check engine light ISUZU KB P190 2007 Workshop Manual PDF

Page 1940 of 6020

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-323
Symptoms - Engine Controls
Symptoms - Engine Controls
Important Preliminary Inspections Before Starting
Perform Diagnostic System Check - Engine Controls
before using the symptom tables, and verify that all of
the following are true:
• The ECM and malfunction indicator lamp (MIL)/ service vehicle soon (SVS) lamp are operating
correctly.
• The scan tool data is within the normal operating range. Refer to Scan Tool Data List in this section.
• Verify the customer concern and locate the correct symptom in the table of contents. Inspect the items
indicated under that symptom.
Visual and Physical Inspection
Several of the symptom procedures ask for careful
visual and physical inspection. This step is extremely
important. The visual and physical inspection can lead
to correcting a problem without further inspections, and
can save valuable time. Ensure that:
• The ECM grounds are clean, tight, and in their proper location.
• The vacuum hoses are not split or kinked, and properly connected. Inspect thoroughly for any
type of leak or restriction.
• The air intake ducts are not collapsed or damaged.
• The exhaust pipes are not collapsed or damaged.
• The engine harness wiring and terminals are properly connected and are not pinched or cut.
Intermittent
Important: Inspect for improper installation of electrical
components if an intermittent condition exists. Inspect
for aftermarket add-on electrical equipment devices,
lights, and cellular phones. Verify that no aftermarket
equipment is connected to the controller area network
(CAN) or other serial data circuit.
Important: The problem may or may not turn ON the
MIL/ SVS lamp or store a DTC. Faulty electrical
connections or wiring cause most intermittent
problems. Perform a careful visual and physical
inspection of the suspect connectors for the following
conditions:
• Improperly mated connector halves
• Terminals that are not seated
• Terminals that are damaged or improperly formed Reform or replace connector terminals in the problem
circuit in order to ensure proper contact tension.
Remove the terminal from the connector body in order
to inspect for poor terminal wire connection.
Road test the vehicle with the DMM connected to the
suspected circuit. An abnormal reading that occurs
when the malfunction occurs is a good indication that
there is a malfunction in the circuit being monitored.
Use the scan tool in order to help detect intermittent
conditions. Useful features of the Tech 2 scan tool
include the following:
• Trigger the Snapshot feature in order to capture and store engine parameters when the malfunction
occurs. Review this stored information in order to
see the specific running conditions that caused the
malfunction.
• Freeze Frame/ Failure Record can also aid in locating an intermittent condition. Review and
capture the information in the Freeze Frame/
Failure Record associated with the intermittent
DTC being diagnosed. Drive the vehicle within the
conditions that were present when the DTC
originally set.
• Use the Plot Function on the scan tool in order to plot selected data parameters. Review this stored
information to aid in locating an intermittent
problem. Refer to the scan tool Users Guide for
more information.
Use the data recording module (DRM) in order to help
detect intermittent conditions. The DRM has ability to
store engine log data when an event of DTC. Maximum
three log data can be stored in the DRM memory. If
more than maximum number of storage is set, oldest
log data is overwritten. However, if same DTC is set
within eight hours that DTC is not stored in the DRM
memory.
The manual trigger function is to store the log data by
an arbitrary operation of the driver when an event of
wrong vehicle performance that is instead of an event
of DTC. If the driver presses and releases the manual
trigger switch once, that time becomes a trigger and
one log data before and behind the trigger is stored in
the DRM memory. When there is a space in the DRM
memory, log data is stored in that space. However,
when more than maximum number of storage is set,
oldest log data is overwritten.
Refer to the DRM Users Guide for more information.
Important: If the intermittent condition exists as a start
and then stall, test for DTCs relating to the vehicle theft
deterrent system. Test for improper installation of
electrical options such as lights, cellular phones, etc..
Any of the following may cause an intermittent MIL/
SVS lamp with no stored DTC:
• The ECM grounds are loose or dirty. Refer to Engine Controls Schematics.

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Page 1943 of 6020

6E-326 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Temperature Sensitivity• An intermittent condition may occur when a component/ connection reaches normal
operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.
• Freeze Frame, Failure Records or Snapshot Data may help with this type of intermittent conditions, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures.
- Underhood/ engine generated heat.
- Circuit generated heat due to a poor connection, or high electrical load.
- Higher than normal load conditions, towing, etc..
• If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in aconnection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern that is temperature related.
Electromagnetic Interference (EMI)
and Electrical Noise Some electrical components/ circuits are sensitive to EMI or other types of electrical
noise. Inspect the following conditions:
• A misrouted harness that is too close to high voltage/ high current devices such as injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the ECM driven solenoid or switch. These conditions can cause a sharp electrical surge. Normally,
the problem will occur when the malfunctioning component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test for any open diodes. Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
- An ECM from another vehicle is installed.
- Revised software/ calibration files have been released for this vehicle.
Important: DO NOT reprogram the ECM with the SAME software/ calibration files that
are already present in the ECM. This is not an effective repair for any type of driveability
problem.
• Verify that the ECM contains the correct software/ calibration. If incorrect programming is found, reprogram the ECM with the most current software/
calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/ or capture the failure conditions.
• Freeze Frame/ Failure Records data, where applicable, contains the conditions that were present when the DTC set.
- Review and record Freeze Frame/ Failure Records data.
- Operate the vehicle under the same conditions that were noted in Freeze Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.
• An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
Checks
Action

