1998 ISUZU TROOPER check engine light

ENGINE ELECTRICAL 6D1 Ð 1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
Battery................................................................................................................................... Section 6D1
Starting System ................................................................................................................... Section 6D2
Charging System.................................................................................................................. Section 6D3
QOS-IIIPreheating System ................................................................................................. Section 6D6
SECTION 6D1
BATTERY
CONTENTS
General Description ......................................... 6D1Ð1
Diagnosis .......................................................... 6D1Ð1
On-Vehicle Service........................................... 6D1Ð3
Battery Charging .......................................... 6D1Ð3Jump Starting .............................................. 6D1Ð3
Removal and Installation of Battery .......... 6D1Ð4
GENERAL DESCRIPTION
There are six battery fluid caps at the top of the
battery. These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes per-
mit the escape of small amounts of gas generated
by the battery.
This type of battery has the following advantages
over conventional batteries:1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self-
discharge than a conventional type battery.
DIAGNOSIS
1. VISUAL INSPECTION
Inspect the battery for obvious physical damage,
such as a cracked or broken case, which would
permit electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it
as necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK
There is a built-in hydrometer (Charge test indica-
tor) at the top of the battery. It is designed to be
used during diagnostic procedures.Before trying to read the hydrometer, carefully
clean the upper battery surface.
If your work area is poorly lit, additional light may
be necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE Ð Go to Step
4.
b. BLUE RING OR DOT NOT VISIBLE Ð Go to
Step 3.

6A – 10 ENGINE MECHANICAL
8. Check the engine oil level and replenish to the
specified level if required.
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel filter
Replacement Procedure
1. Loosen the used fuel filter by turning it
counterclockwise with the filter wrench.
Filter Wrench : 5-8840-0203-0
2. Clean the filter cover fitting faces.
This will allow the new fuel filter to seat properly.
3. Apply a light coat of engine oil to the O-ring.
4. Turn the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn the fuel filter with a filter wrench 2/3 of a turn
until sealed.
Filter Wrench: 5-8840-0203-0Legend
(1) Priming pump
6. Operate the priming pump until the air is discharged
completely from fuel system.
NOTE: The use of an Isuzu genuine fuel filter is
strongly recommended.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator
reserve tank as necessary.
If the coolant level falls below the “‘MIN” line, carefully
check the cooling system for leakage. Then add
enough coolant to bring the level up to the “MAX” line.
NOTE: Do not overfill the reserve tank.
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ENGINE MECHANICAL 6A– 99
OIL COOLER
For Europe1
2050R200001
Legend
(1) Oil Cooler Assembly
(2) Oil Filter Cartridge
OIL FILTER CARTRIDGE
REMOVAL
1. Place a receptacle beneath the oil filter to contain
the drained oil.
2. Remove the oil filter cartridge using filter wrench.
Filter wrench : 5-8840-0203-0
INSTALLATION
1, Lightly apply oil to the O-ring of oil filter cartridge.
2. Turn the new oil filter cartridge by hand until the
sealing face is fitted against the O-ring.
3. Use the filter wrench to turn the oil filter an
additional one and 1/8 turns.
4. Start the engine and check for oil leakage from oil
filter.

ENGINE ELECTRICAL 6D – 1
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
General Description . . . . . . . . . . . . . . . . 6D–1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–1
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–3
Main Data and Specification . . . . . . . . . . 6D–4
Starting System . . . . . . . . . . . . . . . . . . . . . 6D–5
General Description . . . . . . . . . . . . . . . . 6D–5
On Vehicle Service . . . . . . . . . . . . . . . . . 6D–7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . 6D–7
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–8Charging System . . . . . . . . . . . . . . . . . . . . 6D–15
General Description . . . . . . . . . . . . . . . . 6D–15
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6D–16
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . 6D–17
Main Data and Specification . . . . . . . . . . 6D–22
QOS4 Preheating System . . . . . . . . . . . . . . 6D–23
General Description . . . . . . . . . . . . . . . . 6D–23
System Diagram . . . . . . . . . . . . . . . . . . . 6D–23
Inspection of QOS4 System Operation . . 6D–24
BATTERY
GENERAL DESCRIPTION
DIAGNOSIS
There are six battery fluid caps at the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six
small vent holes at the side. These vent holes permit
the escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an excessive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self-
discharge than a conventional type battery.
1. VISUAL INSPECTION (Step 1)
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary. If not, proceed to Step 2.
2. HYDROMETER CHECK (Step 2)
There is a built-in hydrometer (Charge test indicator) at
the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE – Go to
Step 3.3. FLUID LEVEL CHECK (Step 3)
The fluid level should be between the upper level line
and lower level line on side of the battery.
a. CORRECT FLUID LEVEL – Charge the battery.
b. BELOW LOWER LEVEL – Replace battery.
4. VOLTAGE CHECK (Step 4)
(1) Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5.
b. VOLTAGE IS UNDER 12.4V – Go to procedure
(2) below.
(2) Determine fast charge amperage from
specification. (See Main Data and Specifications in
this section.)
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE – Replace battery.

