fuel pump ISUZU TROOPER 1998 Service Repair Manual

6E±228
4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
General Description (Air Induction)
Air Induction System
The air induction system filters contaminants from the
outside air, and directs the progress of the air as it is
drawn into the engine. A remote-mounted air cleaner
prevents dirt and debris in the air from entering the
engine. The air duct assembly routes filtered air to the
throttle body. Air enters the engine by to following steps:
1. Through the throttle body.
2. Into the intake manifold.
3. Through the cylinder head intake ports.
4. Into the cylinders.
General Description (Fuel Metering)
Deceleration Mode
The ECM reduces the amount of fuel injected when it
detects a decrease in the Accelerator position.
Fuel Injector
Fuel injector comprises the solenoid, hydraulic line, and
fuel line. Fuel injection is controlled by the continuity time
signal and continuity start timing signal from ECM to the
solenoid
ECM determines the running conditions of engine by
input signals such as engine speed. Accelerator throttle
valve opening, and engine coolant temperature, thereby
to send the solenoid the best suited signal to the engine
status. When current is carried to the solenoid, the
armature opens the poppet valve to alow high pressure oil
to run into the injector. Under the pressure of the oil, the
piston and plunger are depressed to compress the fuel in
the combustion chamber of the plunger. Specifically, the
pressure of the fuel compressed is increased by a piston
top/ plunger bottom area ratio over the pressure of high
pressure oil, thereby lifting the fuel nozzle end needle for
injecting fuel.
Fuel Metering System Components
The fuel metering system is made up of the following
parts:

The fuel injectors.

The intake throttle body.

The Accelerator position (AP) sensor

The ECM.

The crankshaft position (CKP) sensor.

The camshaft position (CMP) sensor.
Basic System Operation
Fuel is supplied through fuel filter to the fuel pump.
The fuel pump is installed to the oil pump, and fuel is
forced, through the fuel pump outlet, pipe and cylinder
head inside, into the fuel injector.
An orifice is provided at the rear fuel outlet of cylinder
head to control the pressure of oil.The injector is controlled by ECM which gives
opening/closing commands to the solenoid installed on
the top of the injector. Opening/closing operation of the
pressurized engine oil circuit of the injector controls fuel
injection quantity, fuel injection timing, etc.
A/C Clutch Diagnosis
A/C Request Signal
This signal tells the ECM when the A/C mode is selected
at the A/C control head. The ECM uses this to adjust the
idle speed.
Refer to
A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for A/C electrical system.
General Description Exhaust Gas
Recirculation (EGR) System
EGR Purpose
The exhaust gas recirculation (EGR) system is use to
reduce emission levels of oxides of nitrogen (NOx). NOx
emission levels are caused by a high combustion
temperature. The EGR system lowers the NOx emission
levels by decreasing the combustion temperature.
The ECM uses information from the following sensors to
control EGR valve boost pressure.

ECT

ITP

Engine Speed

AP sensor

ENGINE LUBRICATION 6G – 3
To meet a newly adopted electronically controlled fuel
injection system using engine oil two oil pumps have
been provided to increase circulating oil capacity.
The first oil pump serves mainly to lubricate the engine
parts, while the second mainly serves the fuel injectors
and partially cools the pistons.
The oil cooler is provided on the first oil pump side and
uses engine coolant.
OIL FLOW
Legend
(1) Oil Pump
(2) Regulator Valve
(3) Oil Cooler
(4) Oil Filter Relief Valve
(5) Full Flow Filter
(6) Oil Cooler Relief Valve
(7) Gallery
OIL PUMP SPECIFICATIONS
First Second
Pump Revolution 8800 rpm
Delivery Pressure 392 Kpa (4.0 kg/cm
2/57 psi)
Delivery Capacity >48.8 l/min >37.1 l/min
OIL FILTER SPECIFICATIONS
Filtration Method Full flow Paper
Filtration Area 0.32 m
2
Relief Valve opening 981 Kpa (10 kg/cm2/142 psi)pressure
Legend
(1) Oil cooler assembly
(2) Oil filter assembly (25) Edge Filter
(26) Edge Filter
(27) High Pressure Oil Pump Assembly
(28) To Oil Pan
(29) Pressure Control Valve(30) To Oil Pan
(31) Turbocharger
(32) Oil Gallery
(33) Timing Gear Train
17 65 4
3
2
050RW010
For Europe1
2
050R200001

