ISUZU KB P190 2007 Workshop Repair Manual
Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 2271 of 6020
ENGINE DRIVEABILITY AND EMISSIONS 6E–101
5 1. Set the Injector Adapter Cable to injector #1.2. Press the “Push to Start Test” button on the fuelinjector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first second of the test.
5. Set the Injector Adapter Cable to the next injector and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value? 9.5V Go to Step 4Go to Step 6
6 1. Identify the highest voltage reading recorded (other than those above 9.5V).
2. Subtract the voltage reading of each injector from the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted value in step 2
greater than the specified value? 0.6V Go to Step 4Go to Step 7
7 Caution: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any
fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the Towel in an
approved container when the connection of the
fuel pressure gauge is complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge to the fuel pressure test port.
2. Energize the fuel pump using the Scan Tool.
3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading on the fuel pressure gauge.
Is the fuel pressure within the specified values? 296kPa-
376kPa
(43-55psi) Go to Step 8Go to
Fuel
System
Diagnosis
8 Turn the fuel pump OFF. Does the fuel pressure remain constant? —Go to Step 9Go to
Fuel
System
Diagnosis
Step
Action Value(s) Yes No
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Page 2272 of 6020
6E–102 ENGINE DRIVEABILITY AND EMISSIONS
9 1. Connect the 5-8840-0378-0 Fuel Injector Testerand 5-8840-2589-0 Injector Adapter Cable to the
fuel injector harness connector.
2. Set the amperage supply selector switch on the fuel injector tester to the “Balance Test” 0.5-2.5
amp position.
3. Using the Scan Tool turn the fuel pump ON then OFF in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first pressure reading for one fuel injector. The
result is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values. This is the total pressure drop.
11. Divide the total pressure drop by the number of fuel injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value? 10kPa
(1.5psi) Go to Step 10Go to
OBD
System Check
10 Re-test any fuel injector that does not meet the specification. Refer to the procedure in Step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value? 10kPa
(1.5psi) Go to Step 11Go to
Symptoms
11 1. Replace the faulty fuel injector(s). Refer to Fuel
Injector .
2. Disconnect the 5-8840-2589-0 Injector Adapter Cable for F/I check and re-connect the original F/I
check connector.
Is the action complete? — Verify repair —
Step
Action Value(s) Yes No
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Page 2273 of 6020
ENGINE DRIVEABILITY AND EMISSIONS 6E–103
FUEL SYSTEM ELECTRICAL TEST
Circuit Description
When the ignition switch is first turned ON, the engine
control module (ECM) energizes the fuel pump relay
which applies power to the in-tank fuel pump. The fuel
pump relay will remain ON as long as the engine is
running or cranking and the ECM is receiving 58X
crankshaft position pulses. If no 58X crankshaft position
pulses are present, the ECM de-energizes the fuel
pump relay within 2 seconds after the ignition is turned
ON or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and injectors,
then to the fuel pressure regulator. The fuel pressure
regulator controls fuel pressure by allowing excess fuel
to be returned to the fuel tank. With the engine stopped
and ignition ON, the fuel pump can be turned ON by
using a command by the scan tool.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
• Poor connection or damaged harness - Inspect the ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness. Caution: To reduce the risk of fire and personal
injury:
• It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
• A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
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Page 2274 of 6020
6E–104 ENGINE DRIVEABILITY AND EMISSIONS
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Remove the fuel pump relay from the underhood relay center.
3. Start the engine and alow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Pressure Gauge Installation
1. Remove the fuel pressure fitting cap.
2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located in front of and above the right
side valve cover.
3. Reinstall the fuel pump relay.
Fuel System Electrical Test
Step Action Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” performed?
—Go to Step 2Go to
On Board
Diagnostic
(OBD) System Check
2 1. Using the Tech 2, ignition “On” and engine “On”. 2. Select the “Miscellaneous Test” and perform the“Fuel Pump Relay” in the “Relays”.
