battery replacement ISUZU KB P190 2007 Workshop User Guide
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 1156 of 6020
6E-122 Engine Control System (4JH1)
Step Action Value(s) Yes No
4 1. Test the control circuit between the engine
control module (ECM) (pin 96 of C-57 connector)
and the turbocharger solenoid valve (pin 2 of C-
123 connector) for a short to battery or ignition
voltage.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 7 Go to Step 6
5 Replace the turbocharger solenoid valve. Refer to Turbocharger Solenoid Valve Replacement in this
section.
Did you complete the replacement?
Go to Step 7
6 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 7
7 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Monitor the DTC Information with the scan tool.
Did the DTC fail this ignition?
Go to Step 3 Go to Step 8
8 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1171 of 6020
Engine Control System (4JH1) 6E-137
Step Action Value(s) Yes No
7 1. Turn OFF the ignition.
2. Connect a test lamp between the control circuit of the glow relay (pin 3 of X-5 connector) and
battery voltage.
3. Turn ON the ignition, with the engine OFF.
Does the test lamp continuously illuminate (the test
lamp blinks then goes out normally if the engine
coolant temperature lower than 30°C [86°F])?
Go to Step 10 Go to Step 8
8 1. Keep the test lamp with connected. 2. Command the Glow Relay ON with the scan tool.
Does the test lamp illuminate when commanded ON
with the scan tool?
Go to Step 12 Go to Step 11
9 Repair the voltage feed circuit between the ECM (10A) fuse (EB-4) and the glow relay (pin 2 of X-5
connector) for an open circuit or high resistance.
Did you complete the repair?
Go to Step 16
10 1. Test the control circuit of the glow relay between
the engine control module (ECM) (pin 94 of C-57
connector) and the glow relay (pin 3 of X-5
connector) for a short to ground.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 16 Go to Step 15
11 1. Test the control circuit of the glow relay between the ECM (pin 94 of C-57 connector) and the glow
relay (pin 3 of X-5 connector) for an open circuit
or high resistance.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 16 Go to Step 13
12 1. Turn OFF the ignition. 2. Inspect for an intermittent and for poor connections on the glow relay terminals (pins 2
and 3 of X-5 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 16 Go to Step 14
13 1. Turn OFF the ignition. 2. Disconnect the ECM harness connector.
3. Inspect for an intermittent and for a poor connection on the glow relay control circuit at the
harness connector of the ECM (pin 94 of C-57
connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 16 Go to Step 15
14 Replace the glow relay. Did you complete the replacement?
Go to Step 16
15 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 16
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ISUZU KB P190 2007
Page 1173 of 6020
Engine Control System (4JH1) 6E-139
DTC P0380 (Symptom Code 8) (Flash Code 66)
Circuit Description
The engine control module (ECM) controls the glo
w
relay which supplies power to the glow plugs based on
engine coolant temperature. In the after glow phase, the
glow indicator light is not illuminated but glow plugs
remain active for a certain period. If the ECM detects a
short to battery or ignition voltage on the glow rela
y
control circuit, this DTC will set.
Condition for Running the DTC
• The ignition switch is ON.
Condition for Setting the DTC
• The ECM detects that the high voltage condition
on the glow relay control circuit for longer than 1
second when the relay is commanded ON.
Action Taken When the DTC Sets
• The ECM illuminates the malfunction indicato
r
lamp (MIL) when the diagnostic runs and fails.
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.
Notice:
• The glow relay is commanded OFF with ignition
ON and engine OFF when the engine coolant
temperature is reached at 30°C (86°F).
• The glow relay is commanded OFF with engine
run when the engine coolant temperature is
reached at 60°C (140°F).
DTC P0380 (Symptom Code 8) (Flash Code 66)
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or Engine Control Module (ECM)
Connector End Views
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 the scan tool. 2. Turn ON the ignition, with the engine OFF.
3. Perform the Glow Relay test with the scan tool.
4. Command the Glow Relay ON with the scan tool.
Does the glow relay click when commanded ON with
the scan tool?
Go to Diagnostic Aids Go to Step 3
3 1. Turn OFF the ignition. 2. Replace the glow relay with the starter relay or replace with a known good relay.
3. Turn ON the ignition, with the engine OFF.
4. Command the Glow Relay ON with the scan tool.
Does the glow relay click when commanded ON with
the scan tool?
