change time ISUZU KB P190 2007 Workshop User Guide

Engine Control System (4JH1) 6E-203
Step Action Value(s) Yes No
21 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. Turn ON the ignition, with the engine OFF.
5. Observe the Idle Switch and APP parameter while fully depressing and releasing the
accelerator pedal many times.
Does the scan tool indicate the APP parameter
smoothly changed within 0 to 100 % when the
accelerator pedal is depressed and released, then
scan tool indicate the Idle Switch parameter OFF
when the accelerator pedal is depressed and ON
when the accelerator pedal is released? 

Go to Step 22 Go to Step 2
22 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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Engine Control System (4JH1) 6E-239
Glow Control System Check
Description
The glow control system consists of the engine control
module (ECM), the glow relay and glow plugs. The glo
w
control system is operated when the engine coolant
temperature is low, which allows easier engine starting.
The ECM commands the glow relay ON for a certain
length of time at ignition switch is ON with engine OFF.
In after glow phase, the glow plugs remain energized fo
r
a certain period with engine run.


Glow Control Operation
•
The pre glow control system operates when the
engine coolant temperature is less than 30 °C
(86 °F).
• The after glow control system operates when the
engine coolant temperature is less than 60 °C
(140 °F).

Glow Control System Check
Schematic Reference: Engine Controls 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. Turn ON the ignition, with the engine OFF.
4. Monitor the Diagnostic Trouble Code (DTC) Information of the engine control system with the
scan tool and check whether following DTC(s) is
set: • P0115 (Symptom Code 1 & 2)
• P0380 (Symptom Code 4 & 8)
• P0381 (Symptom Code 4 & 8)
Are any of the above DTC(s) set? 

Refer to Applicable DTC Go to Step 3
3 1. Turn OFF the ignition.
2. Make sure the metal bus bar that connects switched battery voltage supply terminal (E-49)
and all glow plugs is secured tightly.
3. Turn ON the ignition, with the engine OFF
4. Connect a test lamp between the metal bus bar (glow plug power supply E-49 terminal) and a
known good ground.
5. Perform the Glow Relay test with the scan tool.
6. Command the Glow Relay ON with the scan tool while observing the test lamp.
Does the test lamp turn ON only when commanded
ON with the scan tool? 

Go to Step 4 Go to Step 5
4 1. Turn OFF the ignition. 2. Remove the metal bus bar from the glow plugs.
3. Measure resistance of each glow plug between the glow plug terminals and a known good
ground. Make sure to record all measurements
and take them quickly as to not allow engine
temperature changes between measurements.
Are the resistances within the specified value each
other? 1
Ω
System OK Go to Step 15

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Engine Control System (4JH1) 6E-263
Checks Action
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect for water contamination in the fuel.
• Inspect for external fuel leaks or fuel leakage into the engine oil.
• Inspect the fuel lines between the fuel tank and fuel injection pump for tightness and
all fuel hoses for cuts, cracks and for the use of proper clamps.
Notice: 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. Air in the fuel system will cause fuel injection pump
internal pressure fluctuations especially at high engine speed and load.
• Inspect for air in the fuel system.
Notice: If many air bubbles appear in the fuel, check the fuel system line connections
between the fuel tank and the fuel injection pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper clamps.
a. Remove the fuel hose that connects to the fuel injection pump suction side.
b. Substitute a clear hose.
Notice: A hose must be cleaned.
c. Connect the clear hose to the fuel injection pump.
d. Bleed the fuel system.
e. Let the engine run at idle for at least 2 minutes.
f. Accelerator the engine between idle and W .O.T. (accelerator pedal full travel) many times while observing the clear hose.
• Inspect the fuel tank vent hose for a plugged or kinked.
• Inspect inside the fuel tank for any foreign material that may be getting drawn into
the fuel line pickup causing a blocked condition. Draw fuel from the fuel tank at the
fuel line (as close to the fuel tank as possible) going to the fuel pickup tube to verify a
clean stream of fuel comes out (use the hand-held vacuum pump 5-8840-0279-0/J-
23738-A with a clear hose or equivalent). This will ensure the fuel pickup tube is not
cracked drawing air into the fuel line.
• Inspect the fuel injection pump operation.
Notice: The fuel injection pump must be timed to the engine.
Inspect the eye bolt for any type of restriction or collapsed gauze filter.
Notice: If any type of restriction found, check for a condition that causes contaminated
fuel, such as the customer is using an aftermarket fuel filter or extended maintenance
interval. Also inspect fuel waxing or icing that is caused by an incorrect fuel type used
in winter season or water intrusion in the fuel system.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at mass air flow (MAF) sensor.
Additional Checks •
Inspect the generator output voltage. Repair if less than 9 volts or more than 16
volts.
• Electromagnetic interference (EMI) on the reference circuit can cause an engine
miss condition. The scan tool can usually detect EMI by monitoring the engine
speed. A sudden increase in speed with little change in actual engine speed change
indicates that EMI is present. If a problem exists, check routing of high voltage
components, such as fuel injection solenoid wiring, near the sensor circuits.


