transfer control system ISUZU KB P190 2007 Workshop Repair Manual

MAINTENANCE AND LUBRICATION 0B-3


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate

SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
CLUTCH
Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Automatic transmission fluid (HFV6)
- - I - - I - - I - - I - - I - - I - R (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - - - I - - - I - - - I - - - I - - - I
* Transfer case oil
- - - I - - - I - - - I - - - I - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I

PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve
(4W D) - L - L - L - L - L - L - L - L - L - L

FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I


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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SCHEDULE (For EUROPE)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate

SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil - R - R - R - R - R - R - R - R - R - R* Engine oil filter - - - R - - - R - - - R - - - R - - - ROil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - I I I I I I I I I I I I I I I I I I I
Valve clearance
- - - A - - - A - - - A - - - A - - - A * Air cleaner element I I I I I I I R I I I I I I I R I I I I ** Fuel filter Replace the fuel filter when the fuel filter indicator light is lit. Engine coolant concentration - I - I - I - I - I - I - I - I - I - I Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I CLUTCH Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Manual transmission with fluid - R - I - - - R - - - I - - - R - - - I * Transfer case oil (MT) - - - I - - - I - - - I - - - I - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I
* Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * Transfer case oil (AT)
- - - I - - - - - - - I - - - - - - - I PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear - I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve (4W D) - L - L - L - L - L - L - L - L - L - L
FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I
Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I

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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-7

Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate

SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R*
Engine oil filter
- - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - - - I - - - I - - - I - - - I - - - I
Valve clearance
- - - A - - - A - - - A - - - A - - - A * Air cleaner element I I I I I I I R I I I I I I I R I I I I ** Fuel filter Replace the fuel filter when the fuel filter indicator light is lit. Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil (MT) - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * Transfer case oil (AT)
- - - R - - - I - - - R - - - I - - - R PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear - I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve
(4W D) - L - L - L - L - L - L - L - L - L - L
FRONT AND REAR AXLE
* Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I


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4C2-2 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2W D) and 4 wheel drive (4W D) electrically b
y
driver's pressing the 4W D switch (push button type) on
instrument panel.
This system controls below operations.
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft b
y
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4W D out signal to other Electronic Hydraulic Control Unit.

System Diagrams
RUW 34BLF000201


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ISUZU KB P190 2007

5A-14 BRAKE CONTROL SYSTEM
Connector List
No. Connector face No. Connector face
B-23
White

Meter-A C-36
SilverEngine room - LH ; Ground
B-24
White

Meter-B C-44
WhiteStoplight switch
B-48
Black
G sensor C-53
OrangeABS sensor Front-RH
B-54
White
J/B I2 C-54
OrangeABS sensor Front-LH
B-56
White
J/B I4 C-67
Black
EHCU
B-58
Black
Data link connector C-107
WhiteJ/B E2
B-62
White
Ignition switch (IGSUB : G1) C-108
WhiteJ/B E1
B-63
White
Ignition switch (IGSUB : G2) C-109
SilverBody-LH ; ground
B-82
Silver
W eld splice 6 (Ground) C-111
BlackTransfer case control module
C-2
Silver
Engine room - RH ground F-4
Gray ABS sensor


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ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-21
EHCU Side
Pin No. Pin Function
Wire Color Typical Value Note
20 Stop Light Switch RED Open: 0V
Close: Battery Voltage Close Condition:
Step on the Brake
Pedal
21 G Sensor Signal YEL/BLK 2.0~3.0V
(MAX 4.0V, MIN 1.0V) 4W D Only
It checks in a flat place
(0G: 2.5V)
DTC C0276, C0285
22 ABS W arning Lamp YEL More than 10V -
23 Not Used - - -
24 Transfer (2-4W D Control Unit) GRY Pulse Signal
(High 4.5V, Low 1.5V) 4W D Only
DTC C0282
25 Serial ORN/W HT- Short to GND:
Flash out DTCs
26 Not Used - - -


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BRAKE CONTROL SYSTEM 5A-83
Step Action
Value(s) Yes No
5 1. Ignition "OFF".
2. Connect 2-4W D control unit.
3. Disconnect EHCU.
4. Ignition "ON," engine "OFF."
5. Install the high impedance digital multimeter.
6. Check the transfer (2-4W D control unit) signal value. (Battery voltage is more than 10V.)
W as the value normal? Transfer 2W D
Mode: 8.3Hz (± 15%)
Transfer 4W D Mode: 4.2Hz (± 15%) Go to Step 7 Go to Step 6
6 Replace 2-4W D control unit.
Is the action complete?
- Go to Step 7 -
7 1. Ignition “ON”, engine “OFF”. 2. Select “Display DTCs” with the Tech 2. Note: Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech 2.
Are any DTCs stored? - Go to Step 8 Verify repair
8 Replace EHCU.
Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2W D model or 4W D model)
Is the action complete? - Verify repair -


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6C – 6 FUEL SYSTEM
INJECTION PUMP



RTW 46CLF000201

4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.

4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.

