start ISUZU KB P190 2007 Workshop Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 1784 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-167
41. Remove the EGR valve assembly from the
engine.
2. Inspect the EGR valve for the following conditions:
• Restricted EGR valve by foreign materials
• Excessive deposits at valve
• Bent valve shaft
3. Repair or replace as necessary.
Did you find and correct the condition? —
Go to Step 7 Go to Step 5
5 1. Turn OFF the ignition.
2. Disconnect the EGR valve harness connector.
3. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the EGR valve (pins 1, 2, 3, 4
and 6 of E-71).
4. Disconnect the ECM harness connector.
5. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the ECM (pins 30, 31, 32, 62 and
63 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 7 Go to Step 6
6 Replace the EGR valve. Refer to EGR Valve
Replacement.
Did you complete the replacement? —
Go to Step 7
—
71. Reconnect all previously disconnected
harness connector(s).
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? —
Go to Step 2 Go to Step 8
8 Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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ISUZU KB P190 2007
Page 1785 of 6020
6E-168 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0405 or P0406 (Flash Code 44)
Circuit Description
The exhaust gas recirculation (EGR) position sensor is
installed on the EGR valve body together with the
control solenoid. The EGR position sensor changes
output voltage according to EGR valve position. The
sensor has the following circuits.
• 5 volts reference circuit
• Low reference circuit
• EGR position sensor signal circuit
The EGR position sensor provides a signal to the ECM
on the signal circuit, which is relative to the position
changes of the EGR valve. If the ECM detects an
excessively low or high signal voltage, DTC P0405 or
P0406 will set.
Condition for Running the DTC • DTCs P0652 and P0653 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
Condition for Setting the DTC • The ECM detects that the EGR position sensor signal voltage is less than 0.2 volts for 3 seconds.
(DTC P0405)
• The ECM detects that the EGR position sensor signal voltage is more than 4.6 volts for 3 seconds.
(DTC P0406) Action Taken When the DTC Sets
• The ECM illuminates the MIL on the second consecutive driving cycle when the diagnostic runs
and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type B. (Euro 4
Specification)
• The ECM illuminates the MIL when the diagnostic runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A.
(Except Euro 4 Specification)
• The ECM inhibits EGR control.
• The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type B. (Euro 4
Specification)
• Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A. (Except Euro 4
Specification)
Diagnostic Aids • If an intermittent condition is suspected, refer to Intermittent Conditions in this section.
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0405
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 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 P0652 also set? —
Go to DTC P0652 Go to Step 3
3 Observe the EGR Position Sensor parameter with
a scan tool.
Is EGR Position Sensor parameter less than the
specified value? 0.2 volts
Go to Step 4 Go to Diagnostic
Aids
4 1. Turn OFF the ignition.
2. Disconnect the EGR valve harness connector.
3. Connect a DMM between the 5 volts reference circuit (pin 1 of E-71) and a known good
ground.
4. Turn ON the ignition, with the engine OFF.
Is the DMM voltage more than the specified value? 4.7 volts
Go to Step 5 Go to Step 6
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Page 1786 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-169
5Connect a 3-amp fused jumper wire between the 5
volts reference circuit and the signal circuit (pins 1
and 3 of E-71).
Is the EGR Position Sensor parameter more than
the specified value? 4.7 volts
Go to Step 8 Go to Step 7
6 1. Test the 5 volts reference circuit between the
ECM (pin 31 of E-90) and the EGR valve (pin
1 of E-71) for an open circuit or high
resistance.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 12 Go to Step 9
7 1. Test the signal circuit between the ECM (pin
32 of E-90) and the EGR valve (pin 3 for E-71)
for the following conditions:
• An open circuit
• A short to ground
• A short to the low reference circuit
• High resistance
2. Repair the circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 12 Go to Step 9
8 1. Inspect for an intermittent and for poor
connections at the harness connector of the
EGR valve (pins 1 and 3 of E-71).
2. Repair the connection(s) as necessary.
Did you find and correct the condition? —
Go to Step 12 Go to Step 10
9 1. Turn OFF the ignition.
2. Disconnect the ECM harness connector.
3. Inspect for an intermittent and for poor connections at the harness connector of the
ECM (pins 31 and 32 of E-90).
4. Repair the connection(s) as necessary.
Did you find and correct the condition? —
Go to Step 12 Go to Step 11
10 Replace the EGR valve. Refer to EGR Valve
Replacement.
Did you complete the replacement? —
Go to Step 12
—
11Important:
Replacement ECM must be
programmed and learned.
Replace the ECM. Refer to ECM Replacement.
