heating ISUZU KB P190 2007 Workshop Owner's Manual

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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Engine Control System (4JH1) 6E-283
Description And Operation
Engine Control Module (ECM) Description



RTW 66ESH001201
The engine control module (ECM) is designed to
withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. W hen testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a digital multi meter (DMM). The ECM should remain
connected to the ECM harness.
The ECM is located on the floor panel. The ECM mainl
y
controls the following.
• The fuel system control
• The exhaust gas recirculation (EGR) system
control
• The preheating (glow) system control
• The A/C compressor control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensor s. The ECM controls the systems that
affect vehicle performance. The ECM performs the
diagnostic function of the system. The ECM can
recognize operational problems, alert the driver through
the malfunction indicator lamp (MIL), and store
diagnostic trouble codes (DTCs). DTCs identify the
system faults to aid the technician in making repairs.





ECM Voltage Description
The ECM supplies a buffered voltage to various
switches and sensor s. The ECM can do this because
resistance in the ECM is so high in value that a test
lamp may not illuminate when connected to the circuit.
An ordinary shop voltmeter may not give an accurate
reading because the voltmeter input impedance is too
low. Use a 10-megaohm input impedance DMM, to
ensure accurate voltage readings. The input and/o
r
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special drivers.
The ECM controls most components with electronic
switches which complete a ground circuit when turned
ON.
Aftermarket Electrical and Vacuum Equipment
Aftermarket or add-on electrical and vacuum equipment
is defined as any equipment which connects to the
vehicle's electrical or vacuum systems that is installed
on a vehicle after the vehicle leaves the factory. No
allowances have been made in the vehicle design fo
r
this type of equipment. No add-on vacuum equipment
should be added to this vehicle. Add-on electrical
equipment must only be connected to the vehicle's
electrical system at the battery power and ground. Add-
on electrical equipment, even when installed to these
guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such as
portable telephones and audios. Therefore, the first
step in diagnosing any powertrain fault is to eliminate all
aftermarket electrical equipment from the vehicle. Afte
r
this is done, if the fault still exists, the fault may be
diagnosed in the normal manner.
Electrostatic Discharge Damage
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused b
y
electrostatic discharge. By comparison, as much as
4,000 volts may be needed for a person to feel even the
zap of a static discharge. There are several ways for a
person to become statically charged. The most
common methods of charging are by friction and
induction. •
An example of charging by friction is a person
sliding across a vehicle seat.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.

Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.

Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled
under every possible driving condition.

Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening o
r
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantit
y
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.


Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.

Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.

Functional inspection
Inspection/adjustment of valve clearance 1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead cente
r
(TDC).





RTW 76ASH001301
Legend
1. TDC



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-57
6. Remove the M6 bolt from the idle gear A.
7. Install the gear case cover. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).


RTW 56ASH020101
Legend
1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)




RTW 56ASH012101
8. Install the vacuum pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the oil pipe (feed side and return side) o
f
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.




LTW 56ASH000101

10. Install the crank pulley.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure fo
r
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.



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6B-6 ENGINE COOLING (4JK1/4JJ1)
Diagnosis
Engine Cooling Trouble
Condition Possible Cause Correction
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system
Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace


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ENGINE COOLING (4JK1/4JJ1) 6B-15
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure: 93.3 - 122.7 kPa (0.95 - 1.25 kg / cm
2 / 13.5 -
17.8 psi)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
Valve opening vacuum: 1.96 - 4.91 kPa (0.02 - 0.05 kg / cm
2 / 0.28 - 0.71
psi)



110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:
• Leakage from the radiator.
• Leakage from the coolant pump.
• Leakage from the water hoses.
• Check the rubber hoses for swelling.



110RS005


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FUEL SYSTEM (4JK1/4JJ1) 6C-37
24. Install the A/C compressor.




RTW 56ASH004201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor

Tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
25. Install the battery.
26. Install the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut


Tighten the nut and bolt to the specified torque.
Bolt Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
Nut Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
27. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure fo
r
Heating and air conditioning in this manual.
28. Install the cooling fan.
29. Install the fan guide.
30. Install the radiator upper hose.
31. Replenish the engine coolant.

Fuel Supply Pump Relearn Procedure
The ECM goes through a fuel supply pump learn
procedure to fine tune the current supplied to the fuel
rail pressure (FRP) regulator. This learning process in
only performed when the engine is idling.
1. Install the scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Supply Pump Learn Reset with the scan tool.
4. Observe the Supply Pump Status parameter with the scan tool. Confirm the scan tool indicates Not
Learn.
5. Start the engine and let idle until engine coolant temperature (ECT) reads 149°F (65°C) or highe
r
while observing Supply Pump Status parameter
with the scant tool. The scan tool changes status
Not Learn > Learning > Learned.
6. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.


