check engine light ISUZU KB P190 2007 Workshop Owner's Guide

Engine Control System (4JH1) 6E-263
Checks Action
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect for water contamination in the fuel.
• Inspect for external fuel leaks or fuel leakage into the engine oil.
• Inspect the fuel lines between the fuel tank and fuel injection pump for tightness and
all fuel hoses for cuts, cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s) to the fuel injection pump is under a
slight vacuum with the engine running. As a result, air can enter the fuel system if
these connections are not tight. Air in the fuel system will cause fuel injection pump
internal pressure fluctuations especially at high engine speed and load.
• Inspect for air in the fuel system.
Notice: If many air bubbles appear in the fuel, check the fuel system line connections
between the fuel tank and the fuel injection pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper clamps.
a. Remove the fuel hose that connects to the fuel injection pump suction side.
b. Substitute a clear hose.
Notice: A hose must be cleaned.
c. Connect the clear hose to the fuel injection pump.
d. Bleed the fuel system.
e. Let the engine run at idle for at least 2 minutes.
f. Accelerator the engine between idle and W .O.T. (accelerator pedal full travel) many times while observing the clear hose.
• Inspect the fuel tank vent hose for a plugged or kinked.
• Inspect inside the fuel tank for any foreign material that may be getting drawn into
the fuel line pickup causing a blocked condition. Draw fuel from the fuel tank at the
fuel line (as close to the fuel tank as possible) going to the fuel pickup tube to verify a
clean stream of fuel comes out (use the hand-held vacuum pump 5-8840-0279-0/J-
23738-A with a clear hose or equivalent). This will ensure the fuel pickup tube is not
cracked drawing air into the fuel line.
• Inspect the fuel injection pump operation.
Notice: The fuel injection pump must be timed to the engine.
Inspect the eye bolt for any type of restriction or collapsed gauze filter.
Notice: If any type of restriction found, check for a condition that causes contaminated
fuel, such as the customer is using an aftermarket fuel filter or extended maintenance
interval. Also inspect fuel waxing or icing that is caused by an incorrect fuel type used
in winter season or water intrusion in the fuel system.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at mass air flow (MAF) sensor.
Additional Checks •
Inspect the generator output voltage. Repair if less than 9 volts or more than 16
volts.
• Electromagnetic interference (EMI) on the reference circuit can cause an engine
miss condition. The scan tool can usually detect EMI by monitoring the engine
speed. A sudden increase in speed with little change in actual engine speed change
indicates that EMI is present. If a problem exists, check routing of high voltage
components, such as fuel injection solenoid wiring, near the sensor circuits.


Surges/Chuggles
Checks Action
DIFINITION:The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down
with no change in the accelerator pedal.

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Engine Control System (4JH1) 6E-265
Checks Action
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect for water contamination in the fuel.
• Inspect for external fuel leaks or fuel leakage into the engine oil.
• Inspect the fuel lines between the fuel tank and fuel injection pump for tightness and
all fuel hoses for cuts, cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s) to the fuel injection pump is under a
slight vacuum with the engine running. As a result, air can enter the fuel system if
these connections are not tight. Air in the fuel system will cause fuel injection pump
internal pressure fluctuations especially at high engine speed and load.
• Inspect for air in the fuel system.
Notice: If many air bubbles appear in the fuel, check the fuel system line connections
between the fuel tank and the fuel injection pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper clamps.
a. Remove the fuel hose that connects to the fuel injection pump suction side.
b. Substitute a clear hose.
Notice: A hose must be cleaned.
c. Connect the clear hose to the fuel injection pump.
d. Bleed the fuel system.
e. Let the engine run at idle for at least 2 minutes.
f. Accelerator the engine between idle and W .O.T. (accelerator pedal full travel) many times while observing the clear hose.
• Inspect the fuel tank vent hose for a plugged or kinked.
• Inspect inside the fuel tank for any foreign material that may be getting drawn into
the fuel line pickup causing a blocked condition. Draw fuel from the fuel tank at the
fuel line (as close to the fuel tank as possible) going to the fuel pickup tube to verify a
clean stream of fuel comes out (use the hand-held vacuum pump 5-8840-0279-0/J-
23738-A with a clear hose or equivalent). This will ensure the fuel pickup tube is not
cracked drawing air into the fuel line.
• Inspect the fuel injection pump operation.
Notice: The fuel injection pump must be timed to the engine.
• Inspect the eye bolt for any type of restriction or collapsed gauze filter.
Notice: If any type of restriction found, check for a condition that causes contaminated
fuel, such as the customer is using an aftermarket fuel filter or extended maintenance
interval. Also inspect fuel waxing or icing that is caused by an incorrect fuel type used
in winter season or water intrusion in the fuel system.
• Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
Additional Checks •
Inspect the generator output voltage. Repair if less than 9 volts or more than 16
volts.
• Inspect the EGR system operating correctly.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation. (A/T only)



