check engine ISUZU KB P190 2007 Workshop Repair Manual

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-13
Rectifier
Measure each of the diode resistances in both
directions (anode/cathode and cathode/anode). If any o
f
the diodes have the same resistance in both directions,
the rectifier must be replaced.



066RS036

Regulator Assembly
There are 3 checkpoints (12V batteries, 10 ohms 3W
resistor, 0-50V/0.5V steps, and 300 ohms 12W variable
resistor). Refer to the schematic below.

Measuring Procedure
1. Measure the voltage (BAT) at the V1 checkpoint. A
10-13 volt reading indicates that the BAT battery is
good.
2. Measure the voltage at checkpoints V1 and V2 as
you gradually increase the resistance of the
variable resistor from 0. The voltage at V1 should
change with the voltage at V2. If it does not, the
regulator is damaged and must be replaced.
3. Measure the voltage at checkpoint V3 with the variable resistor setting fixed. If the measured
voltage is 14.4 ± 0.3, the regulator is good. If the
measured voltage is outside this range, the
regulator is damaged and must be replaced.





RTW 56DMF000301

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6D-20 ENGINE ELECTRICAL (4JK1/4JJ1)
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacement if excessive wear or damage is discovered
during inspection.
Armature
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out mm (in)
Standard Limit
0.05 (0.002) 0.25 (0.010)







RTW 46DSH003501
2. Check the commutator mica segments for
excessive wear.
3. Measure the mica segment depth.
Mica Segment Depth mm (in)
Standard Limit
0.5 - 0.8 (0.020 - 0.030) 0.2 (0.008)
If the mica segment depth is less than the standard but more than the limit, the commutato
r
may be reground.
If the mica segment depth is less than the limit, the commutator must be replaced.


RTW 56DSH000701
Legend
1. Insulator
2. 0.5 - 0.8 mm (0.020 - 0.030 in)
3. Commutator Segments
4. Correct
5. Incorrect

4. Measure the commutator outside diameter.
Commutator Outside Diameter mm (in)
Standard Limit
36.5 (1.44) 35.5 (1.40)
If the measured outside diameter is less than the
specified limit, the commutator must be replaced.





HCW 51ESH000901


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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-21
5. Use a circuit tester to check the armature for
grounding.
1) Hold one probe of the circuit tester against the commutator segment.
2) Hold the other circuit tester probe against the armature core.
If the circuit tester indicates continuity, the armature is grounded.
The armature must be replaced.





RTW 46DSH003601
6. Use the circuit tester to check the armature for
continuity.
1) Hold the circuit tester probes against two commutator segments.
2) Repair Step 1 at different segments of the armature core.
There should be continuity between all segments of the commutator.
If there is not, the armature must be replaced.




RTW 46DSH003701

Yoke
1. Use a circuit tester to check the field winding
ground.
1) Hold one circuit tester probe against the field winding end or brush.
2) Hold the other circuit tester probe against the bare surface of the yoke body.
There should be no continuity. If there is continuity, the field coil is grounded. The yoke
must be replaced.


RTW 46DSH003801
2. Use the circuit tester to check the field winding
continuity.
1) Hold one circuit tester probe against the “M” terminal lead wire.
2) Hold the other circuit tester probe against the field winding brush.
There should be continuity.If there is no continuity, the yoke must be replaced.

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6D-22 ENGINE ELECTRICAL (4JK1/4JJ1)



RTW 46DSH003901
Brush and Brush Holder
1. Use a vernier caliper to measure the brush length
(four brushes).
Replace the brushes as a set if one or more of the brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)



RTW 46DSH004001
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the othe
r
probe to the positive brush holder.
There should be no continuity.




RTW 46DSH004101
3. Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire yoke must be replaced.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.