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Engine Control System (4JH1) 6E-103
DTC P0216 (Symptom Code A, B) (Flash Code 54)
Description
The engine control module (ECM) calculates the
desired fuel injection quantity and timing using data sent
from various sensors. These desired data are sent to
the fuel injection pump control unit (PCU) via a
controller area network (CAN) communication bus. The
PCU also receives signals from the internal inputs:
pump camshaft position (CMP) sensor that is located
inside the fuel injection pump to determine the cam ring
rotation angle and the fuel injection pump speed. The
fuel temperature (FT) sensor is internal the PCU. These
values are used to compare the desired values sent
from the ECM then PCU determines the injection time
r
piston position and fuel injection quantity, and actuates
timing control valve (TCV) & fuel injection solenoid
valve based on control maps in the PCU.
The timing device changes the optimum injection
timing against various engine conditions. The
pressure of the fuel fed from the feed pump is
adjusted and it acts to the timing plunger by TCV
controlled fuel pressure. (
The TCV is installed to the
fuel injection pump rear side and it is controlled by dut
y
ratio cycle from the PCU.) The timing plunger is
connected to the cam ring by a ball pin. Axial
movement of the timing plunger is transferred to the
cam ring in the form of rotational movement.
Movement to the right of the timing plunge
r
advances injection timing.
If the PCU detects an
excessive difference between actual and desired fuel
injection timing, this DTC will set.
Condition for Running the DTC
Symptom Code A
• The engine speed is higher than 700 RPM.
• The fuel injection quantity is higher than 4 mg/strk.
Symptom Code B
• The engine speed is higher than 2014 RPM.
Condition for Setting the DTC
Symptom Code A
• The PCU monitored actual fuel injection timing is
advanced more than desired by 3°CA for longe
r
than 12 seconds or retarded more than desired by
6°CA for longer than 12 seconds.
Symptom Code B
• The PCU monitored actual fuel injection timing is
oscillated higher than desired by 5.2°CA.
Action Taken When the DTC Sets
• The ECM illuminates the malfunction indicato
r
lamp (MIL) when the diagnostic runs and fails.
• The ECM limits fuel injection quantity.
Condition for Clearing the MIL/DTC
• The ECM turns OFF the MIL when the diagnostic
runs and does not fail.
• A history DTC clears after 40 consecutive driving
cycles without a fault. Or clear with the scan tool.
Diagnostic Aids
• If an intermittent condition is suspected, refer to
Intermittent Conditions in this section.
Notice:
• The fuel injection pump installation with incorrect
mechanical timing may set this DTC.
• This DTC most likely indicate loss fuel pressure by
restricted fuel line. Inspect the fuel line restriction
between the fuel injection pump and fuel tank.
• The fuel system from the fuel tank(s) to the fuel
injection pump is under a slight vacuum with the
engine running. As a result, air can enter the fuel
system if these connections are not tight or if there
is a crack in one of the fuel hoses. Air in the fuel
system will cause fuel injection pump internal
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
• Improper fuel will cause this DTC to set. Inspect
fuel waxing or icing that is caused by an incorrect
fuel type used in winter season or water intrusion
in the fuel system.
• Contaminated fuel will cause this DTC to set.
Inspect the pipe connector fixing bolt (eye bolt) on
the fuel injection pump suction side.
Important:
If the fuel tank is empty or near empty, air might be
allowed to go into the fuel system. W ith air in the fuel
system, smooth flow of fuel into the fuel injection pump
is interrupted and this DTC may set. Perform bleeding
of fuel system after refilling. Refer to air bleeding
procedure in fuel system section.

DTC P0216 (Symptom Code A, B) (Flash Code 54)

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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6E-276 Engine Control System (4JH1)
1. Connect the scan tool to the vehicle DLC, with theengine and the scan tool OFF.
2. Turn ON the scan tool.
3. Select Diagnostic > appropriate vehicle identification > Powertrain > 4JH1-TC >
Programming > Program VIN.
4. Input correct VIN reading from stamped VIN o
r
affixed VIN plate on the vehicle.
Select Lock ECU and lock the programmed VIN.

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 be
the scan tool for retrieving diagnostic trouble codes
(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 Onl
y
Memory (EEPROM).
This type of memory allows selected portions o
f
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 engine control
module (ECM) are listed below: • Remote Programming
• Pass Thru Programming
For information on programming an ECM using one o
f
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: • W hen a service procedure instructs you to replace
the ECM. W hen the ECM from another vehicle is
installed, VIN must be changed. And change
vehicle information as necessary such as type o
f
transmission.
• 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.
• The hardware key is plugged into the compute
r
port.
• Vehicle system voltage:
- There are no charging system concerns. All charging system concerns must be repaired
before programming the ECM.
- The battery voltage is greater than 12 volts bu
t
less than 16 volts. The battery must be fully
charged before programming the ECM.
-
A battery charger is NOT connected to the
vehicles battery. Incorrect system voltage o
r
voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
- Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF o
r
disable systems such as:
◊ Heating, ventilation, and air conditioning
(HVAC) systems
◊ Headlights
◊ Room lights
◊ Accessory equipment
• The ignition switch is in the proper position. The
scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position o
f
the ignition switch during the programming
procedure unless instructed to do so.
• All tool connections are secure:
- The RS-232 cable
- The connection at the DLC
- The voltage supply circuits


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