engine 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 1058 of 6020
6E-24 Engine Control System (4JH1)
RTW 66ESF000401
Connector No. C-57
Connector Color Black
Test Adapter No. J-35616-64A
Pin W ire Color Pin Function
82 W HT/BLU Vacuum Pressure Sensor 5
Volts Reference (High Altitude
Only)
83 W HT/RED MAF Sensor 5 Volts Reference
84 BLK/BLU IAT Sensor Signal
85 RED/BLU Vacuum Pressure Sensor Signal (High Altitude Only)
86 Not Used
BLK/W HT Neutral Switch Input (M/T) 87
RED/BLK P & N Position Switch Input (A/T)
88 GRN/RED MAF Sensor Signal
89 GRY ECT Sensor Signal
90 RED CKP Sensor Signal
91 PNK CKP Sensor Signal Output
92 BLK/RED MAF Sensor & IAT Sensor Low Reference
93 BLK/PNK ECT Sensor & Vacuum Pressure Sensor (High Altitude Only) Low
Reference
94 BLK/BLU Glow Relay Control
95 Not Used
96 BRN/RED Turbocharger Solenoid Valve
Control (High Altitude Only)
97 BLK/ORN EGR Solenoid Valve Control
98 W HT CKP Sensor Low Reference
99 RED CAN Low Signal
100 W HT CAN High Signal
101 BLK CKP Sensor Shield Ground
102 Not Used
Connector No. C-57
Connector Color Black
Test Adapter No. J-35616-64A
Pin W ire Color Pin Function
102 Not Used
103 Not Used
105 ORN Engine Shutoff (ESO) Solenoid
Valve Control Signal Output
106 - 121 Not Used
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Page 1059 of 6020
Engine Control System (4JH1) 6E-25
Engine Control Connector End Views
Accelerator Pedal Position (APP) Sensor
RTW 66ESH000301
Connector No. E-22
Connector Color Brown
Test Adapter No. J-35616-33
Pin W ire Color Pin Function
1 RED/GRN APP Sensor Low Reference
2 GRN/ORN APP Sensor Signal
3 BLK/GRN APP Sensor 5 Volts Reference
Brake Switch
RTW 66ESH000401
Connector No. C-44
Connector Color W hite
Test Adapter No. J-35616-40 (Pin 1 – 2)
J35616-2A (Pin 3 – 4)
Pin W ire Color Pin Function
1 GRN Brake Pedal 1 Switch (Stop Lamp
Pedal Switch) 12 Volts Feed
2 RED Brake Pedal 1 Switch (Stop Lamp Pedal Switch) Signal
3 BLU/RED Brake Pedal 2 Switch Ignition Voltage
4 W HT/BLK Brake Pedal 2 Switch Signal
Crankshaft Position (CKP) Sensor
RTW 66ESH000501
Connector No. E-9
Connector Color Black
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
1 W HT CKP Sensor Low Reference
2 RED CKP Sensor Signal
3 BLK CKP Sensor Shield Ground
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ISUZU KB P190 2007
Page 1060 of 6020
6E-26 Engine Control System (4JH1)
Clutch Switch
LNW 46ESH000801
Connector No. C-77
Connector Color W hite
Test Adapter No. J-35616-42
Pin W ire Color Pin Function
1 BLU/RED Clutch Pedal Switch Ignition Voltage
2 YEL Clutch Pedal Switch Signal
Data Link Connector (DLC)
LNW 36ESH015801
Connector No. B-58
Connector Color Black
Test Adapter No. J-35616-2A
Pin W ire Color Pin Function
1
Not Used
2 GRN J1850 (Class 2)
3
Not Used
Connector No. B-58
Connector Color Black
Test Adapter No. J-35616-2A
Pin W ire Color Pin Function
4 BLK Ground
5 BLK Ground
6 BLU Diag Request Switch
7 YEL/BLU Keyword 2000
8
Not Used
9
Not Used
10
Not Used
11 YEL/BLK TCM Diagnostic
12 ORN/W HT ABS C/U Diagnostic
13 RED SRS Diagnostic
14
Not Used
15
Not Used
16 RED/YEL Power Supply
EGR Solenoid Valve
RTW 66ESH000601
Connector No. C-115
Connector Color Black
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
1 BLU/RED Solenoid Valve 12 Volts Feed
2 BLK/ORN Solenoid Valve Control
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Page 1061 of 6020
Engine Control System (4JH1) 6E-27
Engine Coolant Temperature Coolant (ECT) Sensor
LNW 46ESH003901
Connector No. E-41
Connector Color Gray
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
1 GRY ECT Sensor Signal
2 BLK/PNK ECT Sensor Low Reference
Fuel Injection Pump Control Unit (PCU)
RTW 66ESH000701
Connector No. E-6
Connector Color Black
Test Adapter No. J-35616-8
Pin W ire Color Pin Function
1 RED CAN Low Signal
2 YEL CAN High Signal
3
Not Used
Connector No. E-6
Connector Color Black
Test Adapter No. J-35616-8
Pin W ire Color Pin Function
4
Not Used
5 ORN Engine Shutoff (ESO) Solenoid
Valve Control Signal Input
6 BLK Ground
7 BLU/RED Battery voltage
8 PNK CKP Sensor Signal Input
9
Not Used