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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-29
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.
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

















825R300046

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



LNW 21KSH001401



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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-53
Cam/ Crank Sensor Signal/ Synchronization Status
This parameter displays the synchronization state of
the crankshaft position (CKP) sensor signal and
camshaft position (CMP) sensor signal. Asynchronous
indicates the CMP sensor signal is not detected or only
CKP sensor signal is detected. No Crank Signal
indicates CMP sensor signal is detected but CKP
sensor signal is not detected. Synchronous indicates
both sensor signals are detected correctly.
Engine Runtime
This parameter displays the time elapsed since the
engine start. The scan tool will display the time in
hours, minutes and seconds. The engine run time will
reset to zero as soon as the ignition switch is OFF.
Vehicle Speed
This parameter indicates the vehicle speed calculated
by the ECM using the signal from the vehicle speed
sensor (VSS). The scan tool will display a low value at
lower vehicle speeds, and a high value at higher
vehicle speeds.
Transmission Gear
This parameter displays the estimated transmission
gear position as calculated by the ECM based on
inputs from the vehicle speed and the engine speed.
Starter Switch
This parameter displays the input status of the starter
switch to the ECM. When the ignition switch is turned at
START position, the scan tool displays On.
Ignition Switch
This parameter displays the input status of the ignition
switch to the ECM. When the ignition switch is turned
ON position, the scan tool displays On.
Ignition Voltage
This parameter displays the ignition voltage measured
at the ignition feed circuit of the ECM. Voltage is
applied to the ECM when the ignition switch is ON
position.
Battery Voltage
This parameter displays the battery voltage measured
at the ECM main relay switched voltage feed circuit of
the ECM. Voltage is applied to the ECM when the ECM
main relay is energized.
Fuel Pump Relay Command
This parameter displays the commanded state of the
fuel pump relay control circuit. On indicates the fuel
pump relay control circuit is being grounded by the
ECM, allowing fuel pumping from the tank.
Swirl Control Solenoid Command
This parameter displays the commanded state of the
swirl control solenoid control circuit. On indicates the
swirl control solenoid control circuit is being grounded
by the ECM, allowing vacuum pressure to the swirl
control
actuator. Fuel Filter Switch
This parameter displays the input state of the fuel
pressure switch to the ECM. When the large vacuum
pressure is generated in the fuel suction line such as
clogged fuel filter, the scan tool displays Off.
A/C Request Signal
This parameter displays the input state of the air
conditioning (A/C) request to the ECM from the
heating, ventilation, and air conditioning (HVAC)
controls. When the HVAC system is requesting to
ground the A/C compressor clutch, the scan tool
displays On.
A/C Relay Command
This parameter displays the commanded state of the A/
C compressor relay control circuit. On indicates the A/C
compressor relay control circuit is being grounded by
the ECM, allowing voltage to the A/C compressor.
Park/ Neutral Switch
This parameter displays the input state of the neutral
switch to the ECM. When the transmission gear is Park
or Neutral, the scan tool displays Neutral.
Glow Relay Command
This parameter displays the commanded state of the
glow relay control circuit. On indicates the glow relay
control circuit is being grounded by the ECM, allowing
voltage to the glow plugs.
Glow Plug Lamp Command
This parameter displays the commanded state of the
glow indicator lamp control circuit. The glow indicator
lamp should be On when the scan tool indicates
command On. The glow indicator lamp should be Off
when the scan tool indicates command Off.
Brake Switch 1
This parameter displays the input state of the brake
pedal switch 1 to the ECM. When the brake pedal is
depressed, scan tool displays Applied.
Brake Switch 2
This parameter displays the input state of the brake
pedal switch 2 to the ECM. When the brake pedal is
depressed, scan tool displays Applied.
Clutch Pedal Switch
This parameter displays the input state of the clutch
pedal switch to the ECM. When the clutch pedal is
depressed, scan tool displays Applied.
Cruise Main Lamp Command
This parameter displays the commanded state of the
cruise main lamp control circuit. The cruise main lamp
should be On when the scan tool indicates command
On. The cruise main lamp should be Off when the scan
tool indicates command Off.
Cruise Main Switch
This parameter displays the input state of the cruise
main switch to the ECM. When the Cruise Main switch
is pushed, the scan tool displays On.

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