WIRING SYSTEM 8DÐ25
Relay & Fuse Box
FL-1
FL-2 FL-6 FL-5 FL-4 FL-3
F-12 F-11 F-10 F-9 F-8 F-7 F-6 F-5 F-4 F-3 F-2 F-1 RELAY AND FUSE BOX
RHD
FUSIBLE LINK FUSE
MODEL
No.
FL-1
FL-2
FL-3
FL-4
FL-5
FL-6
F-1
F-2
F-3
F-4
F-5
F-6
F-7
F-8
F-9
F-10
F-11
F-12LHD
80A MAIN
50A KEY SW
30A ECM (GASOLINE)
30A CONDENSER FAN
50A GLOW (4JG2)
40A ABS
10A O
2 SENSOR (GASOLINE)
15A HORN HAZARD
15A H/LAMP-LH
15A H/LAMP-RH
15A ANTI-THEFT
20A FOG
20A ABS
15A FUEL PUMP (GASOLINE)
15A TAIL80A MAIN
50A KEY SW
30A ECM (GASOLINE)
30A CONDENSER FAN
50A GLOW (4JG2)
40A ABS
10A O2 SENSOR (GASOLINE)
15A HORN HAZARD
10A H/LAMP-LH (HI)
10A H/LAMP-RH (HI)
10A H/LAMP-LH (LOW)
10A H/LAMP-RH (LOW)
20A FOG
20A ABS
15A FUEL PUMP (GASOLINE)
10A TAIL-LH
10A TAIL-RH —
—
——
810RS027

WIRING SYSTEM 8DÐ27
Relay Location-1 (Relay and Fuse Box)
RHDNo.
X-1
X-2
X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
X-13
X-16
X-17
X-18
X-19
X-20
X-21
X-22
X-23LHD
RELAY ; LIGHTING
RELAY ; A/C THERMO
RELAY ; COMPRESSOR (GASOLINE)
RELAY ; HORN
RELAY ; TAIL
RELAY ; FUEL PUMP (GASOLINE)
RELAY ; ECM MAIN (GASOLINE)
RELAY ; ANTI-THEFT
RELAY ; STARTER (GASOLINE)
RELAY ; CHARGE (DIESEL)
RELAY ; SHIFT ON THE FLY
RELAY ; CONDENSER FAN
(GASOLINE)
RELAY ; RR FOG LIGHT
RELAY ; FRT FOG LIGHTRELAY ; LIGHTING
RELAY ; DIMMER
RELAY ; A/C THERMO
RELAY ; COMPRESSOR (GASOLINE)
RELAY ; HORN
RELAY ; TAIL
RELAY ; FUEL PUMP (GASOLINE)
RELAY ; ECM MAIN (GASOLINE)
RELAY ; ANTI-THEFT
RELAY ; STARTER (GASOLINE)
RELAY ; CHARGE (DIESEL)
RELAY ; SHIFT ON THE FLY
RELAY ; CONDENSER FAN
RELAY ; FRT FOG LIGHT
—
—
—
—
—
—
—
——
—
—
—
—
—
—
—
X-1
X-2
X-3
X-4X-5
X-6
X-7
X-8X-9
X-10 X-12X-11X-13X-16
X-17X-18
X-19X-20
X-21
X-22
X-23 RELAY AND FUSE BOX
810RS029

WIRING SYSTEM 8DÐ31
Fuse Block Circuit
RHD Models
Indication on label
BOFF
STIG2 ACC
STARTER SW
+
_
O SENSOR (V6)
HORN, HAZARD
H/LAMP-LH
H/LAMP-RH
(FRT . FOG)
ABS
F/ PUMP (V6)
P/ WINDOW, S/ ROOF,
P/SEAT
STARTER RELAY
TURN, BACK
ELEC. IGN.
FRT WIPER & WASHER
RR WIPER & WASHER
H/ LAMP WIPER
ENGINE
IGN. COIL (G)
FUEL CUT (D)
METER, GAUGE
AUDIO(ACC)
MIRROR
CIGAR
STOP, A/T CONT.
AUDIO(B)
TEL(B)
CLOCK(B)
ROOM
RR DEFOG
DOOR LOCK
IG1B
STARTER
C
B
AC GENERATOR
BL
IG
F-1
F-2 10A
F-3 15A
F-4 15A
F-5 15A
F-8 20A
F-9 20A
F-10 15A
C/B-2 30A
C-1 10A
C-3 10A
C-4 10A
C-5 15A
C-6 10A
C-7 10A
C-8 15A
C-9 15A
C-10 10A
C-11 10A
C-12 20A
C-14 15A
C-15 20A
C-16 10A
C-17 25A
C-18 20A RELAY; STARTERCHARGE SIGNAL
FUSE BOX
RELAY; ECM MAIN
FUEL
INJECTOR ECM
HYDRAULIC
UNIT FL-3
30A ECM
FL-6
40A ABS
FL-2
50A KEY SW FL-1
80A MAIN2
2
1
5 W
5 W
8 B/R 5 W
F-6
F-7
F-11
RELAY & FUSE BOX
C-2 15A
BLOWERC-19 25A
C-20 10A
5 W 5 W
5 W
1.25 R
5 W
5 W
3 W
2 R
3 W
3 B/R
3 W
3 W/G
3 B/Y 3 B/Y
5 W 5 W
3 B/W
3 W/B
3 W/B 3 W/B3 W/G 2 W
30 B/R
0.85 B/Y
3 L/B
3 W
1.25 R/G
SFL-2
(DIESEL)
SEAT HEATER
FL-3
40A C/HEATER
FL-5
50A GLOW
CERAMIC HEATER
(DIESEL)
GLOW PLUG
(DIESEL)
31
3 R/B3 W
24
3 W/L
3 R/W
ANTI THEFTC-13 10A
3 B/Y
RELAY: LIGHTING
3 B/R
RELAY; FUEL PUMP
42
TAIL
5 W
2 W
AIR CON
RELAY; HEATER & A/C
24
3 W
3 L/R
C-21 10ASRS
FUSE BOX
C-22 10A
F-12 15A
ECM
D08RV551

