ignition ISUZU KB P190 2007 Workshop Repair Manual

FUEL SYSTEM (4JK1/4JJ1) 6C-7
g. Check that the warning lamp in the meter is off.
2. Draining with drain plug in engine room. a. W ith the engine off, open the engine hood and loosen the drain plug (1) located on the left
hand side of the engine room. (3-4 turns)
b. Turn the starter switch to the “ON” position fo
r
10 seconds, and then turn the starter switch to
the “OFF” position for 10 seconds. Then, once
again turn the starter switch to the “ON”
position for 10 seconds.
c. Tighten the drain plug firmly.
d.
After starting the engine, check that there is no
fuel leakage from the drain plug. Also check
that the water separator indicator has turned
off.










RTW 76CSH001301
NOTE:
• If the water separator requires frequent draining,
have the fuel tank drained at your ISUZU/GM
Dealer.
• Be sure to stop the engine when draining the fuel
tank.
• Confirm that there are no combustible materials
under the drain hose, and use a receptacle to
catch the drained water.


Engine starting cautions
• Before starting the engine, turn the ignition switch
to the “ON” position. W ait 15 seconds. Return the
switch to the “LOCK” position. Repeat this
procedure 5 times.
• After starting the engine, allow it to idle for 10
minutes.

Fuel Pump Functional Check
1. Turn the starter switch to “ON” position.
2. Touch the under portion of the Fuel Tank by the hand as shown in the following figure within 12
seconds.





RTW 56CSH003501
Legend
1. Touch this area by the hand

3. Make sure a vibration by the Fuel Pump is
detected.
Fuel Pump stops within 12 seconds of turning the starter switch to the “ON” position.
W hen the check is repeated, return the starte
r
switch to the “LOCK” position for 10 – 15 seconds
and perform procedures 1 – 3.
WARNING: FUEL PUMP FUNCTIONAL CHECK
MUST BE CONDUCTED UNDER THE FOLLOWING
CONDITIONS TO AVOID INJURY.
•
••
•
APPLY THE PARKING BRAKE.
•
••
•
STOP THE ENGINE.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-17
Record the Fuel Injector ID Code Data from
each injector housing
1. Remove each fuel injector harness connector.
2. Record all numbers of each cylinder on the harness connector housing. The correct order fo
r
the fuel injector ID codes of the following
illustration is as follows:
5F 05 00 FB 00 F7 08 F5 19 FF 04 49





RTW 76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector


Programming Fuel Injector ID Codes
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
4. In order to get programming approval, the on- screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the "Tech" 2 on the Diagnostic Tool Selection screen and click "Next".
f. Click "Close" on the Security Access Enabled screen.


g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Reinstall a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
8. Enter 24 figures of replaced fuel injector ID code.
9.
After complete the programming, turn OFF the
ignition for 30 seconds.
10.Start the engine and let idle.
11.Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.


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ISUZU KB P190 2007

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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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-39
Fuel Sedimenter Switch
Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, remove the fuel sedimenter connector, and connect the terminals
of the connectors on the harness side. Confirm
that the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the switch parts and carry out repairs in case o
f
defective connection between circuits or short circuits.




RTW 76CSH001101
Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Valve




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ENGINE ELECTRICAL (4JK1/4JJ1) 6D-7
Diagnosis
On-vehicle Inspection
The charging system warning light tells the vehicle
operator of possible problems with the system.

W hen the ignition switch is moved to the ON position,
the light turns on. The light turns off immediately afte
r
the engine is started. If the light turns on during engine
operation, there is a problem with the charging system.
Perform the checks described below.
1. Check the belt (broken or loose).
2. Check the harness connectors (loose o
r
disconnected).
3. W ith the engine off, turn the ignition switch to the ON position. If the warning lamp does not light,
remove the harness connector from the generator.
Ground the connector IG terminal. The lamp
should light. If it does not, the bulb is burned out.
Replace the bulb.
4. Start the engine. If the warning lamp remains on, the generator must be repaired or replaced.