3. Operate the Tech 2 in accordance with procedure.
Was the fuel pump operated, when the Tech 2 is
operated? —Go to
Fuel
System
Diagnosis Go to Step 3
3 Check the “Fuel Pump” fuse (20A). If the fuse is burnt out, repair as necessary.
Was the problem found? — Verify repair Go to Step 4
4 Check for poor/faulty connection at the fuel pump, fuel pump relay or ECM connector. If a poor/faulty
connection is found, repair as necessary.
Was the problem found?
— Verify repair Go to Step 5
5 Using the DVM and check the fuel pump relay. 1. Ignition “Off”, engine “Off”.
2. Remove the fuel pump relay from the relay box.
3. Check the relay coil.
Was the DVM indicated specified value?
120 - 150ΩGo to Step 6 Replace fuel
pump relay and verify repair
11C56(J2)
F2
X2
Fuel Pump Relay
3
4 2
1
Ω
34
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Page 2275 of 6020
ENGINE DRIVEABILITY AND EMISSIONS 6E–105
6 Using the DVM and check the fuel pump relay powersupply circuit.
1. Ignition “On”, engine “Off”.
2. Remove the fuel pump relay from the relay box.
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 8Go to Step 7
7 Repair the open or short to ground circuit between the “ECM” fuse (15A) and fuel pump relay.
Is the action complete? — Verify repair —
8 Using the DVM and check the fuel pump relay ground circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the ECM connector.
3. Remove the fuel pump relay from the relay box.
4. Check the circuit for open or short to ground circuit.
Was the problem found?
—Repair faulty
harness and verify repair Go to Step 9
9 Using the DVM and check the fuel pump relay power supply circuit.
1. Ignition “Off”, engine “Off”.
2. Remove the fuel pump relay from the relay box.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 11Go to Step 10
Step
Action Value(s) Yes No
V
3
X2
4
11C56(J2)X2
V
1X2
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Page 2276 of 6020
6E–106 ENGINE DRIVEABILITY AND EMISSIONS
10 Repair the open circuit between the fuel pump relayand battery.
Is the action complete? — Verify repair —
11 Using the DVM and check the fuel pump power supply circuit.
1. Ignition “On”, engine “Off”.
2. Disconnect the fuel pump connector.
3. Check the circuit for open or short to ground circuit.
Was the DVM indicated specified value?
10 - 14.5V Go to Step 13Go to Step 12
12 Repair the open or short to ground circuit between the fuel pump relay and fuel pump.
Is the action complete? — Verify repair —
13 Using the DVM and check the fuel pump ground circuit.
1. Ignition “Off”, engine “Off”.
2. Disconnect the fuel pump connector.
3. Check the circuit for open circuit.
Was the DVM indicated specified value?
Continuity Go to Step 15Go to Step 14
14 Repair the open circuit between the fuel pump and body ground.
Is the action complete? — Verify repair —
15 Replace the fuel pump. Was the problem solved? — Verify repair Go to Step 16
16 Is the ECM programmed with the latest software release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved? — Verify repair Go to Step 17
Step
Action Value(s) Yes No
V
1
F2
F-2
Ω
4
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Page 2277 of 6020
ENGINE DRIVEABILITY AND EMISSIONS 6E–107
17 Replace the ECM. Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure. — Verify repair —
Step
Action Value(s) Yes No
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Page 2278 of 6020
6E–108 ENGINE DRIVEABILITY AND EMISSIONS
FUEL SYSTEM DIAGNOSIS
Circuit Description
When the ignition switch is turned ON, the engine
control module (ECM) will turn ON the in-tank fuel
pump. The in-tank fuel pump will remain ON as long as
the engine is cranking or running and the ECM is
receiving 58X crankshaft position pulses. If there are no
58X crankshaft position pulses, the ECM will turn the in-
tank fuel pump OFF 2 seconds after the ignition switch
is turned ON or 2 seconds after the engine stops
running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
fuel pump is designed to provide fuel at a pressure
above the pressure needed by the fuel injectors. A fuel
pressure regulator, attached to the fuel rail, keeps the
fuel available to the fuel injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a
separate fuel return line.
