (ECT)
Sensor Low Reference J1-51 No. 3 Cylinder Fuel Injector Power Supply
J1-2 Blank J1-27 Engine Coolant Temperature (ECT)
Sensor Signal J1-52 No. 1 Cylinder Fuel Injector Power Supply
J1-3 Blank J1-28 Fuel Temperature (FT) Sensor Low
Reference J1-53 No. 4 Cylinder Fuel Injector Solenoid Control
J1-4 Blank J1-29 Fuel Temperature (FT) Sensor Signal J1-54 Suction Control Valve (SCV) High
Control
J1-5 Blank J1-30 EGR Valve Position Sensor Low
Reference J1-55 Intake Throttle Valve Motor 12 Volts Supply
J1-6 Blank J1-31 EGR Valve Position Sensor 5 Volts
Reference J1-56 Intake Throttle Valve Motor Duty Signal Control
J1-7 Blank J1-32 EGR Valve Position Sensor Signal J1-57 Intake Throttle Valve Position Sensor
Signal
J1-8 Blank J1-33 No. 1 Cylinder Fuel Injector Solenoid
Control J1-58 Crankshaft Position (CKP) Sensor Signal
J1-9 Blank J1-34 Suction Control Valve (SCV) High
Control J1-59 Not Used
J1-10 Blank J1-35 Intake Throttle Valve Position Sensor
Low Reference J1-60 ECM Ground (Immobilizer Only)
J1-11 Blank J1-36 Intake Throttle Valve Position Sensor
5 Volts Reference J1-61 Intake Air Temperature (IAT) Sensor Low Reference
J1-12 Blank J1-37 Crankshaft Position (CKP) Sensor 5
Volts Reference J1-62 EGR Valve Motor 12 Volts Supply
J1-13 Blank J1-38 Crankshaft Position (CKP) Sensor
Shield Ground J1-63 EGR Valve Motor Duty Signal Control
J1-14 Blank J1-39 Crankshaft Position (CKP) Sensor
Low Reference J1-64 Camshaft Position (CMP) Sensor Shield Ground
J1-15 Blank J1-40 Mass Air Flow (MAF) Sensor Signal J1-65 Not Used
J1-16 Blank J1-41 Intake Air Temperature (IAT) Sensor
Signal J1-66 Fuel Pump Relay Control
J1-17 Barometric Pressure (BARO) Sensor
Low Reference J1-42 Mass Air Flow (MAF) Sensor Shield Ground J1-67 Swirl Control Solenoid Valve Control
J1-18 Barometric Pressure (BARO) Sensor
Signal J1-43 Mass Air Flow (MAF) Sensor Low Reference J1-68 Fuel Rail Pressure (FRP) Sensor Signal
J1-19 Barometric Pressure (BARO) Sensor 5
Volts Reference J1-44 Camshaft Position (CMP) Sensor Low Reference J1-69 Fuel Rail Pressure (FRP) Sensor Low Reference
J1-20 Not Used J1-45 Camshaft Position (CMP) Sensor
Signal J1-70 Suction Control Valve (SCV) Low Control
J1-21 Not Used J1-46 Camshaft Position (CMP) Sensor 5
Volts Reference J1-71 No. 2 Cylinder Fuel Injector Power Supply
J1-22 Not Used J1-47 Fuel Rail Pressure (FRP) Sensor 5
Volts Reference J1-72 No. 4 Cylinder Fuel Injector Power Supply
J1-23 Not Used J1-48 Fuel Rail Pressure (FRP) Sensor
Signal J1-73 ECM Ground
J1-24 No. 2 Cylinder Fuel Injector Solenoid
Control J1-49 Fuel Rail Pressure (FRP) Sensor Shield Ground
J1-25 No. 3 Cylinder Fuel Injector Solenoid
Control J1-50 Suction Control Valve (SCV) Low Control
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4JJ1-TC Engine-6
Pin No. Fungsi Pin Pin No. Fungsi Pin Pin No. Fungsi Pin
J2-1 Not Used J2-26 Accelerator Pedal Position (APP)
Sensor 2 Shield Ground J2-51 Not Used
J2-2 Diagnostic Request Switch to Data