065RY00035


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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-29
Pre-Heating System
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacement if excessive wear of damage is discovered
during inspection.
Visual Check
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
Glow Relay
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94 - 114

















825R300046

Glow Plug
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9



LNW 21KSH001401



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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-1
SECTION 6E
ENGINE CONTROL SYSTEM(4JK1/4JJ1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-3 Temperature vs Resistance . . . . . . . . . . . . . . . . 6E-3
Altitude vs Barometric Pressure . . . . . . . . . . . . . 6E-3
Diagnostic Trouble Code (DTC) Type Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-4
Diagnostic Trouble Code (DTC) List . . . . . . . . . 6E-4
Schematic and Rounting Diagrams. . . . . . . . . . . . 6E-9 Fuel System Routing Diagram . . . . . . . . . . . . . . 6E-9
Vacuum Hose Routing Diagram . . . . . . . . . . . . . 6E-9
Engine Controls Schematics . . . . . . . . . . . . . . 6E-10
Component Locator. . . . . . . . . . . . . . . . . . . . . . . 6E-27 Engine Controls Component Views . . . . . . . . . 6E-27
Engine Control Module (ECM) Connector End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-30
Engine Control Connector End Views . . . . . . . 6E-33
Diagnostic Information and Procedures . . . . . . . 6E-42 Engine Control System Check Sheet . . . . . . . . 6E-42
Diagnostic Starting Point - Engine Controls . . . 6E-43
Diagnostic System Check - Engine Controls . . 6E-44
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 6E-46
Scan Tool Data Definitions . . . . . . . . . . . . . . . . 6E-49
Scan Tool Output Controls . . . . . . . . . . . . . . . . 6E-54
Scan Tool Does Not Power Up. . . . . . . . . . . . . 6E-55
Scan Tool Does Not Communicate with CAN Device. . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-56
Lost Communication with The Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . 6E-59
Engine Cranks but Does Not Run . . . . . . . . . . 6E-62
DTC P0016 (Flash Code 16) . . . . . . . . . . . . . . 6E-68
DTC P0045 (Flash Code 33) . . . . . . . . . . . . . . 6E-70
DTC P0087 (Flash Code 225) . . . . . . . . . . . . . 6E-72
DTC P0088 (Flash Code 118) . . . . . . . . . . . . . 6E-77
DTC P0089 (Flash Code 151) . . . . . . . . . . . . . 6E-82
DTC P0091 or P0092 (Flash Code 247) . . . . . 6E-85
DTC P0093 (Flash Code 227) . . . . . . . . . . . . . 6E-88
DTC P0101 (Flash Code 92) . . . . . . . . . . . . . . 6E-93
DTC P0102 or P0103 (Flash Code 91) . . . . . . 6E-96
DTC P0107 or P0108 (Flash Code 32) . . . . . 6E-100
DTC P0112 or P0113 (Flash Code 22) . . . . . 6E-104
DTC P0116 (Flash Code 23) . . . . . . . . . . . . . 6E-108
DTC P0117 or P0118 (Flash Code 23) . . . . . 6E-110
DTC P0122 or P0123 (Flash Code 43) . . . . . 6E-114
DTC P0182 or P0183 (Flash Code 211) . . . . 6E-118
DTC P0192 or P0193 (Flash Code 245) . . . . 6E-122
DTC P0201, P0202, P0203 or P0204 (Flash Code 271, 272, 273 or 274) . . . . . . . . 6E-126
DTC P0217 (Flash Code 542) . . . . . . . . . . . . 6E-133
DTC P0219 (Flash Code 543) . . . . . . . . . . . . 6E-135
DTC P0231 or P0232 (Flash Code 69) . . . . . 6E-137
DTC P0234 (Flash Code 42) . . . . . . . . . . . . . 6E-140 DTC P0299 (Flash Code 65) . . . . . . . . . . . . . 6E-143
DTC P0335 (Flash Code 15) . . . . . . . . . . . . . 6E-146
DTC P0336 (Flash Code 15) . . . . . . . . . . . . . 6E-149
DTC P0340 (Flash Code 14) . . . . . . . . . . . . . 6E-151
DTC P0341 (Flash Code 14) . . . . . . . . . . . . . 6E-154
DTC P0380 (Flash Code 66) . . . . . . . . . . . . . 6E-156
DTC P0401 (Flash Code 93) . . . . . . . . . . . . . 6E-159
DTC P0403 (Flash Code 37) . . . . . . . . . . . . . 6E-161
DTC P0404 (Flash Code 45) . . . . . . . . . . . . . 6E-164
DTC P0405 or P0406 (Flash Code 44) . . . . . 6E-166
DTC P0500 (Flash Code 25) . . . . . . . . . . . . . 6E-170
DTC P0501 (Flash Code 25) . . . . . . . . . . . . . 6E-174
DTC P0512 (Flash Code 417) . . . . . . . . . . . . 6E-176
DTC P0562 or P0563 (Flash Code 35) . . . . . 6E-178
DTC P0565 (Flash Code 515) . . . . . . . . . . . . 6E-181
DTC P0566 (Flash Code 516) . . . . . . . . . . . . 6E-183
DTC P0567 (Flash Code 517) . . . . . . . . . . . . 6E-185
DTC P0568 (Flash Code 518) . . . . . . . . . . . . 6E-187
DTC P0571 (Flash Code 26) . . . . . . . . . . . . . 6E-189
DTC P0601 (Flash Code 53) . . . . . . . . . . . . . 6E-192
DTC P0602 (Flash Code 154) . . . . . . . . . . . . 6E-193
DTC P0604 or P0606 (Flash Code 153 or 51) . . . . . . . . . . . . . . . . . 6E-195
DTC P0615 (Flash Code 19) . . . . . . . . . . . . . 6E-196
DTC P0633 (Flash Code 176) . . . . . . . . . . . . 6E-198
DTC P0638 (Flash Code 61) . . . . . . . . . . . . . 6E-199
DTC P0642 or P0643 (Flash Code 55) . . . . . 6E-201
DTC P0650 (Flash Code 77) . . . . . . . . . . . . . 6E-204
DTC P0652 or P0653 (Flash Code 56) . . . . . 6E-207
DTC P0661 or P0662 (Flash Code 58) . . . . . 6E-211
DTC P0698 or P0699 (Flash Code 57) . . . . . 6E-215
DTC P0700 (Flash Code 185) . . . . . . . . . . . . 6E-219
DTC P1064 or P1065 (Flash Code 247) . . . . 6E-220
DTC P1093 (Flash Code 227) . . . . . . . . . . . . 6E-224
DTC P1094 (Flash Code 226) . . . . . . . . . . . . 6E-229
DTC P1196, P1197 or P1198 (Flash Code 461) . . . . . . . . . . . . . . . . . . . . . 6E-235
DTC P124B (Flash Code 157) . . . . . . . . . . . . 6E-237
DTC P1261 (Flash Code 34) . . . . . . . . . . . . . 6E-240
DTC P1262 (Flash Code 34) . . . . . . . . . . . . . 6E-242
DTC P1404 (Flash Code 45) . . . . . . . . . . . . . 6E-244
DTC P1411, P1412 or P1413 (Flash Code 445) . . . . . . . . . . . . . . . . . . . . . 6E-246
DTC P156A or P156B (Flash Code 135) . . . . 6E-248
DTC P161B (Flash Code 179) . . . . . . . . . . . . 6E-251
DTC P1621 (Flash Code 54, 254) . . . . . . . . . 6E-253
DTC P1664 (Flash Code 76) . . . . . . . . . . . . . 6E-255
DTC P2100, P2101 or P2103 (Flash Code 446) . . . . . . . . . . . . . . . . . . . . . 6E-258
DTC P2122 or P2123 (Flash Code 121) . . . . 6E-261

