Documente Academic
Documente Profesional
Documente Cultură
ECM
The ECM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any
circuit. When testing for opens and shorts, do not ground or apply voltage to any of the ECM circuits unless
instructed to do so. In some cases, these circuits should only be tested using a DMM. The ECM should remain
connected to the ECM harness. The ECM mainly controls the following items.
The fuel system control
The EGR system control
The A/C compressor control
The immobilizer system control
On-board diagnostics for engine control
The ECM constantly observes the information from various sensors. The ECM controls the systems that affect
vehicle performance. The ECM performs the diagnostic function of the system. The ECM can recognize operational
problems, alert the driver through the check engine warning light, and store DTCs. DTCs identify the system faults
to aid the technician in making repairs.
Note
ECM input/output
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 1/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Operations of MIL
The MIL is installed in the instrument panel cluster. The MIL shows the engine symbol as ON indication.
The MIL indicates that vehicle maintenance is required due to a failure related to engine performance. The following
is the list of MIL operation modes.
The MIL turns on when the engine is turned OFF with ignition switch ON. This is the light test for confirming that the
MIL turns on.
When there is no failure diagnosis, the MIL turns OFF after the engine is started.
When the ECM detects a failure, the MIL remains on after the engine is started. When the ECM turns on the MIL
due to a failure related to engine performance, a DTC is stored.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 2/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 3/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Boost sensor
The boost sensor is located in the air induction tubing. The boost sensor is a transducer that varies voltage
according to changes in the air pressure inside the air tubing. The boost sensor provides a signal to the ECM on the
signal circuit, which is relative to the pressure changes in the air tubing. The ECM should detect a low signal voltage
at a low boost pressure, such as when the engine load is low. The ECM should detect high signal voltage at a high
boost pressure, such as when the engine load is high.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 4/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
CMP sensor
The CMP sensor is installed on the timing chain sprocket cover at the front of the camshaft idle gear. The CMP
sensor detects five projections in total per engine cycle. Four projections arranged equally every 90° and one
reference projection on the timing chain sprocket surface. The CMP sensor is a magnetic resistance element type
sensor, which generates a square wave signal pulse.
CKP sensor
The CKP sensor is located on the left-hand of the cylinder block rear section. The sensor rotor is fixed on the
crankshaft. There are 56 notches spaced 6°apart and a 30°opening. This opening allows for detection of top dead
center. The CKP sensor is a magnetic resistance element type sensor, which generates a square wave signal pulse.
Detecting the opening from the CKP sensor and one reference projection from the CMP sensor, the ECM
determines cylinder No.1 compression top dead center to ensure they correlate with each other.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 5/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. CKP sensor
2. Sensor rotor
3. Rotational direction
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 6/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
IAT sensor
The IAT sensor is fitted between the air cleaner and turbocharger. The IAT sensor is inside the MAF sensor. The IAT
sensor is a variable resistor and it measures the temperature of the air entering the engine. When the IAT sensor is
cold, the sensor resistance is high. When the air temperature increases, the sensor resistance decreases. With high
sensor resistance, the ECM detects a high voltage on the signal circuit. With lower sensor resistance, the ECM
detects a lower voltage on the signal circuit.
MAF sensor
The MAF sensor is an air flow meter that measures the amount of air that enters the engine. The MAF sensor is
installed between the air cleaner and turbocharger. A small quantity of air that enters the engine indicates
deceleration or idle speed. A large quantity of air that enters the engine indicates acceleration or a high load
condition. The MAF sensor assembly consists of the MAF sensor element and the IAT sensor. Both components are
exposed to the air flow to be measured. The MAF sensor element measures the inflow air volume through a
measurement duct on the sensor housing.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 7/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
The common rail system consists primarily of a fuel supply pump, fuel rail, injectors, and ECM.