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Page 1966 of 6020

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-349
4. In order to get programming approval, the on-screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the “Tech 2” on the Diagnostic Tool Selection screen and click “Next”.
f. Click “Close” on the Security Access Enabled screen.
g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Install a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Program ECU.
8. Verify the VIN on the screen if programmed at previously described SPS. If not programmed or
incorrect VIN, input correct VIN.
9. Input 24 digits of each fuel injector ID code.
10. After complete the programming, turn OFF the ignition for 30 seconds.
11. Start the engine and let idle.
12. Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.
G. Supply Pump Relearn 1. Install a scan tool.
2. Start the engine and let idle until engine coolant temperature reads 65 °C (149 °F) or higher while
observing the Supply Pump Status parameter with
a scan tool. The scan tool parameter changes
status Not Learn > Learning > Learned.
3. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.Service Programming System (SPS)
Description
The service programming system (SPS) allows a
technician to program a control module through the
data link connector (DLC). The information transfer
circuit that is used at the DLC is the same serial data
circuit used by the scan tool for retrieving DTCs,
displaying data, clearing DTCs etc. This procedure
offers the ability to install software/ calibrations
matched to a particular vehicle.
Most control modules have two types of memory. The
software/ calibrations reside in the flash memory. The
two types of memory are listed below:
• Electrically Erasable Programmable Read Only Memory (EEPROM)
This type of memory allows selected portions of
memory to be programmed while other portions
remain unchanged.
Certain learned values reside in the EEPROM,
such as:
- The vehicle identification number (VIN)
- The software/ calibrations identification numbers
- The control module security information
• Flash Read Only Memory-Flash Memory Flash memory has increased memory storage
capacity. During programming, all information
within this type of memory is erased, and then
replaced with entirely new information.
Service Programming Methods
The two methods of programming an ECM are listed
below:
• Remote Programming
• Pass Thru Programming
For information on programming an ECM using one of
the methods listed above, refer to Service
Programming System (SPS) (Remote Procedure) or
Service Programming System (SPS) (Pass-Thru
Procedure).
Before Programming a Control Module
Important: DO NOT program an existing ECM with the
identical software/ calibration package. This procedure is not
a short cut to correct the driveability condition. This is an
ineffective repair. An ECM should only be programmed when
the following occurs:
• When a service procedure instructs you to replace the ECM.
• An updated software/ calibrations is released.
Ensure that the following conditions are met before
programming an ECM:
• The scan tool PCMCIA card is programmed with the latest software.
• The TIS 2000 is installed with the latest software.

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Page 2002 of 6020

6-2 ENGINE DIAGNOSIS (C24SE)
Engine Diagnosis
Hard Starting
1.Starting Motor Does Not Turn Over
Trouble Shooting Procedure
Turn on headlights and starter switch.
Condition Possible cause Correction
Headlights go out or dim
considerably Battery run down or under
charged Recharge or replace battery

Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start
Spark Test Disconnect a high tension cable from any spark plug.
Connect the spark plug tester (use commercially
available tool), crank the engine, and check if a spark is
generated in the spark plug tester. Before cranking the
engine, make sure that the spark plug tester is properly
grounded. To avoid electrical shock, do not touch the
high tension cable while the engine is running.

Condition Possible cause Correction
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Spark plug wire in correct Connect properly or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s)
or engine Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or
broken Connect properly or replace

Electronic Ignition System with
module Replace

Poor connections in engine
harness Correct

Engine Control Module cable
disconnected or defective Correct or replace


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Page 2009 of 6020

ENGINE DIAGNOSIS (C24SE) 6-9
Abnormal Noise Due to Hydraulic Lash Adjuster
Should abnormal noise due to the hydraulic lash
adjuster trouble be heard immediately after the engine
is started, inspect as follows:
Condition Possible cause Correction
Abnormal noise is heard Air contaminated Bleed
HLA is spongy Check ball valve broken Repair
Safety valve in cylinder head
broken Replace
Valve clearance is not zero HLA inside stick
Replace HLA assembly

Troubleshooting Procedure
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with
defective bearing by listening for abnormal noise that
stops when spark plug is shorted out.
Condition Possible cause Correction
Noise from connecting rods or
from connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing
noise, which becomes more
evident when engine is
accelerated) Bearing or crankshaft pin worn Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Crankpin out of round Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing

Troubleshooting Procedure
Abnormal noise stops when the spark plug on the
cylinder with defective parts is shorted out.
Condition Possible cause Correction
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes
gradually as the engine warms up) Piston clearance increased due to
cylinder wear Replace piston and cylinder body

Piston seized Replace piston and cylinder body
Piston ring broken Replace piston and cylinder body
Piston defective Replace pistons and others


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Page 2042 of 6020

6A-28 ENGINE MECHANICAL (C24SE)


2. Install cable to temperature sensor.
3. Install upper bolts of rear toothed belt rear cover.
4. Install camshaft timing gear then check timing according to the corresponding operation.
5. Install camshaft housing cover.
6. Install toothed belt and front cover.
7. Fill up and bleed cooling system according to the corresponding operation.


