4jh1 ISUZU TF SERIES 2004 Workshop Manual

6E–56 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
101 101 CKP Se nso r Shie ld
LineBLK Continuity
with
gro und- - - Connect Ohm 101 GND
102 102 No Connection - - - - - - - - -
103 103 No Connection - - - - - - - - -
104 104 No Connection - - - - - - - - -
105 105 So le no id Valve Shut
Off (MAB) Output Sig-
na l to PSG No.5ORG - - - - - - - -Signal or Continuity Tester Position
Pin
No. B/Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRange (+) (-)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–57
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM &
PSG Con-
nectionRang
e(+) (-)
1 99 CAN (Contro lle r Area
Ne two rk) to ECM
No.99RED Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 1 99
(EC
M)
2 100 CAN (Contro lle r Area
Ne two rk) to ECM
No .100WHT Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 2 100
(EC
M)
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut
Off (MAB) Output
Signa l to ECM
No .105ORG Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 5 105
(EC
M)
6 - Ground BLK Continu-
ity with
gro und- - - Disco n-
nectOhm 6 GND
7 - Batte ry Powe r Sup-
plyBLU/
REDLess
tha n 1V10-14V Disco n-
nectOhm 7 GND
8 91 CKP Sensor Output
ECM No.91 to Pump
Co ntrol Unit (PSG)PNK Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 8 91
(EC
M)
9 - No Connection - - - - - - - - -

6E–58 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNA L
View Looking Into ECM Case
Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)
1 1 ECM Gro und BLK Co ntinu-
ity with
ground---Discon-
ne ctOh m 1 GND
2 2 ECM Gro und BLK Co ntinu-
ity with
ground---Discon-
ne ctOh m 2 GND
3 3 Batte ry Powe r Sup-
plyBLU/
REDLe ss
tha n 1V10-14V Co nnect DC V 3 GND
2525No Connection---------
2626No Connection---------
27 27 Engine Spee d Output
(To Ta cho Mete r)LGN - - Approx .
23Hz by
wave
fo rm or
approx.
6.3V Approx.
67Hz by
wave
fo rm or
approx.
6.8V Co nnect AC V 27 GND
2828No Connection---------
29 29 Throttle Positio n Sig-
na l To TCM (A16)
(AT Only )- Appro x . 140Hz by wav e fo rm (Idle:
Off duty 10% / WOT: Off duty 90%)- ---
30 30 Bra ke Switch 1 Sig-
na lGRN Le ss
tha n 1VPedal is not stepped on: Less than
1V
Pedal is stepped on: 10-14VCo nnect DC V 30 GND
31 31 Clutch Switch Signa l
(MT Only )YEL Less
tha n 1VPedal is not stepped on: 10-14V
Pe da l is ste ppe d o n: Le ss tha n 1VCo nnect DC V 31 GND
3232No Connection---------
33 33 A/C ON Signa l Rela y GRN/
YELLe ss
tha n 1VA/C request switch is turned on: 10-
14V
A/C reque st switch is turne d off:
Less than 1VCo nnect DC V 33 GND
3434No Connection---------
35 35 To Data Link Co n-
necto r No. 6 & Immo-
bilize r Co ntrol Unit
(ICU B8)YEL--------
3636No Connection---------