Note
Fuel system diagram
1. Fuel rail
2. Pressure limiter
3. Fuel leak-off pipe
4. Injector
5. Fuel return pipe
6. Fuel tank
7. Fuel tank unit
8. Fuel filler cap
9. Fuel feed pipe
10. Fuel filter with sedimenter
11. Clogging monitoring switch
12. Fuel supply pump
Injector
Electronic control type injectors controlled by the ECM are used. Compared with conventional injection nozzles, a
command piston, solenoid valve, etc. are added. An ID code indicating various injector characteristic is laser
marked on the connector housing. This system uses injector flow rate information indicated by the ID code to
optimize the injection quantity control. When an injector is newly installed in the vehicle, it is necessary to input the
ID code in the ECM. QR codes or injector flow rate information are used to enhance the injection quantity precision
of the injectors. The use of codes enables injection quantity dispersion control throughout all pressure ranges,
contributing to improvement in combustion efficiency and reduction in exhaust gas emissions.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 9/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. Injector ID code
2. Fuel leak-off pipe
3. 2D barcode
4. Fuel inlet port
5. O-ring
Non-injection state
The TWV closes the outlet orifice by means of a spring force, when no current is supplied from the ECM to the
solenoid. At this point, the fuel pressure applied to the tip of the nozzle is equivalent to the fuel pressure applied
through the inlet orifice to the control chamber. As for the force competition in this state, the sum of pressure on the
command piston upper surface and nozzle spring force is greater than the pressure applied to the nozzle leading
end, and therefore the nozzle is pressed down and the injection hole is closed.
Injection start
When current is supplied from the ECM to the solenoid, the TWV is raised to open the outlet orifice and the fuel
flows into the return port. As a result, the nozzle is pressed up along with the command piston by the fuel pressure
applied to the nozzle leading end and then the nozzle injection hole opens to inject the fuel.
Injection end
When the ECM finishes supplying power to the solenoid, the outlet orifice is closed. As a result, the fuel stops
flowing into the return port from the control chamber and the fuel pressure within the control chamber sharply rises.
Then, the nozzle is pressed down by the command piston and the nozzle injection hole is closed to stop fuel
injection.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 10/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 11/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Fuel rail
Along with the employment of a common rail type electronic control fuel injection system, the fuel rail is provided
between the fuel supply pump and the injectors in order to store highly pressurized fuel. The FRP sensor and
pressure limiter are installed on the fuel rail. The FRP sensor detects the fuel pressure inside the fuel rail and sends
signals to the ECM. Based on this signal, the ECM controls the fuel pressure inside the fuel rail via the FRP
regulator of the fuel supply pump. The pressure limiter mechanically opens the valve in order to relieve the pressure
when the fuel pressure inside the fuel rail is excessive.
FRP sensor
The FRP sensor is installed on the fuel rail and it detects the fuel pressure in the fuel rail, converts the pressure into
a voltage signal, and sends the signal to the ECM. The ECM monitors the FRP sensor signal voltage. The higher
pressure inside the fuel rail provides the higher signal voltage, while the lower pressure provides the lower signal
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 12/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
voltage. The ECM calculates the actual fuel pressure from the voltage signal and uses the result calculated for fuel
injection control and other control tasks.
1. Valve
2. Valve body
3. Valve guide
4. Spring
5. Housing
6. Fuel inlet
7. Fuel outlet
FRP regulator
The FRP regulator is installed on the fuel supply pump. The ECM controls the duty ratio of the FRP regulator in
order to control the quantity of fuel that is supplied to the high-pressure plungers. Since only the quantity of fuel that
is required for achieving the target fuel rail pressure is drawn in, the drive load of the fuel supply pump is decreased.
When current flows to the FRP regulator, variable electromotive force is created in accordance with the duty ratio,
moving the solenoid plunger to the right side and changing the opening of the fuel passage, thus regulating the fuel
quantity. With the FRP regulator is OFF, the return spring stretches, completely opening the fuel passage and
supplying fuel to the plungers. When the FRP regulator is ON, the fuel path is closed by the return spring force. By
turning the FRP regulator ON/OFF, fuel is supplied in an amount corresponding to the actuation duty ratio, and fuel
is discharged by the plungers.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 13/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
EGR system
The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas to the
intake air, the combustion temperature is lowered and the generation of NOx is suppressed. The EGR control
system uses an electronic control system to ensure both drivability and low emission. A control current from the
ECM operates a motor to control the lift amount of EGR valve. Also, it feeds actual valve lift amount back to the
ECM for more precision control of the EGR amount.
