CIRCUIT DIAGRAM ISUZU KB P190 2007 Workshop Repair Manual

BRAKE CON TROL SY STE M 5 A


EHCU, Brake Pipe Diagram .......................................................................................... 5A-5
Hydraulic Unit (H/U) ...................................................................................................... 5A-6
Normal Braking ............................................................................................................. 5A- 7
Pressure Isolation (Pressure Maintain)....................................................................... 5A-8
Pressure Reduction ...................................................................................................... 5A-9
Brake Release ............................................................................................................... 5A -10
Circuit Diagram ............................................................................................................. 5A -11
Connector List ............................................................................................................... 5 A-14
Parts Location ............................................................................................................... 5 A-16
EHCU Pin-Assignment .................................................................................................. 5A-20
System Components .................................................................................................... 5A-22
Electronic Hydraulic Control Unit (EHCU).............................................................. 5A-22
ABS Warning Lamp .................................................................................................. 5A-22
Wheel Speed Sensor (WSS) .................................................................................... 5A-22
G Sensor ................................................................................................................... 5A- 22
Normal and Anti-lock Braking ................................................................................. 5A-22
Electronic Brake-force Distribution (EBD) System................................................ 5A-23
Brake Pedal Travel ................................................................................................... 5A-23
Acronyms and Abbreviations....................................................................................... 5A-23
General Diagnosis ............................................................................................................. 5A-23
General Information ...................................................................................................... 5A-23
ABS Service Precautions ............................................................................................. 5A-23
Computer System Service Precautions ...................................................................... 5A-24
General Service Precautions ....................................................................................... 5A-24
Note on Intermittents .................................................................................................... 5A-24
Test Driving ABS Complaint Vehicles ......................................................................... 5A-24
"ABS" Warning Lamp ................................................................................................... 5A-25
Normal Operation .......................................................................................................... 5A-2 5
SECTION 5A
BRAKE CONTROL SYSTEM
TABLE OF CONTENTS
Ser vice Precau tion ............................................................................................................ 5A -3
General Descrip tio n........................................................................................................... 5A -4

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BRAKE CONTROL SYSTEM 5A-11
Circuit Diagram
With 4JA1 engine


RTW 78AXF007201

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ENGINE ELECTRICAL 6D – 3

GENERAL DESCRIPTION
GENERATOR STARTER MOTOR



066L300004 065L300002

The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.

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6D – 4 ENGINE ELECTRICAL

CHARGING CIRCUIT DIAGRAM





RTW46DSH005101


STARTING CIRCUIT DIAGRAM



RTW46DSH005501




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ENGINE ELECTRICAL 6D – 33
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.



825R300046




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

GLOW PLUG


LNW21KSH001401
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9

EGR SYSTEM 4JA1T (L)
Refer to 6F-9. (EGR system diagram)

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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS

Charging System ................................................ 6D-2
Servicing Cautions .......................................... 6D-2
Important Generator Components and
Function.......................................................... 6D-2
Troubleshooting .............................................. 6D-5
Diagnosis......................................................... 6D-7
Specifications .................................................. 6D-8
Unit Se rv ic ing (4 JJ 1) ....................................... .... ..6D -9
Disassembly .................................................... 6D-10
Inspection and Repair ..................................... 6D-11 Rotor Assembly ........................................... 6D-11
Stator Coil .................................................... 6D-12
Brushes ....................................................... 6D-12
Rectifier ....................................................... 6D-13
Regulator Assembly..................................... 6D-13
Measuring Procedure .................................. 6D-13
Reassembly..................................................... 6D-14
Final Assembly ................................................ 6D-14
Starter Motor ...................................................... 6D-15 Starting Circuit Diagram .................................. 6D-15
Removal and Installation ................................. 6D-15 Important Operations – Removal................. 6D-15
Important Operations – Installation.............. 6D-15
Disassembly .................................................... 6D-16 Disassembly Steps ...................................... 6D-16
Important Operations ................................... 6D-17
Inspection and Repair ..................................... 6D-20 Armature ...................................................... 6D-20
Yoke............................................................. 6D-21
Brush and Brush Holder .............................. 6D-22
Overrunning Clutch...................................... 6D-22
Bearing ........................................................ 6D-23
Reassembly..................................................... 6D-24 Reassembly Steps ....................................... 6D-24
Important Operations ................................... 6D-25
Inspection After Assembly ........................... 6D-26
Magnetic Switch .............................................. 6D-27
Torque Specifications...................................... 6D-28

Pre-Heating System ........................................... 6D-29 Inspection and Repair ..................................... 6D-29 Visual Check................................................ 6D-29
Glow Relay .................................................. 6D-29
Glow Plug .................................................... 6D-29


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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-15
Starter Motor
Starting Circuit Diagram



RTW 46DSH005501
Removal and Installation
Read this Section carefully before performing any
removal and installation procedure. This Section gives
you important points as well as the order of operation.
Be sure that you understand everything in this Section
before you begin.
Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Remove the A/T oil level gage.
3. Remove the Engine oil level gage.
4. Disconnect the magnetic switch cable at the terminal bolts.
5. Disconnect the battery cable at the starter moto
r
and the ground cable at the cylinder body.
6. Remove the starter motor from the engine.

Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention
to the important points during the installation procedure.

Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N⋅m (kg ⋅m/lb ft)
85 (8.7 / 63)
3. Install the Engine oil level gage.
4. Install the A/T oil level gage.
5. Reconnect the battery cable at the starter moto
r
and the ground cable at the cylinder body.
6. Reconnect the battery cable and the ground cable at the battery terminals.