Go to Step 5 Go to Step 4
4 1. Test the control circuit of the glow relay between the engine control module (ECM) (pin 94 of C-57
connector) and the glow relay (pin 3 of X-5
connector) for a short to battery or ignition
voltage.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 7 Go to Step 6
5 Replace the glow relay. Did you complete the replacement?
Go to Step 7
6 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 7
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ISUZU KB P190 2007
Page 1179 of 6020
Engine Control System (4JH1) 6E-145
Step Action Value(s) Yes No
4 1. Test the control circuit of the glow indicator lamp
between the engine control module (ECM) (pin
43 of C-56 connector) and the IPC (pin 6 of B-24
connector) for a short to battery or ignition
voltage.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 7 Go to Step 6
5 Repair or replace the IPC (meter assembly). Did you complete the repair or replacement?
Go to Step 7
6 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 7
7 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Cool down the engine as necessary (allow engine coolant temperature to cool down at least
25 °C [77 °F]).
5. Turn ON the ignition, with the engine OFF.
6. Monitor the DTC Information with the scan tool.
Did the DTC fail this ignition?
Go to Step 2 Go to Step 8
8 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1184 of 6020
6E-150 Engine Control System (4JH1)
Step Action Value(s) Yes No
6 1. Connect a test lamp between the control circuit
of the EGR solenoid valve harness (pin 2 of C-
115 connector) and battery voltage.
2. Perform the EGR Solenoid Valve test with the scan tool.
3. Command the EGR Solenoid Valve ON with the scan tool.
Does the test lamp illuminate when commanded ON
with the scan tool?
Go to Step 7 Go to Step 9
7 Command the EGR Solenoid Valve OFF with the scan tool.
Does the test lamp continuously illuminate same as
step 6 when commanded OFF with the scan tool
(the test lamp slightly illuminates if the circuit is
normal when commanded OFF)?
Go to Step 10 Go to Step 11
8 Repair the open circuit or high resistance on the voltage feed circuit between the ECM (10A) fuse
(EB-4) and the EGR solenoid valve (pin 1 of C-115
connector).
Did you complete the repair?
Go to Step 15
9 1. Test the control circuit between the engine
control module (ECM) (pin 97 of C-57 connector)
and the EGR solenoid valve (pin 2 of C-115
connector) for an open circuit or high resistance.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 15 Go to Step 12
10 1. Test the control circuit between the ECM (pin 97 of C-57 connector) and the EGR solenoid valve
(pin 2 of C-115 connector) for a short to ground.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 15 Go to Step 14
11 1. Turn OFF the ignition. 2. Disconnect the EGR solenoid valve harness connector.
3. Inspect for an intermittent and for poor connections at the harness connector of the EGR
solenoid valve (pins 1 and 2 of C-115 connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 15 Go to Step 13
12 1. Turn OFF the ignition. 2. Disconnect the ECM harness connector.
3. Inspect for an intermittent and for a poor connection on the EGR solenoid valve control
circuit at the harness connector of the ECM (pin
97 of C-57 connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 15 Go to Step 14
13 Replace the EGR solenoid valve. Refer to EGR Solenoid Valve Replacement in this section.
Did you complete the replacement?
Go to Step 15
14 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 15
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ISUZU KB P190 2007
Page 1189 of 6020
Engine Control System (4JH1) 6E-155
DTC P0400 (Symptom Code 8) (Flash Code 32)
Circuit Description
The engine control module (ECM) controls the exhaust
gas recirculation (EGR) flow amount based on the
engine speed, engine coolant temperature, intake ai
r
temperature, barometric pressure and fuel injection
quantity. The ECM controls the EGR valve by
controlling the EGR solenoid valve. The mass air flo
w
(MAF) sensor monitors EGR gas flow amount. An
expected MAF amount should be detected while the
engine running. If the ECM detects that detects a short
to battery or ignition voltage on the EGR solenoid valve
control circuit, this DTC will set.
Condition for Running the DTC
• The ignition switch is ON.
Condition for Setting the DTC • The ECM detects that the high voltage condition
on the EGR solenoid valve control circuit for longe
r
than 3 seconds when the solenoid valve is
commanded ON.
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.
Test Description
The number below refers to the step number on the
diagnostic table.
3. If the control circuit of the EGR solenoid valve
between the ECM and the solenoid valve is normal, the
control circuit voltage low DTC P0400 (Symptom Code
4) will set.
DTC P0400 (Symptom Code 8) (Flash Code 32)
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or Engine Control Module (ECM)
Connector End Views
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Start the engine and warm up (allow engine coolant temperature to reach at least 60°C
[140°F]).