The EGR control starts when the conditions for engine speed, coolant temperature, intake air temperature and
barometric pressure are satisfied. Then, the valve opening is calculated according to the engine speed, and target
fuel injection quantity. Based on this valve opening, the drive duty of the solenoid is provided and the valve is driven
accordingly.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 14/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. EGR cooler
2. Coolant outlet
3. Coolant inlet
4. EGR valve
5. ECM
6. MAF sensor
7. Intake throttle valve
EGR valve
The EGR valve is installed on the inlet manifold. The ECM controls the opening and closing of the EGR valve based
on the driving condition of the engine. The ECM regulates the EGR valve by controlling the motor. The motor is
controlled based on the pulse width modulated signals transmitted from the ECM via CAN. EGR valve control is
performed by changing the duty ratio from 0 % to an appropriate ratio. When the duty ratio increases, the valve
opens. When the duty ratio decreases, the valve closes.
The position of the EGR valve is detected by the controller built into the EGR valve body, and the signal is
transmitted to the ECM via CAN. The ECM detects a low signal voltage when the lift amount is small or at the
closed position. The ECM detects a high signal voltage when the lift amount is large.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 15/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Turbocharger
The turbocharger is used to increase the amount of air that enters the engine cylinders. This allows a proportional
increase of fuel to be injected into the cylinders, resulting in increased power output, more complete combustion of
fuel, and increased cooling of the cylinder heads, pistons, valves, and exhaust gas. This cooling effect helps extend
engine life.
Heat energy and pressures in the engine exhaust gas are utilized to drive the turbine.
Exhaust gas is directed to the turbine housing. The turbine housing acts as a nozzle to direct the shaft wheel
assembly.
Since the compressor wheel is attached directly to the shaft, the compressor wheel rotates at the same speed as
the turbine wheel. Clean air from the air cleaner is drawn into the compressor housing and wheel. The air is
compressed and delivered through a crossover pipe to the engine air intake manifold, then into the cylinders.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 16/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. Exhaust gas
2. Wastegate valve
3. Turbine wheel
4. Compressor wheel
5. Air cleaner
6. Intercooler
The amount of air pressure increase and air volume delivered to the engine from the compressor outlet is regulated
by the wastegate in the exhaust housing. The wastegate valve position is controlled by the pressure amount
accumulated in the intake side of the turbocharger. The diaphragm inside the wastegate is sensitive to pressure. It
controls the valve position inside the turbocharger. The valve position increases or decreases the boost amount to
the turbocharger. (Standard output engine)
The amount of air pressure increase and air volume delivered to the engine from the compressor outlet is indirectly
regulated by the turbocharger nozzle control actuator. The position of the turbocharger nozzles is controlled by the
ECM. The ECM utilizes the turbocharger nozzle control solenoid valve and the boost pressure sensor to control the
turbocharger nozzles. When the engine is not under load, the turbocharger nozzles are in open position A, or the
non-boost condition. When the engine is under load, the ECM commands the control solenoid valve to close the
turbocharger nozzles as in B, which increases the boost. The ECM changes the boost according to the load
requirements of the engine. The ECM uses the pulse width modulation on the control circuit to open and control the
solenoid valve. (High-output engine)
The intercooler also helps the performance of the diesel. Intake air is drawn through the air cleaner and into the
turbocharger compressor housing. Pressurized air from the turbocharger then flows forward through the intercooler
located in the front of the radiator. The air from the intercooler then flows into the intake manifold.
The intercooler is a heat exchange device that uses ambient airflow to dissipate heat from the intake air.
Compression by the turbocharger causes the intake air to heat up. Decreasing the intake air temperature provides a
denser intake charge into the same space, resulting in increased engine efficiency and power.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 17/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Cylinder block
The cylinder block is cast iron, and has a highly rigid structure with appropriate rib placement.
Piston
The pistons are cast autothermatic pistons cast with aluminum alloy struts, and the combustion chamber is a
spherical re-entrant system.
Cylinder head
The cylinder heads are made of aluminum alloy, and there are 4 valves per cylinder. The head bolts should be
tightened using the plastic region rotational angle tightening method. Tightening with the plastic region rotational
angle tightening method further increases the reliability and the durability.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 18/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Cooling system
The cooling system is a force-circulation system, and its main components are the water pump, the thermostat, the
cooling fan, and the radiator.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and the thermostat through the bypass pipe and back to the cylinder body. At this time, the coolant
does not circulate through the radiator.
When the coolant temperature reaches the specified value, the thermostat begins to open to gradually increase the
amount of coolant circulating through the radiator.
