Engine Control Module: Service and Repair
Engine Control Module (ECM) Replacement/Fuel Injector Flow Rate Programming & Option ProgrammingEngine Control Module Replacement Procedure
IMPORTANT:
- If the ECM is to be replaced the following programmed contents MUST be reprogrammed back into the new ECM.
- Fuel Injector Flow Rates (24, 0-9 or A-F characters for each fuel injector)
- Power Take Off (PTO) Options (if equipped)
- Cruise Control Options
- Exhaust Brake Options
- Vehicle Speed Limit Option
- All of the above-programmed contents are to be performed using the Service Programming System (SPS). However, some PTO options can also be programmed using the scan tool.
Retrieving Information with a Communicating ECM
1. Connect the scan tool to the data link connector.
2. Turn ON the ignition with the engine OFF.
3. Retrieve the above-programmed contents on the scan tool following this navigation: Diagnostics > (5) 2005 > Isuzu > NPR/NQR/NRR > F0: Powertrain > (6) 5.2L L4 Diesel > Automatic or Manual > F2: Special Functions > F5: Option Programming.
NOTE: Gear Down Protection Options is not applicable to this model.
4. Record all values.
Retrieving Information with a Non-communicating ECM
If the ECM cannot communicate with the scan tool, the fuel injector flow rates for EACH fuel injector need to be manually recorded from the label on the cylinder head cover OR from the QR plate on the each injector housing. Refer to next procedure.
The following programmed contents have been lost and cannot be retrieved. The technician would need to question the customer if he is aware of any programmed options done by a previous dealer or if PTO equipped, by the upfitter who installed the PTO.
- Power Take Off (PTO) Options (if equipped)
- Cruise Control Options
- Exhaust Brake Options
- Vehicle Speed Limit Option
Recording from the label on cylinder head cover;
IMPORTANT: Only perform this procedure if the fuel injectors are not being replaced in the past.
1. Record all numbers of each cylinder on the label.
Recording from the QR plate on the each injector housing;
1. Remove the cylinder head cover to gain access to the tops of the fuel injectors. Refer to Fuel Injector Replacement in this section.
2. Clean any deposits off the tops of the fuel injectors.
3. Record all numbers of each cylinder on the fuel injector's QR plate.
4. Reinstall the cylinder head cover. Refer to Fuel Injector Replacement in this section.
Removal Procedure
- ECM(1) is attached in the left rear side of transmission(2)
1. Disconnect the negative battery cable.
2. Remove the ECM cover nuts (5) and bolt (4).
3. Remove the ECM cover (3).
4. Disconnect the ECM connector.
5. Remove the ECM fixing bolts (6).
6. Remove the ECM (1).
7. Remove the ECM bracket nuts (7) and bolt (8).
8. Remove the ECM bracket (2).
Installation Procedure
1. Install the ECM bracket (2).
2. Tighten the ECM bracket nuts (7) and bolt (8).
ECM bracket nuts and bolt
Tighten torque: 41 ±10 N.m (30 ±7 lb ft)
3. Install the ECM (1).
4. Tighten the ECM fixing bolts (6).
ECM fixing bolts
Tighten torque: 8.2 ±2.5 N.m (5.8 ±2.1 lb ft)
5. Connect the ECM connector.
6. Install the ECM cover (3).
7. Tighten the ECM cover nuts (5) and bolt (4).
ECM cover nuts
Tighten torque: 6.5 ±2.0 N.m (5 ±1.4 lb ft)
ECM cover bolt
Tighten torque: 8.2 ±2.5 N.m (6 ±2 lb ft)
8. Connect the negative battery cable.
Before Programming the ECM
IMPORTANT: DO NOT program the ECM unless you are directed by a service procedure or you are directed by a service bulletin. Programming the fuel injector at any other time will not permanently correct a customers concern.
Ensure the following conditions are met before programming the ECM.
- Vehicle system voltage
- There is no charging system concern. All charging system concerns must be repaired before programming the ECM.
- Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before programming the ECM if the battery voltage is low.
- A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming failure or ECM damage.
- Turn OFF or disable and system that may put a load on the vehicle's battery.
- Headlights
- Room lights
- Accessory equipment
- The ignition switch is in the proper position. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.
- All tool connections are secure.
- RS-232
- The connection at the data link connector (DLC) is secure.
- Voltage supply circuit
- DO NOT disturb the tool harness while programming. If an interruption occurs during the programming procedure, programming failure or ECM damage may occur.
- Surrounding environment
- Surrounding temperature is more than 32 °F (0 °C) but less than 122 °F (50 °C) during the programming procedure. Excessively low or high temperature may cause the programming failure or ECM damage.
- Electromagnetic interference (EMI) on the tool harness and ECM may cause the programming failure or ECM damage.
ECM Programming Procedure
Fuel injector Flow Rate Programming Procedure
1. Connect the scan tool to the data link connector if disconnected.
2. Connect the RS-232 to the scan tool and PC.
3. Start TIS 2000 and select the Service Programming System (SPS).
4. In the "Select Diagnostic Tool and Programming Process" screen, select the following menu.
- Diagnostic tool "Pass-Thru".
- Select Programming Process "Reprogram ECU".
- ECU Location on the "Vehicle".
5. Ensure that ALL programming contents are entered correctly and were programmed successfully by turning OFF the ignition for 30 seconds.
6. Using the scan tool to check each programmed fuel injector flow rate following this navigation: Diagnostics > (5) 2005 > Isuzu > NPR/NQR/NRR > F0: Powertrain > (6) 5.2L L4 Diesel > Automatic or Manual > F2: Special Functions > F5: Option Programming > F0: Injector Flow Rates.
7. Start the engine and let idle.
8. Inspect for a proper engine running condition and for no DTCs. Refer to the Diagnostic System Check - Engine Control if needed.
Option Programming Procedure
Refer to each procedure in this section.
- Power Take Off (PTO) Options (if equipped)
- Cruise Control Options
- Exhaust Brake Options
- Vehicle Speed Limit Option