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–59
3737No Connection---------
38 38 Throttle Po sitio n
Se nso r (TPS) Out-
put Signa lGRN/
ORGLe ss
tha n 1VLess than 1V Approx.
0.5VCo nnect DC V 38 49
39 39 Ke y Switch Input Sig-
nal Via Engine FuseWH T L e s s
tha n 1V10-14V Co nnect DC V 39 GND
4040No Connection---------
41 41 A/C Compressor
RelayWH T/
GRNLe ss
tha n 1V10-14V A/C comp. is o pe r-
ated: Less than 1V
A/C comp. is no t o pe r-
ate d: 10 - 14VCo nnect DC V 41 GND
42 42 Check Engine La mp GRN/
YELLe ss
tha n 1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 42 GND
43 43 Glo w Lamp ORG/
BLULe ss
tha n 1VLamp is turned on: Less than 1V
Lamp is turned off: 10-14VCo nnect DC V 43 GND
4444No Connection---------
45 45 To Data Link Co n-
necto r No . 6BLU Less
tha n 1V10-14V Co nnect DC V 45 GND
4646No Connection---------
4747No Connection---------
4848No Connection---------
49 49 Throttle Po sitio n
Se nso r (TPS)
GroundBLK/
GRNIdle:
Appro x.
0.4K
ohm /
WO T:
Appro x.
4.0K
ohm---Discon-
ne ctOh m 3 8 4 9
5050No Connection---------
5151No Connection---------
5252No Connection---------
5353No Connection---------
5454No Connection---------
5555No Connection---------
5656No Connection---------
57 57 Throttle Po sitio n
Senso r (TPS) Po wer
SupplyRED/
GRNLe ss
tha n 1VApprox. 5V Connect DC V 57 49
58 58 ECM Re la y BLU/
BLK10-14V Less than 1V Connect DC V 58 GND
5959No Connection---------
6060No Connection---------
6161No Connection---------
6262No Connection---------Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)

6E–60 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
63 63 ECM Po wer Supply - Le ss
tha n 1V10-14V - DC V 63 GND
6464No Connection---------
65 65 Bra ke Switch 2 Sig-
na lWH T/
BLKLe ss
tha n 1VPedal is not stepped on: 10-14V
Pe da l is ste ppe d o n: Le ss tha n 1VCo nnect DC V 65 GND
6666No Connection---------
6767No Connection---------
68 68 Ve hicle Spe ed Sen-
sor (VSS)YEL/
GRN- Appro x. 14.5Hz by wa ve fo rm or
approx. 6.0V at vehicle speed
20km/hCo nnect AC V 68 GND
69 69 Idle Switch GRN/
BLKLe ss
tha n 1VPedal is not stepped on: Less than
1V
Pedal is stepped on: Approx. 5VCo nnect DC V 69 GND
7070No Connection---------
7171No Connection---------
7272No Connection---------
7373No Connection---------
7474No Connection---------
7575No Connection---------
7676No Connection---------
7777No Connection---------
7878No Connection---------
7979No Connection---------
8080No Connection---------
8181No Connection---------
82 82 Boo st Pre ssure Sen-
so r (High Altitude
Spe c. Onl y )WH T/
BLULe ss
tha n 1VApprox. 5V Connect DC V 82 93
83 83 Ma ss Air Flow (MAF)
Se nso r Po wer Sup-
plyWH T/
REDLe ss
tha n 1VApprox. 5V Connect DC V 83 92
84 84 Intake Air Tempera-
ture (IAT) Se nso r
SignalBLK/
BLULe ss
tha n 1V0 deg. C: Approx. 3.6V / 20 deg. C:
Approx. 2.6V / 40 deg. C: Approx.
1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7VCo nnect DC V 84 92
85 85 Manifo ld Pre ssure
Se nsor (High Alti-
tude Spe c. Only)RED/
BLULe ss
tha n 1V- - - Co nnect DC V 85 93
8686No Connection---------
87 87 Neutra l Switch BLK/
WH TLe ss
tha n 1VIn neutral (A/T: P or N): Less than
1 V
Othe r tha n neutra l (A/T: o ther tha n
P o r N): 10-14VCo nnect DC V 87 GND
88 88 Ma ss Air Flow (MAF)
Sensor SignalGRN/
REDLe ss
tha n 1VAppro x.
1V Approx .
1.8VApprox.
2.5VCo nnect DC V 88 92 Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–61
89 89 Engine Coolant Tem-
perature (ECT) Sen-
sor Signa lGRY Le ss
tha n 1V0 deg. C: Approx. 4.4V / 20 deg. C:
Approx. 3.8V / 40 deg. C: Approx.
2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4VCo nnect DC V 89 93
90 90 CKP Senso r Signal RED - - Approx .
47Hz by
wave
form Approx.
134Hz by
wave
fo rm or
approx.
1.1VCo nnect AC V 90 98
91 91 CKP Sensor Output
To Pump Contro l Unit
(PSG) No.8PNK - - Approx .
47Hz by
wave
form Approx.
134Hz by
wave
fo rm or
approx.
0.7VCo nnect AC V 91 GND
92 92 Ma ss Air Flow (MAF)
Se nso r Gro undBLK/
REDCo ntinu-
ity with
ground- - - Connect Ohm 92 GND
93 93 Engine Coolant Tem-
perature (ECT) Sen-
so r & Ma nifo ld
Pressure Sensor
GroundBLK/
PNKCo ntinu-
ity with
ground- - - Connect Ohm 93 GND
94 94 Glo w Re la y BLK/
REDLe ss
tha n 1VGlow system is operated: Less than
1 V
Glow system is not operated: 10 -
14VCo nnect DC V 94 GND
9595No Connection---------
96 96 Turbo charge r Wa ste-
ga te Contro l EVRVBRW/
RED- - Wav e form - - - -
97 97 EGR EVRV BLK/
ORG- - Appro x. 140Hz by
wa ve fo rm whe n
EVRV is operated- ---
98 98 CKP Se nso r Ground WHT Co ntinu-
ity with
ground- - - Connect Ohm 98 GND
99 99 CAN (Contro lle r Area
Ne two rk) to PSG
No .1BLU--------
100 100 CAN (Contro lle r Area
Ne two rk) to PSG
No .2YEL--------
101 101 CKP Senso r Shie ld
LineBLK Co ntinu-
ity with
ground- - - Connect Ohm 101 GND
102102No Connection---------
103103No Connection---------
104104No Connection---------
105 105 Solenoid Valve Shut
Off (MAB) Output
Signa l to PSG No .5ORG --------Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rpmECM
Connec-
tionRan
ge(+) (-)