Did you complete the replacement? —
Go to Step 12
—
121. Reconnect all previously disconnected
harness connector(s).
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? —
Go to Step 3 Go to Step 13
Step
Action Value(s)Yes No
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ISUZU KB P190 2007
Page 1787 of 6020
6E-170 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Circuit/ System Testing DTC P0406
13Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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 a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Observe the EGR Position Sensor parameter with a scan tool.
Is the EGR Position Sensor parameter more than
the specified valve? 4.6 volts
Go to Step 3 Go to Diagnostic
Aids
3 Monitor the DTC Information with a scan tool.
Is DTC P0653 also set? —
Go to Step 4 Go to Step 5
4 1. Turn OFF the ignition.
2. Disconnect the EGR valve harness connector.
3. Turn ON the ignition, with the engine OFF.
Is the EGR Position Sensor parameter less than
the specified value? 0.1 volts
Go to DTC P0653 Go to Step 7
5 1. Turn OFF the ignition.
2. Disconnect the EGR valve harness connector.
3. Turn ON the ignition, with the engine OFF.
Is the EGR Position Sensor parameter less than
the specified value? 0.1 volts
Go to Step 6 Go to Step 7
6 Connect a test lamp between the low reference
circuit (pin 2 of E-71) and battery voltage.
Does the test lamp illuminate? —
Go to Step 9 Go to Step 8
7 Important:
The EGR position sensor may be
damaged if the sensor signal circuit is shorted to a
voltage source.
1. Test the signal circuit between the ECM (pin 32 of E-90) and the EGR valve (pin 3 of E-71)
for the following conditions:
• A short to battery or ignition voltage
• A short to any 5 volts reference
2. Repair the circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 13 Go to Step 12
8 1. Test the low reference circuit between the
ECM (pin 30 of E-90) and the EGR valve (pin
2 of E-71) for an open circuit or high
resistance.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 13 Go to Step 10
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ISUZU KB P190 2007
Page 1788 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-171
91. Inspect for an intermittent and for a poor
connection at the harness connector of the
EGR valve (pin 2 of E-71).
2. Repair the connection(s) as necessary.
Did you find and correct the condition? —
Go to Step 13 Go to Step 11
10 1. Turn OFF the ignition.
2. Disconnect the ECM harness connector.
3. Inspect for an intermittent and for a poor connection at the harness connector of the
ECM (pin 30 of E-90).
4. Repair the connection(s) as necessary.
Did you find and correct the condition? —
Go to Step 13 Go to Step 12
11 Replace the EGR valve. Refer to EGR Valve
Replacement.
Did you complete the replacement? —
Go to Step 13
—
12Important:
Replacement ECM must be
programmed and learned.
Replace the ECM. Refer to ECM Replacement.
Did you complete the replacement? —
Go to Step 13
—
131. Reconnect all previously disconnected
harness connector(s).
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? —
Go to Step 2 Go to Step 14
14 Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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ISUZU KB P190 2007
Page 1795 of 6020
6E-178 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0512 (Flash Code 417)
Circuit Description
The starter switch signal is inputted to the ECM during
the ignition switch START position. If the ECM detects
the starter switch signal continuously ON during the
engine running, this DTC will set.
Condition for Running the DTC • The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the starter switch signal is stuck at the ON position (high voltage) for longer
than 20 seconds.
Action Taken When the DTC Sets • The ECM illuminates the SVS lamp when the diagnostic runs and fails. Refer to DTC Type
Definitions for Action Taken When the DTC Sets -
Type C. Condition for Clearing the DTC
• Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp/ DTC - Type C.
Diagnostic Aids • If an intermittent condition is suspected, refer to Intermittent Conditions in this section.
Notice: • This DTC will set if the ignition switch continues being START position for longer than 20 seconds.
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0512
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. Turn OFF the ignition.
2. Remove the starter cut relay in order to inhibit starter motor engagement at ignition switch
ON.
3. Install a scan tool.
4. Turn ON the ignition, with the engine OFF.
5. Observe the Starter Switch parameter with a scan tool.
Does the Starter Switch parameter indicate OFF? —
Go to Diagnostic Aids Go to Step 3
3 Remove the Starter (10A) fuse in the cabin fuse
block.
Does the Starter Switch parameter indicate OFF? —
Go to Step 4 Go to Step 5
4 1. Test the signal circuit between the starter
switch (pin 1 of B-63) and each terminal of the
ignition switch (pins 1, 2, 3 and 4 of B-62 and
pin 3 of B-63) for short circuit each other at the
ignition switch ON.
