torque ISUZU KB P190 2007 Workshop Repair Manual

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-325
Intermittent Conditions
ChecksAction
Definition:
The problem is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom cannot currently be duplicated, if the problem is not DTC related.
Preliminary Checks • Refer to Symptoms - Engine Controls before starting.
Harness/ Connector Many intermittent open or shorted circuits are affected by harness/ connector
movement that is caused by vibration, engine torque, bumps/ rough pavement, etc.
Test for this type of condition by performing the applicable procedure from the following
list:
• Move related connectors and wiring while monitoring the appropriate scan tool data.
• Move related connectors and wiring with the component commanded ON, and OFF, with the scan tool. Observe the component operation.
• With the engine running, move related connectors and wiring while monitoring engine operation.
If harness or connector movement affects the data displayed, component/ system
operation, or engine operation, inspect and repair the harness/ connections as
necessary.
Electrical Connections or Wiring Poor electrical connections, terminal tension or wiring problems cause most intermittent. To perform the following inspections:
• Poor mating of the connector halves, or terminals improperly seated in the connector body.
• Improperly formed or damaged terminals. Test for poor terminal tension.
• Poor terminal to wire connections including terminals crimped over insulation. This requires removing the terminal from the connector body.
• Corrosion/ water intrusion. Pierced or damaged insulation can allow moisture to enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wires that are broken inside the insulation.
• Harness for pinched, cut or rubbed through wiring.
• Ensure that the wiring does not come in contact with hot exhaust components.
Control Module Power and Grounds
Component Power and Grounds Poor power or ground connections can cause widely varying symptoms.
• Test all control module power supply circuits. Many vehicles have multiple circuits supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/ component connectors, fuses, and any intermediate connections
between the power source and the module/ component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.
• Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and
in splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.

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ISUZU KB P190 2007

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-335
Air Intake System ChecksInspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
• A restriction or damaged at MAF sensor.
• Perform the Swirl Control Solenoid Test with a scan tool. Inspect the diaphragm valve operation when it commanded ON/ OFF.
• Turbocharger wastegate valve operation. Refer to wastegate valve inspection in the Engine Mechanical section. (Standard output)
• Turbocharger nozzle control actuator operation. Refer to Turbocharger Control System Check in this section. (High output)
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
Additional Checks • Inspect the EGR system operating correctly. Refer to EGR Control System Check in
this section.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation. (A/T only)
• Inspect deformed tire(s) that may cause surges at fixed vehicle speed range.
Checks
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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-337
Fuel System ChecksInspect the fuel system for the following conditions. Refer to Fuel System Check chart
and appropriate procedure in the Fuel System section.
• Air in the fuel system.
• Water contamination in the fuel.
• Fuel waxing or icing.
• Fuel filter indicator lamp is continuously or frequently turned ON with engine run.
• External fuel leaks or high engine oil level.
• In-tank fuel pump operation. Refer to In-tank Fuel Pump System Check in this section.
• Fuel leak off from the fuel pressure limiter valve and fuel injectors.
• Fuel lines between the fuel tank and fuel supply pump for being crushed, kinked, tightness, cracks and plugged.
• A plugged fuel tank vent valve and hose.
• Inside the fuel tank for any foreign material that may be getting drawn into the fuel line pickup causing a blocked condition.
• Fuel supply pump operation.
Notice: The fuel supply pump must be timed to the engine and adjustment value must
be learned to the ECM.
• Perform the Cylinder Balance Test with a scan tool.
• Perform the Injector Force Drive with a scan tool.
• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
• A restriction or damaged at MAF sensor.
• Perform the Swirl Control Solenoid Test with a scan tool. Inspect the diaphragm valve operation when it commanded ON/ OFF.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer to turbocharger inspection in the Engine Mechanical section.
• Turbocharger wastegate valve operation. Refer to wastegate valve inspection in the Engine Mechanical section. (Standard output)
• Turbocharger nozzle control actuator operation. Refer to Turbocharger Control System Check in this section. (High output)
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Poor cylinder compression.
• Improper valve gap.
• Broken or weak valve springs.
• Worn camshaft lobes.
Additional Checks • Inspect the EGR system operating correctly. Refer to EGR Control System Check in
this section.
• Observe the Park/ Neutral Switch parameter with a scan tool.
• Inspect for an engine overheat condition. Refer to Engine Cooling section.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation. (A/T only).
Checks
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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-339
Fuel System ChecksInspect the fuel system for the following conditions. Refer to Fuel System Check Chart
and appropriate procedure in the Fuel System section.
• Air in the fuel system.
• Water contamination in the fuel.
• Fuel waxing or icing.
• Fuel filter indicator lamp is continuously or frequently turned ON with engine run.
• External fuel leaks or high engine oil level.
• In-tank fuel pump operation. Refer to In-tank Fuel Pump System Check in this section.
• Fuel leak off from the fuel pressure limiter valve and fuel injectors.
• Fuel lines between the fuel tank and fuel supply pump for being crushed, kinked, tightness, cracks and plugged.
• A plugged fuel tank vent valve and hose.
• Inside the fuel tank for any foreign material that may be getting drawn into the fuel line pickup causing a blocked condition.
• Fuel supply pump operation.
Notice: The fuel supply pump must be timed to the engine and adjustment value must
be learned to the ECM.
• Perform the Cylinder Balance Test with a scan tool.
• Perform the Injector Force Drive with a scan tool.
• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
• A restriction or damaged at MAF sensor.
• Perform the Swirl Control Solenoid Test with a scan tool. Inspect the diaphragm valve operation when it commanded ON/ OFF.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer to turbocharger inspection in the Engine Mechanical section.
• Turbocharger wastegate valve operation. Refer to wastegate valve inspection in the Engine Mechanical section. (Standard output)
• Turbocharger nozzle control actuator operation. Refer to Turbocharger Control System Check in this section. (High output)
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Poor cylinder compression.
• Improper valve gap.
• Broken or weak valve springs.
• Worn camshaft lobes.
Additional Checks • Inspect the EGR system operating correctly. Refer to EGR Control System Check in
this section.
• Inspect for an engine overheat condition. Refer to Engine Cooling section.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation. (A/T only)
Checks
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ISUZU KB P190 2007