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6E-2 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P2127 or P2128 (Flash Code 122) . . . . 6E-265
DTC P2132 or P2133 (Flash Code 123) . . . . 6E-269
DTC P2138, P2139 or P2140 (Flash Code 124, 125 or 126) . . . . . . . . . . . . 6E-274
DTC P2146, P2147 or P2148 (Flash Code 158) . . . . . . . . . . . . . . . . . . . . . 6E-280
DTC P2149, P2150 or P2151 (Flash Code 159) . . . . . . . . . . . . . . . . . . . . . 6E-284
DTC P2227 (Flash Code 71) . . . . . . . . . . . . . 6E-288
DTC P2228 or P2229 (Flash Code 71) . . . . . 6E-291
DTC P2621 or P2622 (Flash Code 94) . . . . . 6E-295
DTC U0001 or U0101 Flash Code 84 or 85) . . . . . . . . . . . . . . . . . . 6E-298
DTC U0167 (Flash Code 177) . . . . . . . . . . . . 6E-299
EGR Control System Check. . . . . . . . . . . . . . 6E-300
Glow Control System Check . . . . . . . . . . . . . 6E-304
In-Tank Fuel Pump System Check . . . . . . . . . 6E-309
Cruise Control System Check . . . . . . . . . . . . 6E-312
Turbocharger Control System Check . . . . . . . 6E-318
Symptoms - Engine Controls . . . . . . . . . . . . . . 6E-321 Symptoms - Engine Controls . . . . . . . . . . . . . 6E-321
Intermittent Conditions . . . . . . . . . . . . . . . . . . 6E-323
Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-326
Rough, Unstable, or Incorrect Idle and Stalling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-328
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . 6E-330
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-331
Surges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-332
Lack of Power, Sluggishness or Sponginess . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-334
Hesitation, Sag or Stumble. . . . . . . . . . . . . . . 6E-336
Abnormal Combustion Noise . . . . . . . . . . . . . 6E-338
Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . 6E-339
Excessive Smoke (Black Smoke) . . . . . . . . . 6E-341
Excessive Smoke (White Smoke) . . . . . . . . . 6E-343
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 6E-345 Engine Control Module (ECM) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6E-345
Service Programming System (SPS) Description . . . . . . . . . . . . . . . . . . . . . . . . . . 6E-347
Service Programming System (SPS) (Remote Procedure) . . . . . . . . . . . . . . . . . . . 6E-348
Service Programming System (SPS) (Pass-Thru Procedure) . . . . . . . . . . . . . . . . . 6E-349
Description and Operation . . . . . . . . . . . . . . . . 6E-351 Engine Control Module (ECM) Description . . 6E-351
Engine Control Component Description . . . . . 6E-353
Fuel System Description . . . . . . . . . . . . . . . . 6E-357
Fuel System Component Description. . . . . . . 6E-358
Fuel Injection System Description . . . . . . . . . 6E-362
Exhaust Gas Recirculation (EGR) System Description . . . . . . . . . . . . . . . . . . . . 6E-363
Turbocharger Description . . . . . . . . . . . . . . . . 6E-364
Special Tools and Equipment . . . . . . . . . . . . . . 6E-366 Special Tools and Equipment . . . . . . . . . . . . . 6E-366