When the coolant temperature reaches the specified value, the thermostat is fully opened. Then all of the coolant
circulates through the radiator to cool the engine effectively.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 19/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. Thermostat
2. Turbocharger
3. EGR cooler (Euro 3 and Euro 4 specifications only)
4. Cylinder head
5. Oil cooler
6. Heater
7. Cylinder block
8. Water pump
9. Cooling fan
10. Radiator
11. Reserve tank
Water pump
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not a disassembled type.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 20/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Thermostat
A wax pellet type thermostat is used.
Radiator
The radiator is a tube type with a corrugated fin. To raise the boiling point of the coolant, a pressurized radiator cap
is attached. The open valve pressure of the radiator cap is 93.3 - 122.7 kPa {0.95 - 1.25 kg/cm2 / 13.5 - 17.8 psi}.
Opening/closing mechanism of the radiator cap is double-action.
The vehicle with a manual transmission is not equipped with the oil cooler.
Caution
When removing the radiator cap, do not pull it by force, but loosen it until it cannot rotate further.
To install the cap, turn the radiator cap until it does not turn.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 21/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Starting system.
The starting system is composed of the batteries, starter, ignition switch, inhibitor switch (for A/T vehicles only) and
starter relay, etc. Each of these main components are wired as shown in the starter circuit diagram.
1. Pinion clutch
2. Ring gear
3. Shift lever
4. Magnetic switch
5. S-terminal
6. B-terminal
7. Inhibitor switch, for A/T only
8. Starter relay
9. Starter switch
10. Battery
11. Armature
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 22/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Note
Starter circuit diagram
Starter
The starter is a magnetic shift type starter and is an outer gearing mesh method reduction starter.
The contact point of the magnetic switch closes and the armature rotates when the ignition switch is turned ON. At
the same time, the plunger is drawn in and the pinion is pushed to the front via the shift lever to mesh with the ring
gear, and when the ring gear rotates the engine starts. After the engine starts, the plunger returns, the pinion
separates from the ring gear, and the armature stops rotating when the ignition switch is turned off. When the
engine rotation increases faster than the pinion, the pinion will be caused to turn in reverse, but because the pinion
is idling, it does not drive the armature.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 23/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. Lead wire
2. Bolt
3. Magnetic switch assembly
4. Torsion spring
5. Plunger
6. Dust cover
7. Magnetic switch
8. Screw
9. Through bolt
10. Rear cover
11. Motor assembly
12. Brush holder
13. Yoke
14. Armature
15. Bolt
16. Bearing retainer
17. Pinion assembly
18. Pinion stopper clip
19. Pinion stopper
20. Return spring
21. Pinion shaft
22. Clutch
23. Dust cover
24. Shift lever
25. Gear case
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 24/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Note
Ignition switch
Charging system
The charging system is an IC integral regulator charging method. The main components are connected as shown in
the drawing. The regulator is an integrated solid-state type regulator. This is installed into the rear end cover along
with the brush holder assembly and is built-in to the generator.
Generator maintenance, such as adjusting the voltage is unnecessary. There are 8 diodes in the rectifier connected
to the stator coil. These convert alternating current voltage into direct current voltage. The direct current voltage is
connected to the generator output terminal.
The generator used for 4JK1 engine cannot be disassembled.
Note
Generator
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 25/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Note
Circuit diagram
Exhaust system
The main components are a front exhaust pipe and exhaust silencer.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 26/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Lubrication system
A full-flow bypass integrated filter element, water-cooling oil cooler, and piston coolant oil jet are adopted for the
lubrication system.
Oil flows through the water cooling oil cooler and around the sliding sections from the oil gallery for lubrication.
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 27/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
Note
Engine control component location diagram
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 28/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 29/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. CMP sensor
2. Engine coolant temperature sensor
1. CKP sensor
1. Boost sensor
2. Turbocharger control solenoid valve
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 30/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. EGR valve
2. Intake throttle valve
1. Common rail
2. Pressure limiter valve
3. FRP sensor
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 31/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. FRP regulator
2. Fuel temperature sensor
1. MAF sensor
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 32/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. Vacuum sensor
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 33/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
1. ECM
Note
Vacuum hose routing diagram
Note
General wiring diagram
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 34/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 35/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 36/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 38/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 39/40
2/7/2018 Function, structure, operation of engine null (4JJ1)
2. Engine number
Note
Engine number stamping position
https://www.css-club.net/isuzu_d7dl/HTML_Manual_E/TFHTML-WEN-1331_HTML/si/95191.html 40/40