8DÐ32 WIRING SYSTEM
LHD Models
FL-4
30A COND.FAN
Indication on label
BOFF
STIG2 ACC
STARTER SW
+
_
O SENSOR (V6)
HORN, HAZARD
H/LAMP-LH(HI)
H/LAMP-RH(HI)
(FRT . FOG)
ABS
F/ PUMP (V6)
P/ WINDOW, S/ ROOF,
P/SEAT
STARTER RELAY
TURN, BACK
ELEC. IGN.
FRT WIPER & WASHER
RR WIPER & WASHER
H/ LAMP WIPER
ENGINE
IGN. COIL (G)
FUEL CUT (D)
METER, GAUGE
AUDIO(ACC)
MIRROR
CIGAR
STOP, A/T CONT.
AUDIO(B)
TEL(B)
CLOCK(B)
ROOM
RR DEFOG
DOOR LOCK
IG1B
STARTER
C
B
AC GENERATOR
BL
IG
F-1
F-2 10A
F-3 15A
F-4 10A
F-5 10A
F-8 20A
F-9 20A
F-10 15A
C/B-2 30A
C-1 10A
C-3 10A
C-4 10A
C-5 15A
C-6 10A
C-7 10A
C-8 15A
C-9 15A
C-10 10A
C-11 10A
C-12 20A
C-14 15A
C-15 20A
C-16 10A
C-17 25A
C-18 20A RELAY; STARTERCHARGE SIGNAL
FUSE BOX
RELAY; ECM MAIN
FUEL
INJECTOR ECM
HYDRAULIC
UNIT FL-3
30A ECM
FL-6
40A ABS
FL-2
50A KEY SW FL-1
80A MAIN2
2
1
ECM
5 W
5 W
8 B/R 5 W
F-6 10A
F-7 10A
F-11 10A RELAY & FUSE BOX
C-2 15A
BLOWERC-19 25A
C-20 10A
5 W 5 W
5 W
1.25 R
5 W
5 W
2 R 2 R3 W
3 B/R
3 W
3 W/G
3 B/Y 3 B/Y
5 W 5 W
3 B/W
3 W/B
3 W/B 3 W/B3 W/G 2 W
30 B/R
0.85 B/Y
3 L/B
3 W
1.25 R/G
SFL-2
(DIESEL)
SEAT HEATER
FL-3
40A C/HEATER
FL-5
50A GLOW
CERAMIC HEATER
(DIESEL)
GLOW PLUG
(DIESEL)
3 W
3 W
24
3 W/L
3 R/W
ANTI THEFTC-13 10A
3 B/Y
3 B/R
RELAY; FUEL PUMP
42
TAIL-RH
3 G/Y
5 W
2 W
AIR CON
RELAY; HEATER & A/C
24
3 W
3 L/R
F-12 10ARELAY; TAIL
24H/LAMP-LH(LO)
H/LAMP-RH(LO)
3
1
2 Y/R RELAY: DIMMER2 Y/G
2
3
1RELAY: LIGHTING
TAIL-LH
RELAY; CONDENSER FAN
131.25 L
1.25 L/O
CONDENSER FAN
D08RV552

