2004 ISUZU TF SERIES glow

6E–120 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
67 P0381 4 ON Glow Plug Indicator Circuit
Voltage LowGlow plug indicator circuit
open or short to ground
circuit.No fail-safe function. Glow plug indicator circuit is
correct condition.1. Glow plug indicator
circuit open or short to
g r o u n d c i r c u i t .
2. Glow plug indicator lamp
m a l f u n c t i o n .
3. ECM malfunction.43 —
8 ON Glow Plug Indicator Circuit
Voltage HighGlow plug indicator circuit
short to voltage circuit.ECM malfunction.
——
32 P0400 3 ON Exhaust Gas Recirculation
Flow Excessive Detected1. Intake air temperature is
between 15 deg. C and
1 0 0 d e g . C .
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1-
T C ) .
3. Barometric pressure is
between 850hpa and
1 1 0 0 h p a .
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)Fuel injection quantity is
reduced. 1. Engine speed is between
1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and 3200rpm (4JH1-TC).



















2. Injection quantity is
below 32mg/strk (4JA1-
TC) or 40mg/stk (4JH1-
T C ) .
3. Correct amount of mass
air flow.1. EGR valve is stuck at
o p e n p o s i t i o n .
2. EGR EVRV malfunction.
3 . A i r i n t a k e i s o b s t r u c t e d .
4. Air intake is leaking.
5. MAF sensor malfunction.
6. ECM malfunction.
8 8 /
97—
4 ON Exhaust Gas Recirculation
Circuit Short to Ground or
Open CircuitEGR EVRV circuit open or
short to ground circuit.Fuel injection quantity is
reduced and EGR EVRV
10% conditions as substitute.EGR EVRV circuit is correct
condition.1. EGR EVRV circuit open
or short to ground circuit.
2. EGR EVRV malfunction.
3. ECM malfunction.97 —
5 ON Exhaust Gas Recirculation
Flow Insufficient Detected1. Intake air temperature is
between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1-
T C ) .
3. Barometric pressure is
between 850hpa and
1 1 0 0 h p a .
4. Large mount of mass air
flow. (Desired mass air
flow - mass air flow is
below -150 mg/strk)Fuel injection quantity is
reduced. 1. Engine speed is between
1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and 3200rpm (4JH1-TC).



















2. Injection quantity is
below 32mg/strk (4JA1-
TC) or 40mg/stk (4JH1-
T C ) .
3. Correct amount of mass
air flow.1. EGR valve is stuck at
c l o s e p o s i t i o n .
2. EGR valve operating
vacuum hose is clogged
or disconnected.
3. EGR EVRV malfunction.


4. MAF sensor signal circuit
short to voltage circuit.
5. MAF sensor malfunction.
6. ECM malfunction.8 8 /
97—
8 ON Exhaust Gas Recirculation
Circuit Short to BatteryEGR EVRV circuit short to
voltage circuit.Fuel injection quantity is
reduced & EGR EVRV 10%
conditions as substitute.EGR EVRV circuit is correct
condition.1. EGR EVRV circuit short
t o v o l t a g e c i r c u i t .
2. EGR EVRV malfunction.
3. ECM malfunction.97 — Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–179
Circuit Description
The ECM is calculates an injection quantity and an
injection timing using the various sensors (crankshaft
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing
decision.
The TCV performs as a variable throttle, using the rapid
opening and closing cycle of the valve needle in the
TCV.
The TCV is assembled in the injection pump. The signal
of desired injection timing and actual injection timing are
ex changed via the CAN-bus between the PSG and
ECM.
If the timer position is out of tolerance (deviation or
fluctuation), DTC P0216 will be stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Insufficient air bleeding of fuel line.
Low fuel quantity in the fuel tank.
Check for the following conditions:
Insufficient air bleeding of fuel line inside, clogged
fuel filter or pinched fuel pipe/hose may cause the
DTC store or improper engine performance.Air bleeding procedure:
1.Operate the priming pump until strong resistance is
felt.
2.Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3.Wait 1 minute, and operate the priming pump until
strong resistance is felt.
4.Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5.Turn the ignition switch to the "START" position and
crank the engine until it starts.
6.If the engine does not start, repeat Step 3 - 5.
7.Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the "Actual Injection Start" display on the Tech2 while
moving connectors and wiring harness related to the
sensor.