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Engine Control System (4JH1) 6E-267
Checks Action
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect for water contamination in the fuel.
• Inspect for external fuel leaks or fuel leakage into the engine oil.
• Inspect the fuel lines between the fuel tank and fuel injection pump for tightness and
all fuel hoses for cuts, cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s) to the fuel injection pump is under a
slight vacuum with the engine running. As a result, air can enter the fuel system if
these connections are not tight. Air in the fuel system will cause fuel injection pump
internal pressure fluctuations especially at high engine speed and load.
• Inspect for air in the fuel system.
Notice: If many air bubbles appear in the fuel, check the fuel system line connections
between the fuel tank and the fuel injection pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper clamps.
a. Remove the fuel hose that connects to the fuel injection pump suction side.
b. Substitute a clear hose.
Notice: A hose must be cleaned.
c. Connect the clear hose to the fuel injection pump.
d. Bleed the fuel system.
e. Let the engine run at idle for at least 2 minutes.
f. Accelerator the engine between idle and W .O.T. (accelerator pedal full travel) many times while observing the clear hose.
• Inspect the fuel tank vent hose for a plugged or kinked.
• Inspect inside the fuel tank for any foreign material that may be getting drawn into
the fuel line pickup causing a blocked condition. Draw fuel from the fuel tank at the
fuel line (as close to the fuel tank as possible) going to the fuel pickup tube to verify a
clean stream of fuel comes out (use the hand-held vacuum pump 5-8840-0279-0/J-
23738-A with a clear hose or equivalent). This will ensure the fuel pickup tube is not
cracked drawing air into the fuel line.
• Inspect the fuel injection pump operation.
Notice: The fuel injection pump must be timed to the engine.
• Inspect the eye bolt for any type of restriction or collapsed gauze filter.
Notice: If any type of restriction found, check for a condition that causes contaminated
fuel, such as the customer is using an aftermarket fuel filter or extended maintenance
interval. Also inspect fuel waxing or icing that is caused by an incorrect fuel type used
in winter season or water intrusion in the fuel system.
Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction or leak in the intercooler.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
• Inspect for a worn or damaged turbocharger turbine wheel, shaft or compressor
wheel. Refer to turbocharger inspection in the Engine Mechanical section.
• Inspect for turbocharger wastegate valve operation. Refer to wastegate valve
inspection in the Engine Mechanical section.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
• Inspect for a restriction in the catalytic converter or exhaust pipes.