Tighten (Torque)
Thermostat housing to cylinder head - 15 N ⋅m/1.5 kgf ⋅m.




Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.


Removal
Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation
Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.


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Page 2064 of 6020

6A-50 ENGINE MECHANICAL (C24SE)

Clean
Sealing surfaces.





013RW 004










Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.

Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4 ×4 model
only]).
8. Install the crossmember.

Tighten (Torque)
Oil intake pipe to oil pump -8N ⋅m (0.8 kgf ⋅m)
Oil intake pipe bracket to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil pan to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
Bearing bridge to cylinder block – 8 N ⋅m (0.8 kgf ⋅m)



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Page 2071 of 6020

ENGINE MECHANICAL (C24SE) 6A-57



Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"


Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.











1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.

Installation
1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.

Important!
Do not allow crankshaft to rotate.

Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° + to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.6 kgf ⋅m) +45 °.



Removal
1. Remove bearing cap and shell.

Measure
W idth of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"

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Page 2224 of 6020

6E–54 ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM
The engine use two ignition coils, one per two cylinders.
A two wire connector provides a battery voltage primary
supply through the ignition fuse.
The ignition control spark timing is the ECM’s method of
controlling the spark advance and the ignition dwell.
The ignition control spark advance and the ignition dwell
are calculated by the ECM using the following inputs.
• Engine speed
• Crankshaft position (CKP) sensor
• Engine coolant temperature (ECT) sensor
• Throttle position sensor
• Vehicle speed sensor
• ECM and ignition system supply voltage
Ignition coil works to generate only the secondary
voltage be receiving the primary voltage from ECM.
The primary voltage is generated at the coil driver
located in the ECM. The coil driver generate the primary
voltage based on the crankshaft position signal. In
accordance with the crankshaft position signal, ignition
coil driver determines the adequate ignition timing and
also cylinder number to ignite.
Ignition timing is determined the coolant temperature,
intake air temperature, engine speed, engine load,
knock sensor signal, etc.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequently fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication .
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels
and lubricating oils with additives. Some electrode wear
will also occur. Engines which are not running properly
are often referred to as “misfiring.” This means the
ignition spark is not igniting the air/fuel mixture at the
proper time. While other ignition and fuel system causes
must also be considered, possible causes include
ignition system conditions which allow the spark voltage
to reach ground in some other manner than by jumping
across the air gap at the tip of the spark plug, leaving
the air/fuel mixture unburned. Misfiring may also occur
when the tip of the spark plug becomes overheated and
ignites the mixture before the spark jumps. This is
referred to as “pre-ignition.”
Spark plugs may also misfire due to fouling, excessive
gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate
and correct the cause.
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds
under light engine loads can keep the spark plug
temperatures so low that these deposits are not burned
off. Very rich fuel mixtures or poor ignition system output
may also be the cause. Refer to DTC P1167.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of
combustion by-products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the center
electrode. If the fouling is found in only one or two
cylinders, valve stem clearances or intake valve seals
may be allowing excess lubricating oil to enter the
cylinder, particularly if the deposits are heavier on the
side of the spark plug facing the intake valve.
Excessive gap means that the air space between the
center and the side electrodes at the bottom of the
spark plug is too wide for consistent firing. This may be
due to improper gap adjustment or to excessive wear of
the electrode during use. A check of the gap size and
comparison to the gap specified for the vehicle in
Maintenance and Lubrication will tell if the gap is too
wide. A spark plug gap that is too small may cause an
unstable idle condition. Excessive gap wear can be an
indication of continuous operation at high speeds or
with engine loads, causing the spark to run too hot.
Another possible cause is an excessively lean fuel
mixture.

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Page 2235 of 6020

ENGINE DRIVEABILITY AND EMISSIONS 6E–65
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Next, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Hints
You can isolate a circuit by:
• Unplugging connectors or removing a fuse to separate one part of the circuit from another
• If only component fails to operate, begin testing the component
• If a number of components do not operate, begin test at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
• Substitute a known good part from the parts department or the vehicle system
• Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
• Service manual
• Bulletins
• Digital multimeter (with a MIN/MAX feature)
• Tech II and Tech II upload function
• Circuit testing tools (including connector kits/ harnesses and jumper wires)
• Experience
• Intermittent problem solving simulation methods
• Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful. For parts and sensors, apply slight vibration to the part
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CAUTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CAUTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
• A lack of understanding by the customer
• A conflict between customer expectations and vehicle design intent
• A system performance that is unacceptable to the customer
What you should do
You can verify that a system is operating as designed
by:
• Reviewing service manual functional/diagnostic checks
• Examining bulletins and other service information for supplementary information
• Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer expectation and system
operation, you should explain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:

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