6E±31 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
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Menu

The following table shows, which functions are used
the available equipment versions.
F0: Diagnostic Trouble Codes
F0: Read DTC Info Ordered By Priority
F1: Read DTC Info As Stored By ECU
F2: Clear DTC Information
F3: Freeze Frame / Failure Records
F1: Data Display
F2: Snapshot
F3: Actuator Tests
F0: Checklight
F1: Glow Time Lamp
F2: EGR Switching Valve
F3: Exhaust Switching Valve 1
F4: Exhaust Switching Valve 2
F4: Miscellaneous Tests
F0: Throttle Motor Control
F1: Rail Pressure Control
F2: EGR Regulating Valve Control
F3: Rail Pressure Control Valve
F4: Injector Balance Test
F5: Programming
F0: Injector Calibration
(F1: Rail Pressure Calibration)

6E±44
4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)
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Circuit Description
The ªCheck Engineº lamp (MIL) should always be
illuminated and steady with the ignition ªONº and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The Engine Control
Module ECM turns the MIL ªONº by grounding the MIL
driver circuit.
Diagnostic Aids
An intermittent MIL may be cause by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:

Inspect the ECM harness and connections for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire
connection, and damaged harness.

If the engine runs OK, check for a faulty light bulb, an
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
If the engine cranks but will not run, check for an open
ECM ignition or battery feed, or a poor ECM to engine
ground.
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. A ªNo MILº condition accompanied by a no-start
condition suggests a faulty ECM ignition feed or
battery feed circuit.
9. Using a test light connected to B+, probe each of the
ECM ground terminals to ensure that a good ground
is present. Refer to
ECM Terminal End View for
terminal locations of the ECM ground circuits.
12.In this step, temporarily substitute a known good
relay for the ECM relay. The horn relay is nearby,
and it can be verified as ªgoodº simply by honking
the horn. Replace the horn relay after completing
this step.

6E±45 4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
No Malfunction Indicator Lamp (MIL)

StepActionValue(s)Ye sNo
1Was the ªOn-Board Diagnostic (OBD) System Checkº
performed?
ÐGo to Step 2
Go to OBD
System
Check
2Attempt to start the engine.
Does the engine start?
ÐGo to Step 3Go to Step 6
3Check the meter fuse for the instrument cluster ignition
feed circuit.
Is the fuse OK?
ÐGo to Step 4Go to Step 16
4Ignition ªON,º probe the ignition feed circuit at the
cluster connector with a test light to ground.
Is the test light ªON?º
ÐGo to Step 5Go to Step 13
51. Ignition ªOFF.º
2. Disconnect the ECM.
3. Jumper the MIL driver circuit at the ECM connector
to ground.
4. Ignition ªON.º
Is the MIL ªON?º
ÐGo to Step 10Go to Step 11
6Check the ECM ignition feed and battery feed fuses (15
A engine fuse and 15 A ECM fuse).
Are both fuses OK?
ÐGo to Step 7Go to Step 15
71. Ignition ªOFF.º
2. Disconnect the ECM.
3. Ignition ªON.º
4. Probe the ignition feed circuit at the ECM harness
connector with a test light to ground.
Is the test light ªON?º
ÐGo to Step 8Go to Step 12
8Probe the battery feed circuit at the ECM harness
connector with a test light to ground.
Is the test light ªON?º
ÐGo to Step 9Go to Step 14
9Check for a faulty ECM ground connection.
Was a problem found?
ÐVerify repairGo to Step 10
10Check for damaged terminals at the ECM.
Was a problem found?
ÐVerify repairGo to Step 17
11Check for an open MIL driver circuit between the ECM
and the MIL.
Was a problem found?
ÐVerify repairGo to Step 18
12Substitute a known ªgoodº relay for the ECM main
relay.
Was the malfunction fixed?
ÐVerify repairGo to Step 13
13Repair the open in the ignition feed circuit.
Is the action complete?
ÐVerify repairÐ
14Locate and repair the open ECM battery feed circuit.
Is the action complete?
ÐVerify repairÐ

6E±50
4JX1±TC ENGINE DRIVEABILITY AND EMISSIONS
Engine Cranks But Will Not Run

 
StepNo Ye s Value(s) Action
10Refer to Engine Mechanical Diagnosis to diagnose the
following conditions:

Faulty camshaft drive belts

Leaking or sticky valves or rings

Excessive valve deposits

Weak valve springs

Incorrect valve timing

Leaking head gasket
Is the action complete?
ÐVerify repairGo to Step 11
11Observe the ªEngine Speedº data display on the Tech 2
while cranking the engine.
Is the engine RPM indicated? (If the Tech 2 is normally
powered from the cigarette lighter socket, and if the
Tech 2 display goes blank while cranking the engine, it
will be necessary to power the Tech 2 directly from the
vehicle battery.)
ÐGo to Step 12Go to Step 17
121. At the ECM (female) side of the connector
mentioned in step, connect a test light between the
ignition + terminal and one of the injector driver
circuits at the same connector.
2. Ignition ªON.º
3. Observe the test light, and repeat the test for each
injector driver circuit by oscilloscope.
Did the test light stay on when checking any of the 4
injector driver circuits?
ÐGo to Step 13Go to Step 15
131. Ignition ªOFF,º disconnect the ECM.
2. Ignition ªON,º observe the test light.
Is the test light ªON?º
ÐGo to Step 14Go to Step 16
14Locate and repair the short to ground in the injector
driver circuit.
Is the action complete?
ÐVerify repairÐ
15Check for an open injector driver circuit.
Was a problem found?
ÐVerify repairGo to Step 16
16Replace the ECM (Refer to the Data Programming in
Case of ECM change).
Is the action complete?
ÐVerify repairÐ
171. Raise the vehicle and disconnect the CKP sensor
harness.
2. Ignition ªON.º
3. With a test light to ground, probe the harness
ignition feed terminal.
Did the light illuminate?
ÐGo to Step 19Go to Step 18
18Check the ignition feed wire between the sensor and
the ECM for a short to ground or open circuit.
Is the action complete?
ÐVerify repairÐ