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Engine Control System (4JH1) 6E-269
Checks Action
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect for water contamination in the fuel.
• Inspect for external fuel leaks or fuel leakage into the engine oil.
• Inspect the fuel lines between the fuel tank and fuel injection pump for tightness and
all fuel hoses for cuts, cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s) to the fuel injection pump is under a
slight vacuum with the engine running. As a result, air can enter the fuel system if
these connections are not tight. Air in the fuel system will cause fuel injection pump
internal pressure fluctuations especially at high engine speed and load.
• Inspect for air in the fuel system.
Notice: If many air bubbles appear in the fuel, check the fuel system line connections
between the fuel tank and the fuel injection pump for tightness and all fuel hoses for
cuts, cracks and for the use of proper clamps.
a. Remove the fuel hose that connects to the fuel injection pump suction side.
b. Substitute a clear hose.
Notice: A hose must be cleaned.
c. Connect the clear hose to the fuel injection pump.
d. Bleed the fuel system.
e. Let the engine run at idle for at least 2 minutes.
f. Accelerator the engine between idle and W .O.T. (accelerator pedal full travel) many times while observing the clear hose.
• Inspect the fuel tank vent hose for a plugged or kinked.
• Inspect inside the fuel tank for any foreign material that may be getting drawn into
the fuel line pickup causing a blocked condition. Draw fuel from the fuel tank at the
fuel line (as close to the fuel tank as possible) going to the fuel pickup tube to verify a
clean stream of fuel comes out (use the hand-held vacuum pump 5-8840-0279-0/J-
23738-A with a clear hose or equivalent). This will ensure the fuel pickup tube is not
cracked drawing air into the fuel line.
• Inspect the fuel injection pump operation.
Notice: The fuel injection pump must be timed to the engine.
• Inspect the eye bolt for any type of restriction or collapsed gauze filter.
Notice: If any type of restriction found, check for a condition that causes contaminated
fuel, such as the customer is using an aftermarket fuel filter or extended maintenance
interval. Also inspect fuel waxing or icing that is caused by an incorrect fuel type used
in winter season or water intrusion in the fuel system.
• Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction or leak in the intercooler.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
• Inspect for a worn or damaged turbocharger turbine wheel, shaft or compressor
wheel. Refer to turbocharger inspection in the Engine Mechanical section.
• Inspect for turbocharger wastegate valve operation. Refer to wastegate valve
inspection in the Engine Mechanical section.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
• Inspect for a restriction in the catalytic converter or exhaust pipes.

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ISUZU KB P190 2007

6E-278 Engine Control System (4JH1)
• Destination Code
j. Select Next.
k. Verify your selection on the Summary screen.
Important:
Refer to Service Bulletins before service programming is
performed if the bulletins are listed along with the
calibration files.
Important:
Select Cancel if you receive a message stating that the
calibration selected is already the current calibration in
the ECM and reprogramming with the same download is
not allowed.
l. Select Reprog.
m. The Transfer Data screen will appear until the progress bar reaches 100%.
6. Close the application and return to the TIS application selection screen after the download is
complete.
7. Turn OFF the scan tool.
8. Disconnect the scan tool from the terminal.
9. Transfer the data from the scan tool to the ECM using the following procedure:
a. Connect the scan tool to the vehicle DLC, with the engine and the scan tool OFF.
b. Turn ON the scan tool.
c. Press Enter at the Title screen.
d. Turn ON the ignition, with the engine OFF.
e. Select Service Programming System.
f. Select the Program ECU on the scan tool.
g. Follow the on-screen instructions and select Continue.
h. Programming in Process will appear until the progress bar reaches 100%.
Important:
The vehicle fitted with automatic transmission, Check
Trans lamp may blink while programming the ECM since
communication between the ECM and TCM is
interrupted. Clear DTC in any module afte
r
programming.
i. Select Continue and exit the program after the scan tool displays Programming W as
Successful.
10. Turn OFF the ignition.
11. Turn OFF the scan tool.
12. Disconnect the scan tool from the vehicle.

Service Programming System (SPS) (Pass-
Thru Procedure)
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughou
t
the programming process. The vehicle must be in close
proximity to the terminal while using Pass-Thru.
Important:
The TIS supports service programming with the scan
tool scan tool only.
1. Launch the TIS application at the terminal.
2. Select the Service Programming System at the main screen.
3. Highlight the following information on the Selec
t
Diagnostic Tool and Programming Process screen:
• Select Diagnostic Tool-Select Pass-Thru
• Select Programming Process-Identify whethe
r
as existing engine control module (ECM) is
being reprogrammed or an ECM is being
replaced with a new one.
• Select ECU Location-Select Vehicle.
4. Select Next.
5. Complete all vehicle data on the Preparing fo
r
Communication/Determine Vehicle screen until
Next is highlighted.
6. Select Next.
7. Follow the instruction on the Preparing fo
r
Communication screen.
Important:
In order to reduce the potential for signal loss, the RS-
232 cable should not be more than 25 feet long.