Glow Plug
LNW 46ESH000701
Connector No. E-49
Connector Color Silver
Pin W ire Color Pin Function
1 BLK/RED Power Supply
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Page 1062 of 6020
6E-28 Engine Control System (4JH1)
Idle Switch
RTW 66ESH000301
Connector No. E-23
Connector Color Gray
Test Adapter No. J-35616-33
Pin W ire Color Pin Function
1 BLK Idle Switch Ground
2 GRN/ BLK Idle Switch Signal
3
Not Used
Mass Air Flow (MAF) / Intake Air Temperature
Sensor
RTW 66ESH000801
Connector No. C-116
Connector Color Black
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
1 BLK/BLU IAT Sensor Signal
Connector No. C-116
Connector Color Black
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
2 BLU/RED MAF Sensor Ignition Voltage Feed
3 BLK/RED MAF Sensor & IAT Sensor Low
Reference
4 W HT/RED MAF Sensor 5 Volts Reference
5 GRN/RED MAF Sensor Signal
Turbocharger Solenoid Valve
RTW 66ESH000901
Connector No. C-123
Connector Color Black
Test Adapter No. J-35616-64A
Pin W ire Color Pin Function
1 BLU/RED Solenoid Valve 12 Volts Feed
2 BRN/RED Solenoid Valve Control
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Page 1063 of 6020
Engine Control System (4JH1) 6E-29
Vacuum Pressure Sensor
RTW 66ESH001001
Connector No. C-124
Connector Color Black
Test Adapter No. J-35616-33
Pin W ire Color Pin Function
1 RED/BLU Vacuum Pressure Sensor Signal
2 BLK/PNK Vacuum Pressure Sensor Low
Reference
3 W HT/BLU Vacuum Pressure Sensor 5 Volts Reference
Vehicle Speed Sensor (VSS)
LNW 46ESH001401
Connector No. E-44
Connector Color Gray
Test Adapter No. J-35616-33
Pin W ire Color Pin Function
1 YEL VSS 12 Volts Feed
2 LT GRN/
WHT VSS Low Reference
3 BLK/YEL VSS Signal
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Page 1064 of 6020
6E-30 Engine Control System (4JH1)
Diagnostic Information And Prosedures
Engine Control System Check Sheet
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name
Customer’s Name Model & Model Year
Driver’s Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading Km/miles
□ Engine Does
Not Run □
Engine does not crank
□No initial combustion
□ No complete combustion
□
Hard Start
□ Engine cranks slowly
□Other ( )
□
Abnormal idling speed
□High idling speed ( RPM)
□ Low idling speed ( RPM)
□
Rough idling □
Incorrect Idle
□ Other ( )
□
Hesitation, sag, stumble
□Surge, chuggles
□ Cut out, misses
□
Lack of power, sluggishness, sponginess □
Poor
Driveability □ Other ( )
□ Soon after starting
□After accelerator pedal depressed
Engine Stall
□ During A/C operation
□After accelerator pedal released
□ Shifting from N to D □
□ Other ( )
□
Black smoke
□White smoke
□ Poor fuel economy
□
Fuel knock, combustion noise
Problem Symptoms
□
Others
□ Other ( )
Dates problem occurred
□
Constant
□Intermittently ( times per day/month)
□ Once only Problem frequency
□ Other (
)
□ Fine
□Cloudy
□Rainy
□ Snow Weather
□ Various/Other (
)
□ Hot (approx. )
□Warm
□Cool
□ Cold (approx. )Outside
Temperature □ Any temperature
□
Highway
□Suburbs
□City area
□ Uphill Place
□ Downhill
□Rough road
□Other (
)
□ Over (approx. tons)
□No load
Load Condition
□ Other (approx. tons)
□ Cold
□Warming up
□After warming up
□ Any temperature Engine
Temperature □ Other ( )
□
Starting
□Just after starting ( Min.)
□ Idling
□
Racing
□Driving
□Constant speed
□ Acceleration
□
Deceleration
□A/C switch On/Off Engine Operation
□ Other ( )
Fuel Amount
□ Full
□Above 1/2
□Below 1/2
□ Near empty
Condition When Problem Occurs
Fuel
Bland
Condition of MIL
□Remains On
□Intermittently turns On
□ Does not turn On
Present Code
□Nothing
□P Code & Symptom Code
No. ( )Diagnostic Trouble
Code (DTC) or Flash
Code History Code □Nothing
□P Code & Symptom Code
No. ( )
Other Additional
Condition
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Page 1065 of 6020
Engine Control System (4JH1) 6E-31
Diagnostic Starting Point - Engine Controls
Begin the system diagnosis with Diagnostic System
Check - Engine Controls. The Diagnostic System Check
- Engine Controls will provide the following information:
• The identification of the control modules which
command the system.