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6E-10 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Engine Controls Schematics
Power Distribution (1)
RTW76EXF003601
X-11
X-11 Heater
relay
1
2
Blower
motor Ignition
switchIgnition
switch Starter
relay
SBF1
Main
120A SBF2
ABS-1
40A SBF3
ABS-2
20A SBF5
IG1
40A SBF4
ECM
40A
SBF6
Blower
30A
EB-13
A/C
10A
2
BLU/
RED
3
BLU/
RED 3
BLU/
RED SBF8
Glow
60A
SBF7
Front
Fog
20A
SBF9
IG2
60A
EB-9
Fog
15A
or
Trailer
20AEB-10
Tail/Illumi
10A
or
Condenser
fan
20A EB-4
Engine
10A
EB-14
4WD
10A EB-15
Horn
10A EB-16
Hazard10A EB-1
ACG
(S)
10AEB-2
ECM
(B)
10AEB-3
F/Pump10A
EB-5 H/L HI(RH)10A Fuse
EB-6 H/L HI(LH)10A Fuse
EB-7 H/L LO(RH)10A Fuse
EB-8 H/L LO(LH)10A Fuse
P-6
Body
Generator P-5
8 BLK/
P-1
P-2
Battery
8
BLK 5WHTSrarter
Srarter
C-3
ELEC IG
10A
Fuse
E-92
0.5 WHT
0.3
BLK 3
WHT/
RED 5
WHT
0.3
BLK 5
RED/
BLU
5
RED
3
WHT/
BLK
30
BLK/
RED
30
BLK/
YEL
P-10
Engine
5
4 X-12
X-12
ECM
Fuel pump relay
ECM
ECM
main
relay
1
2 5
4
X-6
X-6
2
RED/
WHT
0.3
RED/
BLU Fuse/ relay box(Engine room)
2
RED
2
RED
0.5
RED
2
WHT
2
RED/
BLU 2
WHT
2
3 1
5
Lighting
switch Head
lamp
relay
C-36 C-36
RED
P-16
P-15
2nd
Battery
30
BLK/
YEL 30
BLK/
RED
P-10

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-11
Power Distribution (2)
RTW76EXF003701
C-108
5
WHT
3
WHT/
BLK
5
WHT
3
WHT/
BLK
3BLU
3BLK/RED
3
WHT/
BLK
3
BLK/
YEL 3
BLK/
WHT B-62
B-63
2
4
B-62
B-63 1
1
3
C-18
Rr
Def.
20A C-21
Door
lock
20A C-19
Meter
(+B)
10A C-15
Stop
lamp
15A C-22
Anti
theft
10A C-13
Audio
(+B)
15A
C-16
RR
Fog
10A C-17
Room
10A C-20
Power
window
30A Fuse/
relay box
(Cabin)
C-14
Meter
10A C-8
SRS
10AC-7
TCM
10A
or
15A C-9
Front
wiper
20A C-10
Back
up
15A C-6
Engine
10A
C-5
ABS/4WD
10AC-1
Starter
10AC-2
Trailer
10AC-3
ELEC IG
10A C-4
Turn
10AC-12
Cigar
lighter
&
ACC
Socket
20A C-11
Audio
10A
SBF9
IG2
60A Fuse/
relay
box
(Engine
room)
Starter relay
SBF5
IG1
40A
1
2
3 B-62 B1
B2
OFF
ACC
IG2ST
IG1 Ignition
switch