4. Monitor the Diagnostic Trouble Code (DTC) Information with the 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 EGR control solenoid valve harness connector.
3. Start the engine.
4. Monitor the DTC Information with the scan tool.
Does the DTC P0400 (Symptom Code 4) set, but not
DTC P0400 (Symptom Code 8)?
Go to Step 5 Go to Step 4
4 1. Test the control circuit between the engine control module (ECM) (pin 97 of C-57 connector)
and the EGR solenoid valve (pin 2 of C-115
connector) for a short to battery or ignition
voltage.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 7 Go to Step 6
5 Replace the EGR solenoid valve. Refer to EGR Solenoid Valve Replacement in this section.
Did you complete the replacement?
Go to Step 7
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ISUZU KB P190 2007
Page 1198 of 6020
6E-164 Engine Control System (4JH1)
Step Action Value(s) Yes No
12 1. Test the VSS signal circuit between the VSS (pin
3 of E-44 connector) and the IPC (pin 9 of B-23
connector) for the following conditions: • An open circuit
• A short to ground
• A short to battery or ignition voltage
• High resistance
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 20 Go to Step 15
13 1. Test the VSS signal circuit between the engine control module (ECM) (pin 68 of C-56 connector)
and the IPC (pin 10 of B-23 connector) for the
following conditions: • An open circuit
• A short to ground
• A short to battery or ignition voltage
• High resistance
2. Repair the circuit(s) as necessary.
Did you find and correct the condition?
Go to Step 20 Go to Step 16
14 1. Turn OFF the ignition. 2. Disconnect the VSS harness connector.
3. Inspect for an intermittent and for poor connections at the harness connector of the VSS
(pin 1, 2 and 3 of E-44 connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 20 Go to Step 17
15 1. Turn OFF the ignition. 2. Disconnect the IPC B-23 harness connector.
3. Inspect for an intermittent and for poor connections at the harness connector of the IPC
(pins 9 and 10 of B-23 connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 20 Go to Step 18
16 1. Turn OFF the ignition. 2. Disconnect the ECM harness connector.
3. Inspect for an intermittent and for a poor connection on the VSS signal circuit at the
harness connector of the ECM (pin 68 of C-56
connector).
4. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 20 Go to Step 19
17 Replace the VSS. Refer to Vehicle Speed Sensor (VSS) Replacement in this section.
Did you complete the replacement?
Go to Step 20
18 Replace the IPC (meter assembly). Refer to Meter
Replacement in electrical section.
Did you complete the replacement?
Go to Step 20
19 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 20
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ISUZU KB P190 2007
Page 1200 of 6020
6E-166 Engine Control System (4JH1)
DTC P0560 (Symptom Code 1) (Flash Code 35)
Circuit Description
The engine control module (ECM) monitors the system
voltage on the ECM main relay load supply voltage
terminal to make sure that the voltage stays within the
proper range. If the ECM detects an excessively high
system voltage, this DTC will set.
Condition for Setting the DTC
• The ECM detects that the battery voltage feed
circuit voltage is more than 20 volts.
Action Taken When the DTC Sets
• The ECM does not illuminate the malfunction
indicator lamp (MIL) when the diagnostic runs and
fails.
Condition for Clearing the DTC • A history DTC clears after 40 consecutive driving
cycles without a fault. Or clear with the scan tool.
Diagnostic Aids
• A charging system problem may set this DTC.
• Jump starting the vehicle or a battery charger may
have set this DTC.
DTC P0560 (Symptom Code 1) (Flash Code 35)
Schematic Reference: Engine Controls Schematics &
Starting and Charging Schematics
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the Diagnostic Trouble Code (DTC) Information with the scan tool.
Does the DTC fail this ignition?
Go to Step 3 Go to Diagnostic
Aids
3 W as the vehicle recently jump started from 24 volts system?
Go to Step 8 Go to Step 4
4 1. Start the engine and let idle for 30 seconds.
2. Observe the System Voltage parameter with the scan tool.
Is the System Voltage parameter less than the
specified value? 16 volts
Go to Diagnostic Aids Go to Step 5
5 Test the charging system. Refer to Diagnosis of The Charging System in the Charging System Section.
Did you find a charging system problem?
Go to Step 6 Go to Step 7
6 Repair the charging system. Refer to Diagnosis of The Charging System in the Charging System
Section.
Did you complete the repair?
Go to Step 8
7 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 8
8 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Observe the System Voltage parameter with the scan tool.