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6E-6 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
P0501 25 AAA Vehicle Speed Sensor Circuit Range/ Performance
P0512 417 C -- Starter Request Circuit
P0562 35 C AA System Voltage Low
P0563 35 C AA System Voltage High
P0565 515 D D- Cruise Control On Signal
P0566 516 D D- Cruise Control Off Signal
P0567 517 D D- Cruise Control Resume Signal
P0568 518 D D- Cruise Control Set Signal
P0571 26 D D- Brake Switch Circuit
P0601 53 C AA Internal Control Module Memory Check Sum Error
P0602 154 C AA Control Module Programming Error
P0604 153 C AA Internal Control Module RAM Error
P0606 51 C AA ECM Processor
P0615 19 C -- Starter Relay Circuit
P0633 176 C AA Immobilizer Not Programmed
P0638 61 A AA Throttle Actuator Control Range/ Performance
P0642 55 C AA Sensor Reference Voltage 1 Circuit Low
P0643 55 C AA Sensor Reference Voltage 1 Circuit High
P0650 77 A AA Malfunction Indicator Lamp (MIL) Control Circuit
P0652 56 A AA Sensor Reference Voltage 2 Circuit Low
P0653 56 A AA Sensor Reference Voltage 2 Circuit High
P0661 58 C AA Intake Manifold Turning Valve Control Circuit Low
P0662 58 C AA Intake Manifold Turning Valve Control Circuit High
P0698 57 A AA Sensor Reference Voltage 3 Circuit Low
P0699 57 A AA Sensor Reference Voltage 3 Circuit High
P0700 185 A A- Transmission Control System (MIL Request)
P1064 247 A AA Fuel Pressure Regulator Control Circuit
P1065 247 A AA Fuel Pressure Regulator Control Circuit
P1093 227 A AA Fuel Rail Pressure Too Low
P1094 226 A AAFuel Rail Pressure Too Low (FRP Regulator
Commanded High)
P1094 226 C AA Fuel Rail Pressure Too Low (Fuel Pressure Drop)
P1196 461 A AA Intake Throttle Solenoid Control Driver
P1197 461 A AA Intake Throttle Solenoid Control Driver
P1198 461 A AA Intake Throttle Solenoid Control Driver
P124B 157 C AA Injector Circuit Short Across Group 1 & 2
P1261 34 A AA Injector Positive Voltage Control Circuit Group 1
P1261 34 A AAInjector Positive Voltage Control Circuit (Supply Voltage
Low)
DTC
Flash
Code DTC Type
DTC Descriptor
Euro 4
Specification Except Euro 4
Specification
(High Output) Except Euro 4
Specification (Standard Output)