6E-364 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Fuel Injection System Description
Fuel Injection Quantity Control
This control determines the fuel injection quantity by
adding coolant temperature, fuel temperature, intake
air temperature, barometric pressure, mass air flow and
some switch inputs information corrections to the basic
injection quantity is calculated by the ECM based on
the engine operating conditions (engine speed,
accelerator pedal pressing amount and boost pressure
sensor). More fuel rate indicates if the engine load is
increased as the accelerator pedal is stepped on at
constant engine speed.
Combined with high pressure injection of atomized fuel,
this control improves exhaust gas and ensures proper
fuel consumption. Compared with conventional
mechanical governors, an electronic control system
provides higher degree of freedom of fuel injection
quantity control, thereby presenting high accelerator
response (acceleration feeling and pressing feeling).
Starting Injection Quantity Control
At the engine starting (after the key switch is turned to
the START position to start the engine, up to return of
key switch to the ON position), optimum fuel injection
quantity is controlled based on the information on the
engine speed and coolant temperature. At low
temperature, the fuel injection quantity increases.
When the engine started completely, this boosted
quantity mode at the starting is cancelled and normal
running mode is restored.
Idle Speed Control
A control is made so as to achieve stable idling speed
at all time regardless of engine secular changes or
engine condition variations. The ECM sets target idling
speed and controls the fuel injection quantity according
to the engine conditions (actual engine speed, coolant
temperature and engine load) to follow actual engine
speed to the target idling speed so as to ensure stable
idling speed.
Idle Vibration Control
A control is made so as to reduce the engine vibration
caused by torque variations between cylinders due to
variations in fuel injection quantity of each cylinder or
injector performance. The ECM corrects the injection
quantity between cylinders based on the revolution
signals from the crankshaft position (CKP) sensor.
Normal range of correction quantity between cylinders
is within ±5 mm
3.

