uzuIsuzu 4HK1 6HK1 Common Rail Engine Troubleshooting Manual

This Troubleshooting Manual describes the structure and the troubleshooting of electronic control fuel injection system (common rail type) in 4HK1 and 6HK1 industrial engines. Use this manual sufficiently to perform service work properly and quickly.

Table of Contents
How to use this manual. . . . . . . . . . . . . . . . . . . .10D-4
Table of abbreviation . . . . . . . . . . . . . . . . . . . .10D-5
List of parts according to engine control specifications 10D-6
About colors of wirings . . . . . . . . . . . . . . . . . . .10D-7
About wiring diagrams . . . . . . . . . . . . . . . . . . .10D-8
Precautions on Service Work . . . . . . . . . . . . . .10D-11
Procedure of trouble diagnosis . . . . . . . . . . . . .10D-12
Interview. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10D-14
Pre-inspection . . . . . . . . . . . . . . . . . . . . . . . .10D-16
Trouble Diagnosis . . . . . . . . . . . . . . . . . . . . .10D-16
How to read DTC . . . . . . . . . . . . . . . . . . . . . .10D-17
Confirmation after repair . . . . . . . . . . . . . . . .10D-19
List of final check items . . . . . . . . . . . . . . . . .10D-19
How to clear DTC. . . . . . . . . . . . . . . . . . . . . .10D-20
Trouble diagnosis with scan tool . . . . . . . . . .10D-21
How to use trouble diagnosis-related tool . . . . .10D-26
How to use Tech2. . . . . . . . . . . . . . . . . . . . . .10D-26
Rewrite setting of Q-key correction data by Tech2. . .10D-49
How to use TIS 2000 . . . . . . . . . . . . . . . . . . .10D-69
How to use injector checker . . . . . . . . . . . . . .10D-79
How to use flush tool . . . . . . . . . . . . . . . . . . .10D-84
How to use breaker box . . . . . . . . . . . . . . . . .10D-85
Engine Control System . . . . . . . . . . . . . . . . . . .10D-88
Description of function and operation. . . . . . .10D-88
Engine Control Module (ECM) . . . . . . . . . . . .10D-98
Circuit diagram. . . . . . . . . . . . . . . . . . . . . . .10D-119
Engine harness location. . . . . . . . . . . . . . . .10D-135
Connector list . . . . . . . . . . . . . . . . . . . . . . . .10D-145
List of function checks. . . . . . . . . . . . . . . . . . .10D-148
OBD system check. . . . . . . . . . . . . . . . . . . .10D-149
Diagnosis lamp illumination circuit system check10D-151
Diagnosis lamp blinking circuit system check . .10D-153
Scan tool power supply circuit system check10D-156
Scan tool communication circuit system check .10D-anu158
Starting circuit system check . . . . . . . . . . . .10D-161
Starting system check . . . . . . . . . . . . . . . . .10D-167
Fuel system check . . . . . . . . . . . . . . . . . . . .10D-170
Intake system check. . . . . . . . . . . . . . . . . . .10D-172
Exhaust system check . . . . . . . . . . . . . . . . .10D-173
EGR control system check. . . . . . . . . . . . . .10D-174
QOS system check . . . . . . . . . . . . . . . . . . .10D-177
List of diagnostic trouble code. . . . . . . . . . . . .10D-181
DTC: P0087 (Flash code 227) . . . . . . . . . . .10D-206
DTC: P0088 (Flash code 118) . . . . . . . . . . .10D-214
DTC: P0089 (Flash code 151) . . . . . . . . . . .10D-219
DTC: P0090 (Flash code 247) . . . . . . . . . . .10D-224
DTC: P0107 (Flash code 71) . . . . . . . . . . . .10D-230
DTC: P0108 (Flash code 71) . . . . . . . . . . . .10D-237
DTC: P0112 (Flash code 22) . . . . . . . . . . . .10D-243
DTC: P0113 (Flash code 22) . . . . . . . . . . . .10D-249
DTC: P0117 (Flash code 23) . . . . . . . . . . . .10D-257
DTC: P0118 (Flash code 23) . . . . . . . . . . . .10D-263
DTC: P0182 (Flash code 211) . . . . . . . . . . .10D-270
DTC: P0183 (Flash code 211) . . . . . . . . . . .10D-275
DTC: P0192 (Flash code 245) . . . . . . . . . . .10D-282
