DTC: P1625 (Flash code 416) Main relay fault Page 1 of 6

DTC: P1625 (Flash code 416) Main relay fault

(*: Specifications (fuse current value etc.) vary depending on each machine. Refer to the machine’s manual.)

Description of circuit
The main relay is installed near the blower motor inside the instrument panel. The ECM turns the main relay “ON” when
the key switch inputs “ON” signal, and turns the main relay “OFF” when the key switch is “OFF”. The battery voltage is
supplied to the main relay via fuse, and turning the main relay “ON” will supply the power supply voltage to the ECM.
The ECM sets the DTC when the output to/input from the main relay do not match.
Main trouble symptom
Engine does not start or power supply cannot be shut off.
Preconditions when DTC is set
Varies depending on the machine manufacturer.
l Key switch input voltage is 18 V or more.
l Key switch input voltage is 16 V or more.
l DTC P1630 is not detected.
l 3 seconds or more has elapsed after key switch ON.
l Main relay drive indication ON
l DTC P1625, or P0606 is not detected.

DTC set condition

l Main relay input power supply voltage is 1 V or less for 2 seconds or more.

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021
DTC: P1625 (Flash code 416) Main relay fault Page 2 of 6

l Relay does not cut off for 5 seconds or more even after the main relay coil OFF command is sent.
Action taken when DTC is set
l Trouble is displayed on the monitor of the machine* or diagnosis lamp comes on. (* Nothing is displayed depending
on the machine manufacturer.)
Back-up mode
l No back-up action

Recovery from failure

Refer to List of Diagnostic Trouble Codes and “About recovery from failure” in this section for recovery from failure.
The conditions to clear the MIL/DTC
Varies depending on the machine manufacturer.
l The present trouble turns to history trouble when the condition is out of the range from DTC set condition (recovery
from failure).
l The diagnosis lamp will go off after the code turns to history trouble and the key switch is turned “OFF” then “ON”
again.
l Using the scan tool, or memory clear switch and diagnostic switch operation enables to clear DTCs.

Diagnostic aid
If the intermittent trouble is suspected, the followings may be the cause.
l Fault in switch body
l Improper adjustment of switch
l Improper connection of harness connector
l Defective harness routing
l Worn harness cladding
l Wire disconnection inside harness cladding
The following inspections are necessary to detect these causes.
l Improper connection of harness connector and ECM connector
Poor connection of terminal from connector
Unmatched terminals are fitted.
Damage of connector lock
Poor contact between terminal and wire
l Damaged harness
Visually check the harness for damage.
Check the relevant items on the scan tool data display while moving the connector and the harness which are
related to the sensor. The variation of the display indicates the faulty part.
Test description
Numbers below indicate step numbers in the chart.
STEP 4 . If the main relay is stuck closed, it is possible to communicate with ECM using a scan tool even with the key
switch “OFF”.
STEP 5 . If it is still possible to communicate with ECM using a scan tool and the DTC is detected when the main relay
is removed, the circuit beyond the relay or ECM is faulty.
STEP 8 . If the “Main relay voltage” displays the specified value or more when terminals between the main relay
installing portion are shorted, the circuit beyond the relay is normal including ECM.
The diagnosis table is displayed.

Step Action Value YES NO

Perform the OBD system check. Go to OBD
1 Is the procedure completed? — STEP 2 system check .

Is the scan tool (KW communication) available?

2 — STEP 3 STEP 17

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021
DTC: P1625 (Flash code 416) Main relay fault Page 3 of 6

1. Turn the key switch to “ON”.

2. Check the “Main relay voltage” on the data display using a 1V
3 scan tool.
Is the “Main relay voltage” the specified value or more? STEP 4 STEP 7
1. Turn the key switch to “OFF”. Go to
2. Check the DTC. Diagnostic
4 —
Is DTC P1625 detected? STEP 5 aid .
1. Remove the main relay.
2. Check the DTC.
Note:
5 Refer to the machine’s manual for installing position and —
installation/removal procedures of the main relay.
Is DTC P1625 detected? STEP 6 STEP 11
1. Check the circuit (contact point side) between main relay and
ECM for short circuit to the power supply circuit or ignition
power supply circuit using breaker box or DMM.
6 Refer to Breaker box inspection procedure . —
2. If the fault is detected, repair as required.
Is the fault detected? STEP 12 STEP 15
Check the installation condition of the main relay and ECM
connector.
1. Check for play or looseness in the connection.
7 —
2. If the fault is detected, repair as required.
Is the fault detected? STEP 15 STEP 8
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Short between the terminals 1 – 2 and 3 – 5 in the main relay
installing portion respectively using jump cable.
24 V
8 4. Turn the key switch to “ON”.
5. Check the “Main relay voltage” on the data display using a
scan tool.
Is the “Main relay voltage” the specified value or more? STEP 11 STEP 9
1. Check for the followings in the circuit between slow-blow
fuse and main relay.
l Open circuit
l Short circuit to ground circuit
9 —
l High resistance
2. If the fault is detected, repair as required.
Is the fault detected? STEP 15 STEP 10
1. Check for the followings in the circuit between main relay
and ECM using breaker box or DMM.
Refer to Breaker box inspection procedure .
l Open circuit
10 l Short circuit to ground circuit —
l High resistance
2. If the fault is detected, repair as required.
Is the fault detected? STEP 15 STEP 12
Replace the main relay.