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-43
Diagnostic Information and Procedures
Engine Control System Check Sheet

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6E-44 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Diagnostic Starting Point - Engine Controls
Begin the system diagnosis with Diagnostic System
Check - Engine Controls. The Diagnostic System
Check - Engine Controls will provide the following
information:
• The identification of the control modules which command the system.
• The ability of the control modules to communicate through the serial data circuit.
• The identification of any stored diagnostic trouble codes (DTCs) and the their statuses.
The use of the Diagnostic System Check - Engine
Controls will identify the correct procedure for
diagnosing the system and where the procedure is
located.
Important: Engine Control System Check Sheet must
be used to verify the complaint vehicle, you need to
know the correct (normal) operating behavior of the
system and verify that the customer complaint is a valid
failure of the system. Reading Flash Diagnostic Trouble Codes (DTC)
The provision for communicating with the ECM is the
Data Link Connector (DLC). The DTC(s) stored in the
ECM memory can be read either through a hand-held
diagnostic scanner such as Tech 2 plugged into the
DLC or by counting the number of flashes of the
malfunction indicator lamp (MIL) or the service vehicle
soon (SVS) lamp when the diagnostic test terminal of
the DLC is grounded. The DLC terminal "1" (diagnostic
request) is pulled "Low" (grounded) by jumped to DLC
terminal "4", which is a ground wire. Once terminals "1"
and "4" have been connected, turn the ignition switch
ON, with the engine OFF. The MIL (except Euro 4
specification) or the SVS lamp (Euro 4 specification)
will indicate a DTC three times is a DTC is present and
history. If more than one DTC has been stored in the
ECM's memory, the DTCs will be output set order with
each DTC being displayed three times. The flash DTC
display will continue as long as the DLC is shorted.
RTW76ESF000301
ON
OFF
ON
OFF
1.2
3.2
2.62.6
2nd digit number1st digit number
3.20.6 2
1.2
0.60.60.6
0.30.30.3
0.30.30.30.30.3
Example:DTC 23 stored
Unit: Second
Example:DTC 225 stored
3rd digit
number 2nd digit number1st digit number
0.60.60.60.60.60.60.60.6
3
0.30.31.21.2
2
25

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