DTC: P0193 (Flash code 245) . . . . . . . . . . .10D-288
DTC: P0201 (Flash code 271) . . . . . . . . . . .10D-295
DTC: P0202 (Flash code 272) . . . . . . . . . . .10D-302
DTC: P0203 (Flash code 273) . . . . . . . . . . .10D-309
DTC: P0204 (Flash code 274) . . . . . . . . . . .10D-316
DTC: P0205 (Flash code 275) . . . . . . . . . . .10D-323
DTC: P0206 (Flash code 276) . . . . . . . . . . .10D-328
DTC: P0219 (Flash code 543) . . . . . . . . . . .10D-333
DTC: P0237 (Flash code 32) . . . . . . . . . . . .10D-335
DTC: P0238 (Flash code 32) . . . . . . . . . . . .10D-342
DTC: P0335 (Flash code 15) . . . . . . . . . . . .10D-349
DTC: P0336 (Flash code 15) . . . . . . . . . . . .10D-355
DTC: P0340 (Flash code 14) . . . . . . . . . . . .10D-361
DTC: P0341 (Flash code 14) . . . . . . . . . . . .10D-368
DTC: P0380 (Flash code 66) . . . . . . . . . . . .10D-374
DTC: P0381 (Flash code 67) . . . . . . . . . . . .10D-379
DTC: P0487 (Flash code 44) . . . . . . . . . . . .10D-384
DTC: P0488 (Flash code 45) . . . . . . . . . . . .10D-389
DTC: P0522 (Flash code 294) . . . . . . . . . . .10D-395
DTC: P0523 (Flash code 295) . . . . . . . . . . .10D-401
DTC: P0601 (Flash code 53) . . . . . . . . . . . .10D-408
DTC: P0603 (Flash code 54) . . . . . . . . . . . .10D-410
DTC: P0606 (Flash code 51/52) . . . . . . . . .10D-412
DTC: P0611 (Flash code 34) . . . . . . . . . . . .10D-414
DTC: P0612 (Flash code 34) . . . . . . . . . . . .10D-417
DTC: P0650 (Flash code 77) . . . . . . . . . . . .10D-420
DTC: P1093 (Flash code 227) . . . . . . . . . . .10D-425
DTC: P1095 (Flash code 225) . . . . . . . . . . .10D-434
DTC: P1095 (Flash code 225) . . . . . . . . . . .10D-434
DTC: P1112 (Flash code 295) . . . . . . . . . . .10D-443
DTC: P1113 (Flash code 295) . . . . . . . . . . .10D-451
DTC: P1173 (Flash code 542) . . . . . . . . . . .10D-458
DTC: P1225 (Flash code 31) . . . . . . . . . . . .10D-464
DTC: P1261 (Flash code 158) . . . . . . . . . . .10D-468
DTC: P1262 (Flash code 159) . . . . . . . . . . .10D-478
DTC: P1271 (Flash code 24) . . . . . . . . . . . .10D-488
DTC: P1277 (Flash code 24) . . . . . . . . . . . .10D-494
DTC: P1278 (Flash code 24) . . . . . . . . . . . .10D-499
10D-3 Electronic control fuel injection system (Common rail type)
DTC: P1282 (Flash code 24) . . . . . . . . . . . 10D-504
DTC: P1283 (Flash code 24) . . . . . . . . . . . 10D-509
DTC: P1345 (Flash code 16) . . . . . . . . . . . 10D-514
DTC: P1625 (Flash code 416) . . . . . . . . . . 10D-519
DTC: P1630 (Flash code 36) . . . . . . . . . . . 10D-526
DTC: P1631 (Flash code 55) . . . . . . . . . . . 10D-528
DTC: P1632 (Flash code 55) . . . . . . . . . . . 10D-531
DTC: P1633 (Flash code 55) . . . . . . . . . . . 10D-534
DTC: P1634 (Flash code 55) . . . . . . . . . . . 10D-537
DTC: P1635 (Flash code 55) . . . . . . . . . . . 10D-540
DTC: U2104 (Flash code 84) . . . . . . . . . . . 10D-543
DTC: U2106 (Flash code 85) . . . . . . . . . . . 10D-548
List of trouble symptom . . . . . . . . . . . . . . . . . 10D-553
Engine start failure . . . . . . . . . . . . . . . . . . . 10D-554
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . 10D-558
Engine hunting, rough idling . . . . . . . . . . . . 10D-562
Engine output shortage. . . . . . . . . . . . . . . . 10D-566
Exhaust gas contains a lot of white smoke. 10D-570
Exhaust gas contains a lot of black smoke. 10D-573
Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-576
Fuel consumption deteriorates.. . . . . . . . . . 10D-578
Oil consumption deteriorates. . . . . . . . . . . . 10D-581
Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-583
Difference by each machine manufacturer . . 10D-584
JCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10D-584
About wiring diagrams. . . . . . . . . . . . . . . . . 10D-590