2. Repair the circuit(s) as necessary.
Did you find and correct the condition? —
Go to Step 8 Go to Step 7
5 1. Test the signal circuit between the ECM (pin
44 of C-58) and the Starter (10A) fuse or
starter relay (pin 3 of X-8) 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 8 Go to Step 6
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Page 1796 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-179
61. Turn OFF the ignition.
2. Disconnect the ECM harness connector.
3. Inspect the connection on the starter switch signal circuit at the harness connector of the
ECM (pin 44 of C-58) for corrosion.
4. Repair the connection(s) as necessary.
Did you complete the action? —
Go to Step 8
—
7Repair or replace the ignition switch.
Did you complete the repair or replacement? —
Go to Step 8—
81. Reconnect all previously disconnected relay
or harness connector(s).
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine.
5. Operate the vehicle within the Conditions for Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? —
Go to Step 2 Go to Step 9
9 Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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ISUZU KB P190 2007
Page 1797 of 6020
6E-180 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0562 or P0563 (Flash Code 35)
Circuit Description
The ECM monitors the ignition voltage on the ignition
feed terminal to make sure that the voltage stays within
the proper range. If the ECM detects an excessively
low or high ignition voltage, DTC P0562 or P0563 will
set.
Condition for Running the DTC • The battery voltage is more than 9 volts.
Condition for Setting the DTC • The ECM detects that the ignition voltage feed circuit is less than 8 volts for 5 seconds. (DTC
P0562)
• The ECM detects that the ignition voltage feed circuit is more than 16 volts for 5 seconds. (DTC
P0563)
Action Taken When the DTC Sets • The ECM illuminates the SVS lamp when the diagnostic runs and fails. Refer to DTC Type
Definitions for Action Taken When the DTC Sets -
Type C. (Euro 4 Specification) • The ECM illuminates the MIL when the diagnostic
runs and fails. Refer to DTC Type Definitions for
Action Taken When the DTC Sets - Type A.
(Except Euro 4 Specification)
• The ECM limits fuel injection quantity. (DTC P0563)
• The ECM inhibits pilot injection. (DTC P0563)
• The ECM inhibits cruise control. (DTC P0563)
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the SVS Lamp/ DTC - Type C. (Euro 4
Specification)
• Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A. (Except Euro 4
Specification)
Diagnostic Aids • A charging system problem may set this DTC.
• The weakened battery may set DTC P0562.
• Jump starting the vehicle or a battery charger may have set this DTC P0563.
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0562
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 a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine and let idle.
4. Load the electrical system by turning ON the headlights, A/C, etc. while observing the
Ignition Voltage parameter with a scan tool.
Does the scan tool indicate more than the specified
value? 10.0 volts
Go to Diagnostic Aids Go to Step 3
3 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 4 Go to Step 5
4 Repair the charging system. Refer to Diagnosis of
The Charging System in the Charging System
Section.
Did you complete the repair? —
Go to Step 6
—
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ISUZU KB P190 2007
Page 1798 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-181
Circuit/ System Testing DTC P0563
51. Turn OFF the ignition.
2. Disconnect the ECM harness connector.
3. Inspect for an intermittent, for a poor connection and for corrosion at the harness
connector of the ECM (pin 72 of C-58).
4. Repair the connection(s) as necessary.
Did you find and correct the condition? —
Go to Step 6 Go to Diagnostic
Aids
6 1. Reconnect all previously disconnected
harness connector(s).
2. Clear the DTCs with a scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine and let idle.
5. Load the electrical system by turning ON the headlights, A/C, etc. while observing the
Ignition Voltage parameter with a scan tool.
Does the scan tool indicate more than the specified
value? 10.0 volts
Go to Step 7 Go to Step 3
7 Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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 Was the vehicle recently jump started or a battery
charger placed on the battery? —
Go to Step 7 Go to Step 3
3 1. Install a scan tool.
2. Start the engine and let idle.
3. Observe the Ignition Voltage parameter with the scan tool.
Does the scan tool indicate less than the specified
value? 16.0 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 Diagnostic
Aids
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 6
—
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ISUZU KB P190 2007
Page 1799 of 6020
6E-182 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
61. 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.
5. Observe the ignition Voltage parameter with a scan tool.
Does the scan tool indicate less than the specified
value? 16.0 volts
Go to Step 7 Go to Step 4
7 Observe the DTC Information with a scan tool.
Are there any DTCs that you have not diagnosed? —
Go to DTC List System OK
Step
Action Value(s)Yes No
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ISUZU KB P190 2007