ENGINE PROTECTION SYSTEM
Contents
1. TIO OL IEEE YOSNAS T3A311 1NY 1009 OL UR 1NY1009 CHD m ee f p Honos aNnouo 7 H31N39 YOLOW dOLS 3NION3 I sivas _ S ng 9 8 SNVUL LHMWOIA OWNOLLdO ber layovua anus o WOL WOY a um TWANVW SH3NMO JHL OL 43434 STIVLS0 ONIYIM SH 96 o C 2 0 1 0 9206 2 t dOLS ON3 1 UE vers NOILO31OHd3NION3 aay a e a anv 19 9 We 2 gt EZH 898 35 8 E Rr E Izd ed a Ea ro ame EIS Mm PX MS A39 vos 233 vog H MS YALYVLS Page 4 of 8 Engine Protection System Production Description Rev D Date 3 19 04 TROUBLE SHOOTING GUIDE Diagnostic and Test Information CONSTANT ALARM ON LOW OIL PRESSURE A CAUTION If engine is hot use extreme caution when checking oil pressure sensor Verify proper oil level Ensure correct oil level er 9 Ensure that the EPS Cab and Engine harness junction connector is l fully mated Connector is located approximately 18 from the EPS module near the lower left side o the dash and the left side kick panel See diagram on page 4 Verify continuity of EPS harness and oil pressure sensor Disconnect the connector from the oil pressure sensor located at the right rear of the engine On harness side of the sensor connector using a continuity meter verify that the BLACK wir2. EPS Cab and Engine harness junction connector is fully mated The connector is located approximately 18 from the EPS module near the lower left side of the dash and the left side kick panel See diagram on page 4 Verify continuity of EPS harness and high temperature sensor Disconnect the connector from the high temperature sensor located at the top left front of the engine On harness side of the sensor connector using a continuity meter verify that the BLACK WHITE wire is supplying a reliable ground If not grounded repair BLACK WHITE wire on Cab and or Engine harness from the harness side of the sensor connector through the harness junction Pin G to the EPS module connector Pin 4 If BLACK WHITE wire is grounded or continuity to the ground tests good go to the next step See diagram of page 8 Using a jumper wire connect the VIOLET wire on the harness side of the sensor connector to the vehicle ground Start the Engine After system self tests if the alarm cancels the high temperature sensor is defective Stop the engine and replace the high temperature sensor elf the alarm persists using a continuity meter check the VIOLET wire for continuity from the EPS module connector Pin 14 through the harness junction Pin B to the harness side of the sensor connector See diagram on page 5 and 10 If the circuit is open no continuity repair the VIOLET wire appropriately If the circuit test is good continuity EPS Modu
3. TROUBLE SHOOTING GUIDE ENGINE PROTECTION SYSTEM TABLE OF CONTENTS SUBJECT Engine willl not Start or will not Shutdown Wire Identification Wiring Diagram Constant Alarm on Low Oil Pressure Constant Alarm on High Temperature Constant Alarm on Low Coolant Level Sensor Location Diagram Rev D Date 3 19 04 Production Description Engine Protection System PAGE NUMBER 2 O C Page 1 of 8 TROUBLE SHOOTING GUIDE Diagnostic and Test Information A CAUTION DURING INSTALLATION OR REPLACEMENT OF MODULE IGNITION MUST BE OFF AND KEY REMOVED ENGINE WILL NOT START OR WILL NOT SHUTDOWN NOTE Locate connector B 67 and B 68 at the bottom of the steering column Disconnect the EPS interconnection harnesses side from B 67 and B 68 connectors and disconnect other ends of the interconnect harnesses from the vehicles harnesses Reconnect the vehicle harness into connectors B 67 and B 68 If the engine starts and or shuts down with the ignition key reconnect both interconnect harnesses previously disconnected B 67 B 68 Then continue the diagnostic and test procedure If the engine doesn t starts and or shutdown with the ignition key then refer to the Isuzu Service Manual After repaired start or shutdown circuitry by Isuzu Standard reconnect the interconnection harnesses B 67 and B 68 NOTE For connector pin location and identification see diagrams on pages 3 and 4 eMake sure all connectors are fully mat
4. connection harness from connectors B 67 and B 68 male and female and reconnect the original vehicle harness If the engine starts and stops with ignition key Engine Protection Module is defective Replace Module and reconnect harness system After all previous testing and diagnostics and the engine will not start or will not stop refer to the vehicle service manual for ignition and engine stop motor PIN IDENTIFICATION COLOR 1 N A N A 2 NA N A ENGINE PROTECTION EPS Cab and Engine Harness Junction WIRE INSERTION VIEW 9 GRO TO THANS TEMP SW BLK WHT 4 GRD TO ENGINE TEMP SW BLK alt 5 GRD TO OIL PRESS SW BLK Be 6 GRD OUTPUT TO HOUR METER BRN 6e nsertn view 7 IGNITION IN RED 8 4 9 EPS Engine EPS Cab Harness 5 Harness Connector Connector ale 10 GRD FOR MODULE IN BLK YEL 37 11 COOLANT LEVEL SENSOR X ERNSTUSEE a 12 INPUT SW IN GRY B VIOLET F NOT USED ale 13 TRANS TEMP SW IN VIO WHT C YELLOW BLACK WHITE 14 ENGINE TEMP SW IN VIO D NOT USED H BLACK 15 OIL PRESS SW IN GRN 16 RELAY COMMON HARNESS SIDE LT BLU WHT 17 RELAY NC LT BLU YEL 18 RELAY N O STOP MOTOR SIDE LT BLUWHT Rev D Date 3 19 04 Production Description Engine Protection System Page 3 of 8 TROUBLE SHOOTING GUIDE 9 N HOLIMS SYNLVYAdWAL JLIHNVMOV TH 2 H1 E 33 13 lOIA yOvIg_ SN DOE lt m FIR HOLIMS 5