Surges/Chuggles
Checks Action
DIFINITION:The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down
with no change in the accelerator pedal.

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Engine Control System (4JH1) 6E-271
Checks Action
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks •
Inspect the EGR system operating correctly.
• Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.


Poor Fuel Economy
Checks Action
DEFINITION:Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Are excessively heavy loads being carried?
• Is the acceleration too much, too often?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (A/T only).
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
• Suggest to the driver to read the Important Facts on Fuel Economy in the Owner
Manual.
• Inspect the odometer is correctly operated.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect the fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to the Cooling System
Section.
• Inspect the engine coolant level.
• Inspect the engine thermostat for always being open or for the wrong heat range.
• Inspect the engine cooling fan for always being ON.

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6E-288 Engine Control System (4JH1)
Fuel Injection System Description




RTW 66EMF000401
Legend
1. Drive Shaft
2. Fuel Feed Pump
3. Pump Camshaft Position (CMP) Sensor
4. Fuel Injection Pump Control Unit (PCU)
5. Distributor Head
6. Constant Pressure Valve (CPV) Holder


7. Fuel Injection Solenoid Valve
8. Constran Pressure Valve (CPV)
9. Timing Control Valve (TCV)
10. Timer
11. Radial Plunger


Bosch VP44 Fuel Injection Pump
Instead of the previous face cam type, the radial
plunger distributor type injection pump utilizes a cam
ring to enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, lo
w
smoke, low noise, high output and low exhaust
emissions.
The engine control module (ECM) calculates the
desired fuel injection quantity and timing using data sent
from various sensor s. 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.




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6E-50 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Scan Tool Data Definitions
This information will assist in emission or driveability
problems. The displays can be viewed while the vehicle
is being driven. Always perform the Diagnostic System
Check - Engine Controls first. The Diagnostic System
Check will confirm proper system operation.
Engine Speed
This parameter displays the rotational speed of the
crankshaft as calculated by the ECM based on inputs
from the crankshaft position (CKP) sensor or camshaft
position (CMP) sensor.
Desired Idle Speed
This parameter displays the idle speed requested by
the ECM. The ECM will change desired idle speed
based on engine coolant temperature and other inputs.
Calculate Engine Load
This parameter displays the engine load in percent
based on inputs to the ECM from various engine
sensors. The scan tool will display a lower percentage
when the engine is at idle with little or no load. The
scan tool will display a higher percentage when the
engine is running at high engine speed under a heavy
load.
Coolant Temperature
This parameter displays the temperature of the engine
coolant as calculated by the ECM using the signal from
the engine coolant temperature (ECT) sensor. The
scan tool will display a low temperature when the ECT
sensor signal voltage is high, and a high temperature
when the ECT sensor signal voltage is low.
Engine Coolant Temperature Sensor
This parameter displays the voltage signal sent to the
ECM from the engine coolant temperature (ECT)
sensor. ECT sensor is a range of value indicating a low
voltage when the temperature is high, and a high
voltage when the temperature is low.
Intake Air Temperature
This parameter displays the temperature of the intake
air as calculated by the ECM using the signal from the
intake air temperature (IAT) sensor. The scan tool will
display a low temperature when the IAT sensor signal
voltage is high, and a high temperature when the IAT
sensor signal voltage is low. Intake Air Temperature Sensor
This parameter displays the voltage signal sent to the
ECM from the intake air temperature (IAT) sensor. IAT
sensor is a range of value indicating a low voltage
when the temperature is high, and a high voltage when
the temperature is low.
Fuel Temperature
This parameter displays the temperature of the fuel as
calculated by the ECM using the signal from the fuel
temperature (FT) sensor. The scan tool will display a
low temperature when the FT sensor signal voltage is
high, and a high temperature when the FT sensor
signal voltage is low.
Fuel Temperature Sensor
This parameter displays the voltage signal sent to the
ECM from the fuel temperature (FT) sensor. FT sensor
is a range of value indicating a low voltage when the
temperature is high, and a high voltage when the
temperature is low.
MAF (Mass Air Flow)
This parameter displays the air flow into the engine as
calculated by the ECM based on the mass air flow
(MAF) sensor input. The scan tool will display a high
value at higher engine speeds, and a low value at lower
engine speed.
MAF Sensor (Mass Air Flow)
This parameter displays the voltage signal sent to the
ECM from the mass air flow (MAF) sensor. MAF sensor
is a range of value indicating a low voltage at lower
engine speed, and a high voltage at a higher engine
speeds.
Barometric Pressure
This parameter displays the barometric pressure
(BARO) as calculated by the ECM using the signal from
the BARO sensor. The scan tool will display a low
barometric pressure in high altitude area.
Barometric Pressure Sensor
This parameter displays the voltage signal sent to the
ECM from the barometric pressure (BARO) sensor.
BARO sensor is a range of value indicating a low
voltage in high altitude area, and a middle voltage in
sea level.
Immobilizer Signal Yes/ NoYes Yes
Security Wait Time Inactive/ Time
(hour: minute: second) Inactive
Inactive
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle Typical Data Value at 2000RPM