Te s t D e s c r i p t i o n
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line as shown in the fuel system illustration. Wrap a shop
towel around the fuel pressure connection in order to
absorb any duel leakage that may occur when
installing the fuel pressure gauge. With the ignition
switch ON and the fuel pump running, the fuel
pressure indicated by the fuel pressure gauge
should be 283-376 kPa (41-55 psi). This pressure is
controlled by the amount of pressure the spring
inside the fuel pressure regulator can provide.
3. A fuel system that cannot maintain a constant fuel pressure has a leak in one or more of the following
areas:
• The fuel pump check valve.
• The fuel pump flex line.
• The valve or valve seat within the fuel pressure regulator.
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Page 2279 of 6020
ENGINE DRIVEABILITY AND EMISSIONS 6E–109
• The fuel injector(s).
4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using a
Tech 2 Scan Tool.
Following are applicable to the vehicle with
closed Loop System:
If an extremely lean condition occurs, the oxygen
sensor(s) will stop toggling. The oxygen sensor
output voltage(s) will drop below 500 mV. Also, the
fuel injector pulse width will increase.
Important: Make sure the fuel system is not
operating in the “Fuel Cut-Off Mode.”
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly
as the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF.
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
• Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service .
• Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and
personal injury that may result from fuel
spraying on the engine, verify that the fuel rail is
positioned over the fuel injector ports and verify
that the fuel injector retaining clips are intact.
• Pressurize the fuel system by connecting a 20 amp fused jumper between B+ and the fuel
pump relay connector.
• Visually and physically inspect the fuel injector nozzles for leaks.
17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may
cause a 45 to set. Driveability conditions associated with rich conditions can include hard starting
(followed by black smoke) and a strong sulfur smell
in the exhaust.
20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a 44 to
set. Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.
22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure.
Command the fuel pump ON with the scan tool. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
psi) may damage the fuel pressure regulator. Caution: To reduce the risk of fire and personal
injury:
• It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
• A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Located on the intake manifold which is at the top right part of the engine.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Pressure Gauge Installation
1. Remove the fuel pressure fitting cap.
2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located on the upper right side of the
engine.
3. Reinstall the fuel pump relay.
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Page 2280 of 6020
6E–110 ENGINE DRIVEABILITY AND EMISSIONS
Fuel System Diagnosis
StepAction Value(s) Yes No
1 Was the “On-Board Diagnostic (OBD) System Check” performed? — Go to Step 2Go to
OBD
System Check
2 1. Turn the ignition OFF. 2. Turn the air conditioning system OFF.
3. Relieve fuel system pressure and install the fuel pressure gauge.
4. Turn the ignition ON.
NOTE: The fuel pump will run for approximately 2
seconds. Use the Scan Tool to command the fuel
pump ON.
5. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits? 283-376 kPa
(41-55 psi) Go to Step 3Go to Step 17
3 Does the fuel pressure indicated by the fuel pressure gauge remain constant?
NOTE: The fuel pressure will drop when the fuel
pump stops running, then it should stabilize and
remain constant. — Go to Step 4Go to Step 12
4 1. When the vehicle is at normal operating temperature, turn the ignition ON to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure gauge.
Did the reading drop by the amount specified after the
engine was started? 21-105 kPa
(3-15 psi) Go to Step 5Go to Step 9
5 Is fuel pressure dropping off during acceleration, cruise, or hard cornering? — Go to Step 6Check for
improper fuel
6 Visually and physically inspect the following items for a restriction:
• The in-line fuel filter.
• The fuel feed line.
Was a restriction found? — Verify repair Go to Step 7
7 Remove the fuel tank and visually and physically inspect the following items:
• The fuel pump strainer for a restriction.
• The fuel line for a leak.
• Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas? — Verify repair Go to Step 8
8 Replace the fuel pump. Is the action complete? — Verify repair —
9 1. Disconnect the vacuum hose from the fuel pressure regulator.
2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure
gauge drop by the amount specified? 21-105 kPa
(3-15 psi) Go to Step 10Go to Step 11
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