Link Connector (DLC) No. 6 J2-27 Accelerator Pedal Position (APP) Sensor 1 Low Reference J2-52 Battery Voltage Feed (Backup)
J2-3 Neutral Switch Input J2-28 Accelerator Pedal Position (APP)
Sensor 1 Shield Ground J2-53 Not Used
J2-4 Thermo Replay Signal Input J2-29 Not Used J2-54 Not Used
J2-5 Not Used J2-30 Not Used J2-55 A/C Compressor Relay Control
J2-6 Not Used J2-31 Not Used J2-56 Accelerator Position Output Duty Signal
J2-7 Accelerator Pedal Position (APP)
Sensor 3 5 Volts Reference J2-32 Not Used J2-57 Malfunction Indicator Lamp (MIL) Control
J2-8 Accelerator Pedal Position (APP)
Sensor 3 Signal J2-33 Engine Speed Signal Output J2-58 Not Used
J2-9 Accelerator Pedal Position (APP)
Sensor 2 5 Volts Reference J2-34 Not Used J2-59 Not Used
J2-10 Accelerator Pedal Position (APP)
Sensor 2 Signal J2-35 Not Used J2-60 Not Used
J2-11 Accelerator Pedal Position (APP)
Sensor 1 5 Volts Reference J2-36 Not Used J2-61 Not Used
J2-12 Accelerator Pedal Position (APP)
Sensor 1 Signal J2-37 Glow Replay Control J2-62 Vehicle Speed Sensor Signal Input
J2-13 Not Used J2-38 Not Used J2-63 ECM Main Relay 12 Volts Supply
J2-14 Not Used J2-39 Not Used J2-64 Not Used
J2-15 Not Used J2-40 Not Used J2-65 Not Used
J2-16 Not Used J2-41 Not Used J2-66 Not Used
J2-17 Not Used J2-42 Not Used J2-67 Not Used
J2-18 Not Used J2-43 ECM Main Relay 12 Volts Supply J2-68 Keyword 2000 to Data Link Connector
(DLC) No. 7
J2-19 Not Used J2-44 Starter Signal Input J2-69 Not Used
J2-20 Not Used J2-45 Not Used J2-70 Not Used
J2-21 Not Used J2-46 Not Used J2-71 Not Used
J2-22 Not Used J2-47 Not Used J2-72 Ignition Switch Voltage Input
J2-23 Accelerator Pedal Position (APP)
Sensor 3 Low Reference J2-48 Not Used J2-73 ECM Main Relay Voltage Input
J2-24 Accelerator Pedal Position (APP)
Sensor 3 Shield Ground J2-49 Not Used
J2-25 Accelerator Pedal Position (APP)
Sensor 2 Low Reference J2-50 Not Used
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4JJ1-TC Engine-7
DTC yang berhubungan Fail-Safe (Back Up)
Sub System Status
DTC
(Kode
Gejala)
Nama DTC di
Scan Tool
Kondisi untuk
Menjalankan
DTC
Kondisi untuk
Menentukan DTC Fuel
Injection
Quantity
Limitation EGR
Control
Intake
Throttle
Control
Status
Control
Lainnya
Kemungkinan Penyebab
P0601
(1) ECM Program
Code
Checksum
-Total data ROM
tidak sama dengan
nilai register.
--- -
Kerusakan ECM.
ECM ground resistannya besar atau kurang kencang
P0601
(2) ECM
Calibration
Checksum
-Total data ROM
tidak sama dengan
nilai register
kalibrasi.
--- -
Kerusakan ECM.
ECM ground resistannya besar atau kurang kencang
P0601
(3) ECM Memory
Failure -Kesaahan Pemba- caan data didalam
EEPROM.
--- -
Kerusakan ECM.
ECM ground resistannya besar atau kurang kencang
P0601
(4) ECM Memory
Failure -Kesalahan data VIN atau immobilizer
data didalam
EEPROM.
--- -
Kerusakan ECM.
ECM ground resistannya besar atau kurang kencang
P0601
(5) ECM Memory
Failure -Kesalahan ID code Injector didalam
EEPROM.
--- -
Kerusakan ECM.
ECM ground resistannya besar atau kurang kencang
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