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-75
31. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Accelerate the engine between idle and W.O.T. (accelerator pedal full travel) many
times while observing the DTC Information
with a scan tool.
Does the DTC fail this ignition? —
Go to Step 4 Go to Diagnostic
Aids
4 1. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 5 Go to Step 10
5 1. Start the engine.
2. Perform the Cylinder Balance Test with a scan tool.
3. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 12 Go to Step 6
6 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Start the engine and check for high side fuel system leaks at the fuel supply pump and fuel
rail.
Notice: Fuel may leak under the cylinder head
cover from the inlet high pressure line. In such
case, the engine oil level will rise. Inspect for fuel
leakage into the engine oil.
3. Repair any fuel system leaks as necessary.
Did you find and correct the condition? —
Go to Step 14 Go to Step 7
Step
Action Value(s)Yes No

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-77
91. Turn OFF the ignition.
2. Disconnect the FRP regulator harness connector.
3. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the FRP regulator (pins 1 and 2
of E-50).
4. Disconnect the ECM harness connector.
5. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the ECM (pins 34, 50, 54 and 70
of E-90).
6. Test for high resistance on each circuit.
7. Repair the connection(s) or circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 14 Go to Step 13
10 1. Turn OFF the ignition.
2. Disconnect the FRP sensor harness connector.
3. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the FRP sensor (pins 1, 2 and 3
of E-48).
4. Disconnect the ECM harness connector.
5. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the ECM (pins 47, 48, 68 and 69
of E-90).
6. Test for high resistance on each circuit.
7. Repair the connection(s) or circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 14 Go to Step 11
11 Replace the FRP sensor. Refer to FRP sensor
Replacement.
Did you complete the replacement? —
Go to Step 14
—
12Important:
Replacement fuel injector must be
programmed.
Replace the appropriate fuel injector that does not
change engine speed when commanded OFF.
Refer to Fuel Injector Replacement/ Fuel Injector
ID Code Data Programming.
Did you complete the replacement? —
Go to Step 14
—
13Important:
The fuel supply pump must be timed to
the engine and adjustment value must be learned
to the ECM.
Notice: Always replace the fuel filter cartridge
when a fuel supply pump is replaced.
Replace the fuel supply pump and fuel filter
cartridge. Refer to Fuel Supply Pump Replacement
and Fuel Filter Cartridge Replacement.
Did you complete the replacement? —
Go to Step 14
—
Step Action Value(s)Yes No

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6E-80 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
21. 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 P0089, P0091, P0092, P0192, P0193,
P0201 - P0204, P0219, P1064, P1065, P124B or
P2146 - P2151 set? —
Go to Applicable DTC Go to Step 3
3 1. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Accelerate the engine between idle and W.O.T. (accelerator pedal full travel) many
times while observing the Fuel Rail Pressure
parameter with a scan tool.
Does the Fuel Rail Pressure parameter ever
exceed the specified value? 190 MPa
(27,600 psi)
Go to Step 4 Go to Step 11
4 1. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 5 Go to Step 10
5 1. Start the engine.
2. Perform the Cylinder Balance Test with a scan tool.
3. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 13 Go to Step 6
6 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Start the engine and check for high side fuel system leaks at the fuel supply pump and fuel
rail.
Notice: Fuel may leak under the cylinder head
cover from the inlet high pressure line. In such
case, the engine oil level will rise. Inspect for fuel
leakage into the engine oil.
3. Repair any fuel system leaks as necessary.
Did you find and correct the condition? —
Go to Step 15 Go to Step 7
Step
Action Value(s)Yes No

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6E-92 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
61. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Perform the Cylinder Balance Test with a scan tool.
5. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 14 Go to Step 7
7 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Repair or replace as necessary.
Did you find and correct the condition? —
Go to Step 16 Go to Step 8
8 Notice:
Make sure the in-tank fuel pump operation
before performing the following procedures. Refer
to In-tank Fuel Pump System Check in this section.
1. Turn OFF the ignition.
2. Disconnect the fuel hose from the fuel supply pump suction side. In order to measure the
discharged fuel amount, put the hose into a
bottle or a container with a scale. (The inlet of
a bottle or a container must be larger than the
diameter of hose.)
3. Turn ON the ignition for 20 seconds, with the engine OFF.
4. Turn OFF the ignition for 10 seconds.
5. Perform 3 and 4 three times. The accumulated fuel of three ignition cycles must be more than
300 cc. (Normal amount is more than 100 cc
per one ignition cycle.)
Notice: If there is a leak or a restriction on the
suction side, the fuel from the hose will not flow out
sufficiently that is most likely caused by fuel
leakage, clogged fuel filter, kinked or crushed fuel
hose or pipe. Also inside the fuel tank for any
foreign materials may be getting drawn into the fuel
line pickup.
6. Repair fuel system leaking or restrictions as necessary.
Did you find and correct the condition? —
Go to Step 16 Go to Step 9
Step
Action Value(s)Yes No

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