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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-71
DTC P0045 (Flash Code 33)
Circuit Description
The position of the turbocharger nozzle is controlled by
the ECM. The ECM utilizes a turbocharger nozzle
control solenoid valve and a boost pressure sensor to
control the turbocharger nozzles. When the engine is
not under load, the turbocharger nozzles are in an open
position, or no boost condition. When the engine is
under load, the ECM commands the control solenoid
valve to close the turbocharger nozzles, thus
increasing the boost. The ECM will vary the boost
dependant upon the load requirements of the engine.
The ECM uses a pulse width modulation (PWM) on the
control circuit to open and control the solenoid valve. If
the ECM detects an open circuit or short circuit on the
solenoid valve circuit, this DTC will set.
Condition for Running the DTC • The ignition switch is ON.
Condition for Setting the DTC
Either of following condition is met: • The ECM detects a low voltage condition on the turbocharger nozzle control solenoid circuit when
the solenoid is commanded OFF.
• The ECM detects a high voltage condition on the turbocharger nozzle control solenoid circuit when
the solenoid is commanded ON. Action Taken When the DTC Sets
• The ECM illuminates the MIL when the diagnostic runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A.
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Diagnostic Aids • If an intermittent condition is suspected, refer to Intermittent Conditions in this section.
Test description
The number below refers to the step number on the
Circuit/ System Testing.
4. If the solenoid control circuit between the ECM and
the solenoid is normal, the test lamp changes from
Bright to Dim when commanded from Increase to
Decrease.
Schematic Reference: Vacuum Hose Routing
Diagram and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0045
Step Action Value(s)Yes No
1 Did you perform the Diagnostic System Check -
Engine Controls? —
Go to Step 2 Go to Diagnostic
System Check -
Engine Controls
2 1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the DTC Information with a scan tool.
Does the DTC fail this ignition? —
Go to Step 3 Go to Diagnostic
Aids
3 1. Turn OFF the ignition.
2. Disconnect the turbocharger nozzle control solenoid valve harness connector.
3. Connect a test lamp between the ignition voltage feed circuit (pin 2 of E-106) and a
known good ground.
4. Turn ON the ignition, with the engine OFF.
Does the test lamp illuminate? —
Go to Step 4 Go to Step 5

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6E-74 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0087 (Flash Code 225)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. In case of fuel
rail overpressure, a pressure limiter valve threaded into
the fuel rail will open to release overpressure and
return fuel back to the fuel tank. If the ECM detects that
the fuel rail pressure went excessively high, then
sharply decreased, this DTC will set indicating high fuel
pressure, which activated the pressure limiter valve.
Condition for Running the DTC • DTCs P0192 and P0193 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the pressure limiter valve is activated with overpressure (more than 190 MPa
[27,600 psi]) in the fuel rail.
Action Taken When the DTC Sets • The ECM illuminates the MIL when the diagnostic runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A. • The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Diagnostic Aids • An intermittently sticking FRP regulator may have allowed the fuel pressure to become high enough
to open the pressure limiter valve.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Notice: • If the fuel tank is empty or near empty, air might be allowed to go into the fuel system. With air in the
fuel system, smooth flow of fuel into the supply
pump is interrupted and this DTC may set. Perform
bleeding of fuel system after refilling.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0087
Step Action Value(s)Yes No
1 Did you perform the Diagnostic System Check -
Engine Controls? —
Go to Step 2 Go to Diagnostic
System Check -
Engine Controls
2 1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the DTC Information with a scan tool.
Is DTC P0088, P0089, P0091, P0092, P0192,
P0193, P0201 - P0204, P1064, P1065, P124B or
P2146 - P2151 set? —
Go to Applicable DTC Go to Step 3

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-79
DTC P0088 (Flash Code 118)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail.
If the ECM detects that the fuel pressure went
excessively high for a certain length of time, this DTC
will set (First Stage). If the ECM detects that during the
same ignition cycle the fuel pressure rose even higher
than the amount to set DTC P0088 for a certain length
of time, the engine is stopped (Second Stage). If the
engine is stopped, the fuel pressure was too high and
the pressure limiter valve did not active or did not active
quick enough.
Condition for Running the DTC • DTCs P0192 and P0193 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC
First Stage • The ECM detects that the fuel rail pressure is more than 197 MPa (28,600 psi) for longer than 5
seconds.
Second Stage
• The ECM detects that the fuel rail pressure is more than 200 MPa (29,000 psi) for longer than 5
seconds.
Action Taken When the DTC Sets
First Stage • The ECM illuminates the MIL when the diagnostic runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A.
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Second Stage • The ECM illuminates the SVS lamp when the
diagnostic runs and fails. Refer to DTC Type
Definitions for Action Taken When the DTC Sets -
Type C. (Euro 4 Specification)
• The ECM illuminates the MIL when the diagnostic runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A.
(Except Euro 4 Specification)
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
• The ECM stops engine running when the vehicle speed is lower than 5 km/h (3 MPH) for 5 seconds.
The engine will run after the key is cycled when the
ignition has been tuned OFF for longer than 10
seconds.
Condition for Clearing the DTC
First Stage • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Second Stage
• Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp/ DTC - Type C. (Euro 4
Specification)
• Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A. (Except Euro 4
Specification)
Diagnostic Aids • An intermittently sticking Fuel Rail Pressure regulator may have allowed the fuel pressure to
become high enough to set this DTC.
• Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at idle is
around 27 to 33 MPa (3,900 to 48,00 psi) after
warm up.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0088
Step Action Value(s)Yes No
1 Did you perform the Diagnostic System Check -
Engine Controls? —
Go to Step 2 Go to Diagnostic
System Check -
Engine Controls

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