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EXHAUST SYSTEM (4JK1/4JJ1) 6F-1
SECTION 6F
EXHAUST SYSTEM
CONTENTS

Exhaust Silencer and Exhaust Pipe ................... 6F-2
Main Data and Specifications .......................... 6F-2
Components .................................................... 6F-3
Removal .......................................................... 6F-4
Installation ....................................................... 6F-4
Inspection and Repair ..................................... 6F-5
Torque Specifications...................................... 6F-6
EGR Cooler ........................................................ 6F-7 Components (Standard Output) ...................... 6F-7
Components (High Output) ............................. 6F-8
Removal .......................................................... 6F-9
Installation (Standard Output) ......................... 6F-9
Installation (High Output)................................. 6F-10
Torque Specifications (Standard Output) ........ 6F-11
Torque Specifications (High Output) ............... 6F-12



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6F-4 EXHAUST SYSTEM (4JK1/4JJ1)
Removal
1. Rear hanger rubber
2. Silencer front nut
3. Exhaust silencer
4. Silencer hanger rubber
5. Front hanger rubber
6. Middle pipe nut (4 ×2 High Ride Suspension, 4 ×4)
7. Middle pipe (4 ×2 High Ride Suspension, 4 ×4)
8. Front pipe nut
9. Exhaust pipe gasket
Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention
to the important points during the installation procedure.

1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque: 67 N â‹…
â‹…â‹…
â‹…
m (6.8 kg â‹…
â‹…â‹…
â‹…
m / 49 lb ft)
2. Middle pipe Nut (4 ×2 High Ride Suspension,4 ×4)
Connect the middle pipe to the front pipe.
Torque: 43 N â‹…
â‹…â‹…
â‹…
m (4.4 kg â‹…
â‹…â‹…
â‹…
m / 32 lb ft)
3. Silencer Front Nut
Connect the silencer to the front or middle pipe.
Torque: 43 N â‹…
â‹…â‹…
â‹…
m (4.4 kg â‹…
â‹…â‹…
â‹…
m / 32 lb ft)


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ISUZU KB P190 2007

6F-6 EXHAUST SYSTEM (4JK1/4JJ1)
Torque Specifications




RTW 76FMF000201


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EXHAUST SYSTEM (4JK1/4JJ1) 6F-9
Removal
1. Drain the coolant.
2. Remove the intercooler.
3. Remove the heat protector.
4. Disconnect the water hoses from the EGR coole
r
water pipes.
5. Remove the EGR cooler.
Installation (Standard Output)
1. Gasket
2. EGR Cooler
3. Nuts and Bolts







RTW 56FSH000201
• Temporary tightening order
1 – 2 – 4 – 5 - 3
• Fully tightening order
4 – 5 – 1 – 2 - 3
Tighten the nuts and bolts to the specified torque.
Tightening torque: 27 N â‹…
â‹…â‹…
â‹…
m (2.8 kg â‹…
â‹…â‹…
â‹…
m / 20 lb ft)
4. W ater hose
5. Heat protector • Tighten the bolts to the specified torque.
Tightening torque: 10 N â‹…
â‹…â‹…
â‹…
m (1.0 kg â‹…
â‹…â‹…
â‹…
m / 87 lb in)







RTW 56ASH014601
6. Replenish the engine coolant.

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6F-10 EXHAUST SYSTEM (4JK1/4JJ1)
Installation (High Output)
1. Gasket
2. EGR Cooler
3. Nuts and Bolts




6
543
1
2

RTW 76FSH000201
• Temporary tightening order
1 →2→ 3→ 4→ 5→ 6
• Fully tightening order
3 →4→ 5→ 1→ 2→ 6
Tighten the nuts and bolts to the specified torque.
Tightening torque: Nuts and bolts 1-5: 27 N â‹…
â‹…â‹…
â‹…
m (2.8 kg â‹…
â‹…â‹…
â‹…
m / 20 lb ft)
Bolt 6: 52 Nâ‹…
â‹…â‹…
â‹…
m (5.3 kg â‹…
â‹…â‹…
â‹…
m / 38 lb ft)
4. W ater hose
5. Heat protector • Tighten the bolts to the specified torque.
Tightening torque: 25 N â‹…
â‹…â‹…
â‹…
m (2.5 kg â‹…
â‹…â‹…
â‹…
m / 18 lb ft)



RTW 76FSH000101
6. Replenish the engine coolant.


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ISUZU KB P190 2007