8. Select Next.
9. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen and select Next.
Important:
If the ECM is replaced to new one, VIN does no
t
displayed. Input correct VIN reading from stamped VIN
or affixed VIN plate on the vehicle. If the ECM from
another vehicle is installed, input correct VIN by same
way. 10. Highlight Engine on the System Type screen and
select Next, if requested.
11. Complete the following information based on the service ID plate on the Validate Vehicle Data
screen until Next is highlighted:
• Model
• Model Year
• Engine
• Type of Transmission
• Destination Code
12. Select Next.
13. Verify your selection on the Summary screen.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-21
Removal
1. Remove the engine hood.
2. Remove the engine cover.
3. Set the hoist and the engine hanger of the special tool (special tool 5-8840-2823-0).
4. Remove the engine mount.
• Before removing the engine mount, hang the engine with a hoist.
• Remove the bolts of the engine mount.
• Hoist the engine assembly slightly to remove the engine mount.











RTW 56ASH004501

Installation
1. Install the engine mount and tighten up with the
specified torque.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
2. Install the engine cover.
3. Install the engine hood. • Check if nothing is wrong with the engine
mount by starting the engine.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-141
Functional Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil o
r
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.






RTW 56ASH015501
Legend
1. Oil Pressure Switch

5. W arm the engine.
6. Measure the oil pressure, to check whether it is more than 400 kPa (4 kg/cm
2 / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.
Engine oil
•
Ensure the car is on level ground. Before starting
the engine or when 30 minutes or more have
elapsed after stopping the engine, check the
engine oil volume using the level gauge. The
volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lowe
r
limit. Also, check for contamination of the engine
oil.




RTW 56ASH015601







RTW 56ASH015701
Legend
1. Lower Limit
2. Upper Limit



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6A-162 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the oil pressure SW .
2. Remove the nipple; oil gallery.
3. Remove the nipple; oil pressure warning SW and gasket.
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.
If there is no connectivity, replace with normal parts.





LNW 21HSH003301

Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the circuit between the meter and the oil pressure
switch, and repair the disconnected locations.






LNW 21HSH003401
Installation
1. Install the nipple; oil gallery, oil pressure warning
SW and gasket.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
2. Install the Nipple. Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)
3. Install the oil pressure SW . Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)


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6C-6 FUEL SYSTEM (4JK1/4JJ1)
Fuel injector



RTW 76CMH000201
Legend
1. Terminal
2. Fuel Injector ID Code
3. Two Dimensional Barcode
4. Parts Number
5. Port for Mounting the Injection Pipe
6. O-ring

Fuel filter





RTW 76CSH001001
Legend
1. Element
2. Air Bleeding Plug
3. Switch; Clogging Monitoring
4. Sensor; W ater
5. Drain Plug

Functional check
Air bleeding
1. Ignition switch is turned to the ON position for 15 seconds.
2. Ignition switch is turned to the OFF position.
3. The above operation is repeated 5 times.
Note: If the air bleeding work is insufficient then it could
lead to faults in the engine. Therefore, the procedures
after starting the engine should always be implemented.

Water drain
A warning lamp will light up if water above the specified
volume collects in the sedimenter. In such cases, drain
out the water by performing the following operations:
1. Draining with fuel filter drain plug. a. Set a container at the tip of the plastic hose.
b. Loosen the air bleeding plug and the drain plug.
c. Discharge the water.
d. Tighten the drain plug after discharging the water.
e. Tighten the air bleeding plug to the specified torque.
Tightening torque: 3 N ⋅m(0.3 kg ⋅m/26 lb in)
f. Ignition switch is turned ON for 15 seconds check for fuel leakage.

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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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