6E–62 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into PSG Case
Signal or Continuity Tester Position
Pin
No. B/
Box
No.Pin Function Wire
ColorKey SW
OffKey SW
OnEngine
IdleEngine
2000rp
mECM &
PSG Con-
nectionRang
e(+) (-)
1 99 CAN (Contro lle r Area
Ne two rk) to ECM
No.99RED Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 1 99
(ECM
)
2 100 CAN (Contro lle r Area
Ne two rk) to ECM
No .100WHT Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 2 100
(ECM
)
3 - No Connection - - - - - - - - -
4 - No Connection - - - - - - - - -
5 105 Solenoid Valve Shut
Off (MAB) Output
Signa l to ECM
No .105ORG Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 5 105
(ECM
)
6 - Ground BLK Continu-
ity with
gro und- - - Disco n-
nectOhm 6 GND
7 - Batte ry Powe r Sup-
plyBLU/
REDLess
tha n 1V10-14V Disco n-
nectOhm 7 GND
8 91 CKP Sensor Output
ECM No.91 to Pump
Co ntrol Unit (PSG)PNK Continu-
ity
between
ECM &
PSG- - - Disco n-
nectOhm 8 91
(ECM
)
9 - No Connection - - - - - - - - -

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–63
Crankshaft Position (CKP) Sensor Reference Wave Form









0V








Measurement Terminal: 90(+) 98(-)
Measurement Scale: 20V/div 2ms/div
Measurement Condition: Approx imately 2000rpm
Engine Speed Output Signal Reference Wave Form









0V








Measurement Terminal: 27(+) GND(-)
Measurement Scale: 5V/div 10ms/div
Measurement Condition: Approximately 2000rpm
Crankshaft Position (CKP) Sensor & TDC Output Signal
Re fe re nce Wa v e Fo rm
CH1
0V