6E–180 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Diagnostic Trouble Code (DTC) P0216 (Symptom Code B) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Step Action Value(s) Yes No
1 Was the "On-Board Diagnostic (OBD) System Check"
performed?
-Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select "F0: Read DTC Infor As Stored By ECU" in
"F0: Diagnostic Trouble Codes".
Is the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored as "Present Failure"? - Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. 1Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
c l e a r t h e D T C i n f o r m a t i o n .
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored in this ignition cycle? - Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Perform the air bleeding in the fuel line sufficiently.
A ir Bleeding Procedure:
1. Operate the priming pump until strong resistance
is felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump
until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position
and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
DTC Re-check:
1. Using the Tech 2, ignition "On" and engine "Off".
2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
c l e a r t h e D T C i n f o r m a t i o n .
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
Was the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) restored in this ignition cycle? - Go to Step 5Verify repair

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–217
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 4)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0380 (SYMPTOM CODE 8)
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The voltage on the coil of the relay glow plug is supplied
by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
66 P0380 4 ON Glo w Re la y Circuit Volta ge
Lo wGlow relay circuit open or
sho rt to ground circuit.No fa il-sa fe fun ctio n.
8 ON Glo w Re la y Circuit Volta ge
HighGlo w re la y circuit short to vo lt-
age circuit.

6E –218 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
 Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection. 
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P0380 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 4) (Flash Code 66) Glow Relay Circuit Voltage Low
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check ”
performed?
— Go to Step 2 Go to
On Board
Diagnostic
(OBD) System Check
2 1. Connect the Tech 2. 2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU ” in
“ F0: Diagnostic Trouble Codes ”.
Is the DTC P0380 (Symptom Code 4) stored as
“ Present Failure ”? —Go to Step 3 Refer to
Diagnostic Aids and Go to Step
3
3 1. Using the Tech 2, ignition “On ” and engine “Off ”.
2. Select “F1: Clear DTC Information ” in “F0:
Diagnostic Trouble Codes ” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU ” in the “F0:
Diagnostic Trouble Codes ”.
Was the DTC P0380 (Symptom Code 4) stored in this
ignition cycle? —Go to Step 4 Refer to
Diagnostic Aids and Go to Step
4
4 Check for poor/faulty connection at the glow relay or ECM connector. If a poor/faulty connection is found,
repair as necessary.
Was the problem found?
— Verify repair Go to Step 5
5 Using the DVM and check the glow relay. 1. Ignition “Off ”, engine “Off ”.
2. Remove the glow relay from the relay box .
3. Check the relay coil.
Was the DVM indicated specified value?
Approx imately 105
Go to Step 6 Replace glow
relay and verify repair
94
3
4
2
1
X-5
C-57
Grow Relay




4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E –219
6 Using the DVM and check the glow relay power
supply circuit.
1. Ignition “On ”, engine “Off ”.
2. Remove the glow relay from the relay box .
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
10-14.5V Go to Step 8Go to Step 7
7 Repair the open or short to ground circuit between the ECM main relay and glow relay.
Is the action complete? —Verify repair —
8 Using the DVM and check the glow relay ground circuit.
Breaker box is available:
1. Ignition “Off ”, engine “Off ”.
2. Install the breaker box as type A. (ECM disconnected) Ref. Page 6E-103
3. Remove the glow relay from the relay box .
4. Check the circuit for open or short to ground circuit.
Was the problem found?
Breaker box is not available: 1. Ignition “Off ”, engine “Off ”.
2. Disconnect the ECM connector.
3. Remove the glow relay from the relay box .
4. Check the circuit for open or short to ground circuit.
Was the problem found?
— Repair faulty
harness and verify repair Go to Step 9
Step Action Value(s) Yes No
2
V
X-5
X- 594Breaker Box




3
94
X-5
C-57

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–221
Diagnostic Trouble Code (DTC) P0380 (Symptom Code 8) (Flash Code 66)
Glow Relay Circuit Voltage High
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0380 (Symptom Code 8) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0380 (Symptom Code 8) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
4 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 5
5 Substitute a known good ECM and recheck.
Was the problem solved?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. —Go to Step 6—
6 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Verify repair—

6E–222 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer
activated.
In the after glow phase the lamp is not illuminated butthe glow plugs remain active for a certain period
depending on engine coolant temperature.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
67 P0381 4 ON Glo w Plug Indica to r Circuit
Voltage LowGlo w plug indicator circuit
open or short to ground cir-
cuit.No fa il-sa fe fun ctio n.
8 ON Glo w Plug Indica to r Circuit
Vo lta ge HighGlo w plug indicator circuit
short to voltage circuit.