8DÐ34 WIRING SYSTEM
Connector No. Cable harness Location Parts (Load)
C-39
Windshield washer motor1
C-39
Windshield wiper motor2
C-39
FRT fog light relay4
C-39Meter, Vehicle speed sensor (Meter),
Fuel tank unit 6
Engine room
harnessFender-RH
E-28
ECM, O2 sensor
E-29ECM, Data link connector
Engine ECGI
harnessEngine-common
chamber
R-3
RR washer motor, Rear wiper motor, Luggage
room light, RR defogger, High mount stoplight,
Tailgate key SW, RR door lock actuator-LH,
Tailgate lock actuator-LH, RR power window
SW-LH
R-4Taillight, Stoplight, RR turn signal light, Backup
light, License plate light, Fuel tank unit, Fuel
pump, Trailer harness connector, RR fog light Rear body
harnessBody-RR
E-30
E-31ECM, Data link connector, A/T Shift indicator
control unit DIS
C-39Fuel pump relay, ECM main relay 5
C-39Windshield intermittent relay3
M-16
TCMMission
harnessEngine
C-39Side turn signal light (RH) 7
C-39Vehicle speed sensor, Brake fluid SW 8
I-39
AudioInstrument
harnessBody-FRT
C-85
EBCMEngine room
harnessBody-Center
U-2
SDMSRS
harnessBody-FRT

8DÐ36 WIRING SYSTEM
Connector No. Cable harness Location Parts (Load)
C-39
Windshield washer motor, Side turn signal
light (RH)1
C-39
Windshield wiper motor2
C-39
Headlight-LH, FRT fog light relay4
C-39Meter, Vehicle speed sensor (Meter),
Fuel tank unit 6
Engine room
harnessFender-RH
E-28
ECM, O2 sensor
E-29ECM, Data link connector
Engine ECGI
harnessEngine-common
chamber
R-3
RR washer motor, Rear wiper motor, Luggage
room light, RR defogger, Tailgate key SW,
Tailgate lock actuator-LH, RR Door lock
actuator-LH, High mount stoplight, RR power
window SW-LH
R-4Taillight, Stoplight, RR turn signal light, License
plate light, Fuel tank unit, Fuel pump, Backup
light Rear body
harnessBody-RR
E-30
E-31ECM, Data link connector, A/T Shift indicator
control unit DIS
C-39Condenser fan (Saudi Arabia)
5
C-39Windshield intermittent relay3
M-16
TCMMission
harnessEngine
C-39Pump & VSV, Headlight-RH, Fuel pump relay,
ECM main relay 7
C-39High-beam indicator light, Vehicle speed
sensor, Headlight wiper timer 8
I-39
AudioInstrument
harnessBody-FRT C-85
EBCMBody-Center

8DÐ82 WIRING SYSTEM
Circuit Diagram (RHD 6V
*1)Ð2
PCM : POWERTRAIN CONTROL MODULE
P C M
AE
E 0.5
B
1.0
B/L 0.5
R/W
0.5
R/W
X-111C-397 7
3X-11C-3 E13
FUEL PUMP
RELAY
FUEL
PUMP
F-10 15A
FUEL PUMPF-2 20A
OXYGEN SENSOR
HEATER
JOINT
CONNECTOR
KNOCK
SENSOR
2.0
B2.0
B 2.0
B/R2.0
B/R2.0
B/R2.0
B/R 2.0
R2.0
R1.25
B/L0.85
B/L
0.85
R/W
FENDER-RH2.0
WF-4
2H-4620H-332H-1315X-114
2X-11
1F-4
H-5
C-88
1410
16
E-30C-2C9
C-2C7
COMMON CHAMBER
R-4
BODY-RR
1.25
B/P
1.0
B/R1.25
B/P
0.5
B0.5
Y
0.5
Y
H-513E-29C-2C8
COMMON CHAMBER
H-613
1C-1E-14A2
D
M
POWER
STEERING
PRESSURE
SW
0.5
G/Y
0.5
G/YH-616
1C-1E-4 B11
H-42
13
H-33
D08RW588

WIRING SYSTEM 8DÐ97
Circuit Diagram (LHD 6V
*1)Ð2
PCM : POWERTRAIN CONTROL MODULE
P C M
AE
E 0.5
B
1.0
B/L 0.5
R/W
0.5
R/W
X-111C-397 7
3X-11C-3 E13
FUEL PUMP
RELAY
FUEL
PUMP
F-10 15A
FUEL PUMPF-2 20A
OXYGEN SENSOR
HEATER
JOINT
CONNECTOR
KNOCK
SENSOR
2.0
B2.0
B 2.0
B/R2.0
B/R2.0
B/R2.0
B/R 2.0
R2.0
R1.25
B/L0.85
B/L
0.85
R/W
FENDER-RH2.0
WF-4
2H-4620H-338H-135X-114
2X-11
1F-4
H-5
C-88
1410
16
E-30C-2C9
C-2C7
COMMON CHAMBER
R-4
BODY-RR
1.25
B/P
1.0
B/R1.25
B/P
0.5
B0.5
Y
0.5
Y
H-513E-29C-2C8
COMMON CHAMBER
H-613
1C-1E-14A2
D
M
POWER
STEERING
PRESSURE
SW
0.5
G/Y
0.5
G/YH-616
1C-1E-4 B11
H-42
7
H-33
D08RW902