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021
DTC: P1625 (Flash code 416) Main relay fault Page 4 of 6

11 Is the procedure completed? — STEP 15

Is EMPS available?
12 — STEP 13 STEP 14
1. Check the version of ECM software.
Refer to the EMPS manual for check and rewriting of ECM.
2. Rewrite the software if version upgraded is necessary.
Note:
13 EGR valve position learning is required after replacing or —
rewriting the ECM.
Refer to Installation of ECM in this section for learning
of EGR.
Is the procedure completed? STEP 15 STEP 14
Replace the ECM.
Note:
EGR valve position learning is required after replacing or
rewriting the ECM.
14 —
Refer to Installation of ECM in this section for learning of
EGR.
Is the procedure completed? STEP 15
Check the DTC again.
1. Connect all the harnesses.
2. Clear the DTC.
Refer to How to clear DTC in this section for how to clear
DTCs.
15 —
3. Turn the key switch to “OFF” for more than 10 seconds.
4. Test run with the “Preconditions when DTC is set”.
5. Check the DTC.
Is DTC P1625 detected? STEP 2 STEP 16

Check if other DTC is detected. Go to each

DTC
16 Is other DTC detected? —
diagnosis. Verify repair.
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Turn the key switch to “ON”. 1V
17 4. Connect the DMM between the main relay connector coil-
side terminal and the ground.
Is the DMM indication the specified value or more? STEP 18 STEP 21
1. Turn the key switch to “OFF”. Go to
2. Check the DTC. Diagnostic
18 —
Is DTC P1625 detected? STEP 19 aid .
1. Remove the main relay.
2. Check the DTC.
Note:
19 Refer to the machine’s manual for installing position and —
installation/removal procedures of the main relay.
Is DTC P1625 detected? STEP 20 STEP 11
1. Check the circuit (contact point side) between main relay and
ECM for short circuit to the power supply circuit or ignition

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021
DTC: P1625 (Flash code 416) Main relay fault Page 5 of 6

power supply circuit using breaker box or DMM.

Refer to Breaker box inspection procedure .
20 2. If the fault is detected, repair as required. —
Is the fault detected? STEP 12 STEP 15
Check the installation condition of the main relay and ECM
connector.
1. Check for play or looseness in the connection.
21 —
2. If the fault is detected, repair as required.
Is the fault detected? STEP 15 STEP 22
1. Turn the key switch to “OFF”.
2. Remove the main relay.
3. Turn the key switch to “ON”. 24 V
22 4. Connect the DMM between the main relay connector
terminal (contact point side) and the ground.
Is the DMM indication the specified value or more? STEP 11 STEP 9

Breaker box inspection procedure

Perform the inspection in the following procedure if there is such an instruction to use breaker box in the step. After
inspection, return to the diagnostic step.
Ways to measure voltage and resistance are different when using a breaker box.
Refer to Example of use for breaker box .

Name:
1. Breaker box
2. DMM

Step Item to be checked Checking Measuring Terminal No. Normal Abnormal

method condition value value
STEP 6 , Short circuit to Voltage l Disconnect the 2 – GND 0V 18 V or
STEP 20 power supply circuit measurement relay. 5 – GND more
l Key switch
“ON”
STEP 10 Open circuit/high Resistance l Disconnect the 2 – Relay installing 100Ω or 10 MΩ or
resistance measurement relay. terminal No. 2 less more
l Key switch 5 – Relay installing
“OFF” terminal No. 2
21 – Relay
installing terminal

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021
DTC: P1625 (Flash code 416) Main relay fault Page 6 of 6

No. 5
40 – Relay
installing terminal
No. 5
Short circuit to Resistance l Disconnect the 2 – GND 10 MΩ or 100Ω or less
ground measurement relay. 5 – GND more
l Key switch 21 – GND
“OFF” 40 – GND

file:///F:/documents/ISUZU/Manual/GENERAL_24V/1000/4HK1/contents/data/s001/S00... 3/25/2021