CH2
0V

Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)
Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div
Measurement Condition: Approximately 2000rpm
Vehicle Speed Sensor (VSS) Reference Wave Form









0V








Measurement Terminal: 68(+) GND(-)
Measurement Scale: 5V/div 50ms/div
Measurement Condition: Approximately 20km/h

6E–64 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR ECM AND
SENSORS
Engine Control Module (ECM)
The engine control module (ECM) is located flower
panel just under the passenger's seat.
The fuel quantity and injection timing related functions
are controlled by the pump control unit (PSG).
The engine control module (ECM) performs the
following functions.
Control of the ex haust gas re-circulation (EGR)
Control of the quick on start (QOS) glow control
system
Control of the A/C compressor
Ex ecution of the immobilizer function
Pump Control Unit (PSG) & Data Exchange
Between Control Module
The radial plunger distributor type injection pump uses
two control modules to ex ecute full control of the enginemanagement system.
Engine Control Module (ECM)
Pump Control Unit (PSG) = Pumpen Steuer Great
(German)
The pump control unit (PSG) receives signals from the
sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from ex ternal sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
module (ECM) and the pump control unit (PSG) is
perfumed via a CAN-bus system. The abbreviation CAN
stands for Controller Area Network. By having two
separate control modules, the high pressure solenoid
valve. This prevents the discharge of any disturbing
signals.
The information ex change between the two control
modules takes place via two means.
Via analogue signal leads
Via the CAN-bus
The analogue signal leads are used to ex change the
following information.
Engine speed signal (ECM terminal 91)
Pump Speed (ECM terminal 105)
Fuel Cutoff solenoid valve signal (MAB signal) (ECM
terminal 105)
The engine speed signal is sent from the ECM to PSG
based on the input from the crank shaft position (CKP)
sensor.
The analogue CKP sensor signal is converted by the
ECM into a square wave signal.
The fuel cutoff solenoid valve signal is also referred to
as MAB signal.
MAB in this case, refers to the German abbreviation
Magnet ventil ABschaltung that stands for high pressure
solenoid v alv e cut off.
The MAB signal wire is used for two purposes.
-As a reference for the engine control module (ECM) for
the pump speed (back up for the CKP sensor).
-To turn Off the engine.
Sel f Dia gn osis / Interfa ce / Si gn al
To High Pressure Solenoid
Engine Speed
Injection Timing
Accelerator Pedal
Injection Quantity
In ta ke Air Temperat ure
Response Signal
Ma ss Air Flow
Additional Signal
Others

Additional Operations To Timing Control Valve (TCV)
Engin e
Con trol
Modu le
(ECM) Cam Rin g Rota tiona l Angle
Fuel Temper atu re
High Pressure
Solenoid Valve
Pump
Con tr ol Fuel Inject ion
Unit (Mechanical)
(PSG)

Ti m i n
g Devi ce

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–65
The following signals are ex changed via the CAN-bus:
From ECM to PSG
Desired injection quantity
Desired injection timing
Engine speed
From PSG to ECM
Fuel temperature
Pump speed
Cylinder identifier
Control pulse (actual injection quantity + actual
injection timing)
PSG status
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor
The mass air flow (MAF) sensor is part of the intake air
system.
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine.
The mass air flow (MAF) sensor uses a hot film element
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both ex posed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an ex trapolation to the entire
mass air flow to the engine.The IAT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other
words it measures a temperature value. Low air
temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is
hot.
(1) Air Cleaner Case
(2) Mass Air Flow (MAF) & Intake Air Temperature
(IAT) Sensor

1 2
Characteristic of IAT Sensor -Reference-
10 100 1000 10000 100000
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
Intake Air Temp. (deg. C) (Tech2 Reading)
Resistance (ohm) (Solid Line)