• The ability of the control modules to communicate
through the serial data circuit.
• The identification of any stored diagnostic trouble
codes (DTCs) and the their statuses.
The use of the Diagnostic System Check - Engine
Controls will identify the correct procedure fo
r
diagnosing the system and where the procedure is
located.
Important:
Engine Control System Check Sheet must be used to
verify the complaint vehicle, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure o
f
the system.
Reading Flash Diagnostic Trouble Codes
The provision for communicating with the ECM is the
Data Link Connector (DLC). The DTCs stored in the
ECM memory can be read either through a hand-held
diagnostic scanner such as scan tool plugged into the
DLC or by counting the number of flashes of the MIL
when the diagnostic test terminal of the DLC is
grounded. The DLC terminal “6” (diagnostic request
switch) is pulled “Low” (grounded) by jumped to DLC
terminal “4”, which is a ground wire.
Once terminals “4” and “6” have been connected, the
ignition switch must be moved to the “ON” position, with
the engine not running. The MIL will initially flash 12.
Then, the MIL will flash the first stored DTC three times,
second stored DTC three times and so on. All the
stored DTCs are flashed, then return 12 and continue to
flash the DTC. If no DTC exists, the MIL flashes 12
continuously. The flash DTC display will continue as
long as the DLC is shorted.
RTW 66ESF000501
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Page 1066 of 6020
6E-32 Engine Control System (4JH1)
Breaker Box
Breaker Box Connection Type A
RTW 66ESH003601
Legend
1. Engine Control Module (ECM)
2. Harness Adapter
3. ECM - Harness Connector
4. Breaker Box
5. ECM is disconnected
Breaker Box Connection Type B
RTW 66ESH003701
Legend
1. Engine Control Module (ECM)
2. Harness Adapter
3. ECM - Harness Connector
4. Breaker Box
5. ECM is connected
Although probe to the engine control module (ECM)
harness connector is possible by Test Adapter,
Breaker Box Connection Type A is suitable usage to
prevent misprobe and damage of female terminals
when test open circuit or short to ground between the
ECM and electrical components, since the terminals
where the harness connector of the ECM is thin have
gathered.
The ECM and other connectors have water proof
terminal that is not allowed to back probe. Breaker
Box Connection Type B is suitable usage to test short
to voltage circuit or signal check between the ECM
and electrical components.
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Page 1067 of 6020
Engine Control System (4JH1) 6E-33
Diagnostic System Check - Engine
Controls
Description
The Diagnostic System Check-Engine Controls is an
organized approach to identifying a condition that is
created by a malfunction in the electronic engine control
system. The Diagnostic System Check must be the
starting point for any driveability concern. The
Diagnostic System Check directs the service technician
to the next logical step in order to diagnose the concern.
Understanding and correctly using the diagnostic table
reduces diagnostic time, and prevents the replacement
of good parts.
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Lack of communication may be because of a partial
or a total malfunction of the Keyword 2000 serial data
circuit. The specified procedure determines the
particular condition.
11. If there are other modules with DTCs set, refer to
the DTC list. The DTC list directs you to the appropriate
diagnostic procedure. If the control module stores
multiple DTCs, diagnose the DTCs in the following
order.
• Component level DTCs, such as sensor DTCs,
solenoid DTCs, actuator DTCs, and relay DTCs.
Diagnose the multiple DTCs within this category in
numerical order. Begin with the lowest numbered
DTC, unless the diagnostic table directs you
otherwise.
Important:
• DO NOT perform this diagnostic if there is not a
driveability concern, unless another procedure
directs you to this diagnostic.
• Before you proceed with diagnosis, search fo
r
applicable service bulletins.
• Unless a diagnostic procedure instructs you, DO
NOT clear the DTCs.
• If there is a condition with the starting system, refe
r
to the starting system section in the engine
mechanical.
• Ensure the battery has a full charge.
• Ensure the battery cables (+) (-) are clean and
tight.
• Ensure the ECM grounds are clean, tight, and in
the correct location.
• Ensure the ECM harness connectors are clean and
correctly connected.
• Ensure the ECM terminals are clean and correctl
y
mating.
• Ensure the fuel injection pump control unit (PCU)
ground is clean, tight, and in the correct location.
• Ensure the PCU harness connectors are clean and
correctly connected.
• Ensure the PCU terminals are clean and correctl
y
mating.
• Ensure the vehicle maintenance has been done
enough.
Step Action Value(s) Yes No
1 Install the scan tool.
Does the scan tool turn ON?
Go to Step 2 Go to scan tool
Does Not Power Up
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