5. e is supplying a reliable ground If not grounded repair BLACK wire on Cab and or Engine harness from the harness side of the sensor connector through the harness junction Pin H to the EPS module connector Pin 5 If BLACK wire is grounded or continuity to the ground tests good go to the next step See diagram on page 8 Using a jumper wire connect the GREEN wire on the harness side of the sensor connector to the vehicle ground Turn the ignition key to the ON position After system self tests if the alarm cancels the oil pressure sensor is defective Replace the oil pressure sensor elf the alarm persists using a continuity meter check the GREEN wire for continuity from the EPS module connector Pin 15 through the harness junction Pin A to the harness side of the sensor connector See diagram on pages 5 and 10 If the circuit is open no continuity repair the GREEN wire appropriately If the circuit test is good continuity EPS Module is defective Replace the Module located under the left side dash panel next to the TCM module Rev D Date 3 19 04 Production Description Engine Protection System Page 5 of 8 TROUBLE SHOOTING GUIDE Diagnostic and Test Information CONSTANT ALARM ON HIGH TEMPERATURE A CAUTION If engine is hot use extreme caution when checking coolant sensor Verify proper coolant level Ensure correct levels in the radiator and the coolant overflow tank reservoir Ensure that the
6. ed between The EPS Module and mating EPS harness connector located near the original Transmission Control Module TCM bracket under the left side of the dash panel The engine protection interconnection harness and the power feed connector harness B 67 located at the bottom of the steering column See diagram on page 4 The engine protection interconnection harness and the engine stop motor connector harness B 68 located at the bottom of the steering column See diagram on page 4 eCheck fuse 7 5A on the RED wire of the EPS harness located approximately 6 inches from the module connector under the left side of the dash panel near the TCM bracket If fuse blown burned out replace with correct 7 5 amp fuse Turn ignition to ON position the RED wire Pin 7 of Engine Protection harness must have 12 volts If there is no voltage check the connector B 67 located on the bottom of the steering Rev D Date 3 19 04 Production Description Engine Protection System Page 2 of 8 TROUBLE SHOOTING GUIDE column to make sure both side of the interconnections are mated properly If the connectors are mated properly and if there is still no voltage refer to the truck owners manual and or service manual for vehicle power distribution regarding troubleshooting Verify Black wire Pin 10 of the EPS harness has a reliable ground located on the TCM bracket Previous tests are good positive disconnect the engine protection inter
7. le is defective Replace the Module located under the left side dash panel next to the TCM module Rev D Date 3 19 04 Production Description Engine Protection System Page 6 of 8 TROUBLE SHOOTING GUIDE Diagnostic and Test Information CONSTANT ALARM ON LOW COOLANT LEVEL A CAUTION If engine is hot use extreme caution when checking coolant level sensor Verify proper coolant level Ensure correct levels in the radiator and the coolant overflow tank reservoir fluid must cover sensor completely Ensure that the EPS Cab and Engine harness junction connector is fully mated The connector is located approximately 18 from the EPS module near the lower left side of the dash and the left side kick panel See diagram on page 4 Verify continuity of EPS harness and low coolant level sensor Disconnect the connector from the coolant level sensor located in the middle of the radiator top tank reservoir On the harness side of the coolant sensor using a jumper wire connect the terminal to the vehicle ground Start the engine If after the system self tests if the alarm cancels the coolant level sensor is defective Stop the engine and verify the coolant level sensor as follows See Diagram on page 8 Remove the coolant level sensor and clean the internal probe of any residue Using a continuity meter check for continuity between the internal probe and the terminal of the coolant level sensor connector If the circuit tes
8. t good continuity reinstall the coolant sensor If the circuit is open NO continuity change the coolant level sensor elf the alarm persists using a continuity meter check the YELLOW wire for continuity from the EPS module connector Pin 11 through the harness junction Pin C to the harness side of the sensor connector See diagram on page 3 4 and 8 If the circuit is open no continuity repair the YELLOW wire appropriately If the circuit test is good continuity EPS Module is defective Replace the Module located under the left side dash panel next to the TCM module Rev D Date 3 19 04 Production Description Engine Protection System Page 7 of 8 TROUBLE SHOOTING GUIDE Coolant Level Sensor 9 L torque to 86 in bs 10 5 N m torque to 96 in ibs 10 5 N m Rev D Date 3 19 04 Production Description Engine Protection System Page 8 of 8
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