Is the System Voltage parameter less than the
specified value? 16 volts
Go to Step 9 Go to Step 5
9 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1201 of 6020
Engine Control System (4JH1) 6E-167
DTC P0560 (Symptom Code 2) (Flash Code 35)
Circuit Description
The engine control module (ECM) monitors the system
voltage on the ECM main relay load supply voltage
terminal to make sure that the voltage stays within the
proper range. If the ECM detects an excessively lo
w
system voltage, this DTC will set.
Condition for Setting the DTC
• The ECM detects that the battery voltage feed
circuit voltage is less than 7 volts.
Action Taken When the DTC Sets
• The ECM does not illuminate the malfunction
indicator lamp (MIL) when the diagnostic runs and
fails.
Condition for Clearing the DTC
• 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.
• A charging system problem may set this DTC.
DTC P0560 (Symptom Code 2) (Flash Code 35)
Schematic Reference: Engine Controls Schematics &
Starting and Charging Schematics
Connector End View Reference: Engine Control
Module (ECM) Connector End Views
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the Diagnostic Trouble Code (DTC) Information with the scan tool.
Does the DTC fail this ignition?
Go to Step 3 Go to Diagnostic
Aids
3 1. Start the engine and let idle for 30 seconds. 2. Load the electrical system by turning ON the headlights, A/C, etc.
3. Observe the System Voltage parameter with the scan tool.
Is the System Voltage parameter more than the
specified value? 10 volts
Go to Diagnostic Aids Go to Step 4
4 Test the charging system. Refer to Diagnosis of The Charging System in the Charging System Section.
Did you find a charging system problem?
Go to Step 5 Go to Step 6
5 Repair the charging system. Refer to Diagnosis of The Charging System in the Charging System
Section.
Did you complete the repair?
Go to Step 8
6 1. Turn OFF the ignition.
2. Disconnect the ECM harness connector.
3. Inspect for an intermittent, for a poor connection and corrosion on the battery voltage feed at the
harness connector of the ECM (pin 3 of C-56
connector).
4. Repair or clean the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 8 Go to Step 7
7 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 8
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ISUZU KB P190 2007
Page 1203 of 6020
Engine Control System (4JH1) 6E-169
DTC P0560 (Symptom Code A) (Flash Code 35)
Circuit Description
The fuel injection pump control unit (PCU) monitors the
system voltage on the engine control module (ECM)
main relay load supply voltage terminal to make sure
that the voltage stays within the proper range. If the
ECM detects an excessively high or low system voltage,
this DTC will set.
Condition for Setting the DTC
• The PCU battery voltage feed circuit voltage is
less than 4.5 volts or more than 27 volts.
Action Taken When the DTC Sets
• The ECM does not illuminate the malfunction
indicator lamp (MIL) when the diagnostic runs and
fails.
Condition for Clearing the DTC
• 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.
• A charging system problem may set this DTC.
• Jump starting the vehicle or a battery charger may
have set this DTC.
Notice:
• PCU is part of the fuel injection pump assembly.
DTC P0560 (Symptom Code A) (Flash Code 35)
Schematic Reference: Engine Controls Schematics &
Starting and Charging Schematics
Connector End View Reference: Engine Controls
Connector End Views
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the Diagnostic Trouble Code (DTC) Information with the scan tool.
Is DTC P0560 (Symptom Code 1 or 2) set?
Go to Applicable DTC Go to Step 3
3 1. Start the engine and let idle for 30 seconds. 2. Monitor the Diagnostic Trouble Code (DTC) Information with the scan tool.
Does the DTC fail this ignition?
Go to Step 4 Go to Diagnostic
Aids
4 1. Turn OFF the ignition. 2. Disconnect the fuel injection pump control unit (PCU) harness connector.
3. Inspect for an intermittent, for poor connections and corrosion on the voltage feed or ground at
the harness connector of the PCU (pins 6 and 7
of E-6 connector).
4. Repair or clean the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 6 Go to Step 5
5 Important: The fuel injection pump must be timed to
the engine.
Replace the fuel injection pump. Refer to Fuel
Injection Pump Replacement in engine mechanical
section.
Did you complete the replacement?
Go to Step 6
6 1. Reconnect all previously disconnected harness connector(s).
2. Clear the DTCs with the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine and let idle for 30 seconds.
5. Monitor the DTC Information with the scan tool.
Did the DTC fail this ignition?
Go to Step 2 Go to Step 7
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ISUZU KB P190 2007