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6E-12 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Starting and Charging System
RTW76EXF003801
EB-1
ACG(S)
10A
0.5
WHT
2
WHT
SBF1
Main
120A SBF5
IG1
40A Refer to
power
distribution Fuse/ relay
box(Engine room)
SBF9
IG2
60A
5
WHT 5
WHT
P-8 P-5
8 BLK/
RED
P-1
P-2
Battery
8
BLK
30
BLK/
YEL
P-10
P-16
P-15
2nd
Battery
30
BLK/
RED
30
BLK/
RED
30
BLK/
YEL
P-10 X-8
X-8
E-4
Generator H-1Starter
relay
1
1
H-4 E-92
8
2
4
E-4 E-17
2 B-23
3 B-24
8
3 X-7
X-7 Starter
cut
relay
1 3
45
Starter
P-4
1
B
S
SB
L
P-3 0.3
WHT/
BLU
5
WHT
5
WHT
0.5
WHT
Charge
lightIP
cluster
H-6
1
0.5
WHT/
BLU
0.5
WHT/
BLU H-49
1 C-108
3
WHT/
BLK
3
WHT/
BLK
3
BLK/
YEL
0.5
YEL 3
BLK/
WHT B-62
B-63
2
3
C-14
Meter
10A C-1
Starter
10A C-6
Engine
10A
0.5
WHT/
GRN
0.5
WHT/
GRN
0.5
RED/
WHT
0.5RED/WHT
0.5WHT/GRN
0.5
RED/
WHT
Starter switchsignal Ignition
switchsignal Glow relay
DRM
ECM Refer to
power
distribution
Fuse/relay
box(Cabin)
1
2
3 B-62 1 B-63
5 5 9 C-107
B-56
44
35 72
B1
B2
OFF
ACC
IG2
ST
IG1 Ignition
switch
Relay
control
4
0.3
BLK/
WHT
3
BLK/
YEL
0.3
BLK/
YEL
3
WHT
0.5YEL
Fuse/relay box(Engine room)3WHT/BLK
0.5
BLU/
YEL
H-4
A/T
M/T
C-36
E-10 0.5
BLK/
WHT
Inhibitor
switch 0.3
BLK 0.5
ORN/
BLU
0.5
BLK E-51
7
(4)
E-51
10
(1) C-58
( )...High output

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-13
ECM Power and Ground
RTW76EXF004501
X-12
X-12 ECM
main
relay
4
5
2 65
45 63 Ground
73
C-58 E-90
Ground
1
X-13
X-13 Fuel
pump
relay
0.5
ORN/
BLU 5
RED/
BLU
5
RED/
BLU
0.5 ORN/BLU
Fuel
pump 0.5
ORN/
BLK
0.5
BLK
C-109 Relay
control
Fuel
pump
resistor H-9
F-2 5
RED
0.5
BLU/
RED
0.5
BLU/
RED
0.5
BLU/
RED
2
RED/
BLU
EB-3
F/Pump
10A
SBF4
ECM
40A
EB-2
ECM
(B)
10A
Refer to
Power
distribution
TCM 0.5
YEL/
VIO
0.5
RED/
WHT
0.5
RED/
WHT
0.5
RED
0.5
RED 3
1
5
2
1
C-157
1 F-24
C-57
2 0.3
BLK
2
BLK
C-36 C-2E-10
Battery voltage
Battery voltage
(Back up) Fuse/
relay
box ECM
main
relay
control
4
H-49
1
52 C-58
ECM
54
73 EB-4
Engine
10A
Fuse (Engine
room)
0.5
BLK
0.3
BLKH-18
1
2
BLKB-82
Weld
splice 6
5
BLK
H-18
13
Ignition voltage
ECM

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6E-24 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
A/C Control System and Glow Control System
RTW76EXF001701
9 C-107C-58
X-14
X-14 A/C
compressor
relay
13
5 2 X-5
X-5
H-4 Glow
relay
42
1
3
ECM
Ignition
signal
Thermo
relay
signal X-15
X-15 Thermo
relay
Refrigerant
pressure
switch 0.5
GRN/
YEL 0.5
GRN/
BLK 0.5
GRN/
ORN
0.5
GRN/
BLK 0.5
GRN/
ORN
3
BLK/
RED
Glow
plug
Compressor
clutch
Relay
control Relay
control
H-4
E-3
( )=A/T 0.5
BRN
0.5
GRN/
RED 0.5
BLK/
BLU
0.5
WHT/
GRN 3
RED/
WHT
3
BLK/
RED
0.5
GRN/
BLK
0.5
BRN
0.5
BRNEB-13
A/C
10A Fuse/
relay
box
(Engine room)
0.5
BRN
23 1
5
1 SBF8
Glow
60A Fuse/
relay
box
(Cabin)
C-6
Engine
10A
0.5
WHT/
GRN
0.5
WHT/
GRN
Starter
cut
relay Refer to
Power distribution
15 19
(28)
E-49
72
37
55
4

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