key ISUZU KB P190 2007 Workshop Owner's Guide
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Page 1558 of 6020
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
Page 1574 of 6020
FUEL SYSTEM (4JK1/4JJ1) 6C-33
Installation
1. Install the O-ring to the fuel supply pump.
2. Install the fuel supply pump.
Apply soapy water to the O-ring before attaching.
Note: Take care not to twist the O-ring. 3. Install the fuel supply pump bracket.
Temporarily tighten with the bolts and nuts (Gea
r
case side).
Temporarily tighten with the bolts (Cylinder bod
y
side).
Fully tighten the nuts and bolts (Gear case side).
Fully tighten the bolts (Cylinder body side).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m /18 lb ft)
RTW 56CSH002001
Legend
1. Fuel Supply Pump
2. Fuel Supply Pump Bracket
4. Confirm that the supply pump camshaft key is
turned to the right and is horizontal.
RTW 56CSH004301
5. Install the fuel supply pump gear to the pump
shaft.
a.
Align the fuel pump gear timing mark (1) with
the idle gear A paint marks (2).
b. Ensure that the pump gear is bitten with main gear (3) of the idle gear A. Depress the pump
gear when it is bitten with scissors gear (4) o
f
the idle gear A.
RTW 56CSH005101
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Page 1631 of 6020
6E-14 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DLC and CAN (Standard output)
RTW76EXF004601
7
6766 C-58
31
16
4 5 B-58 1
614 B-58
32 B-2356 B-68
C-19
Meter(+B)
10A
Fuse/
relay
box
(Cabin)
0.5
BLU
0.5
RED/
YEL
ICU
IP cluster
40.5
YEL
0.5
BLU 0.5
YEL
0.5
BLU
DLC
0.5
YEL
IP
cluster
W/O Immobilizer ICU
H-44
5
0.5
BLU
11
4 2
1 3 4
2
1 3
H-18
C-2
0.5
BLK
0.5
BLK
0.5
RED/
YEL
+B
2
BLK
B-82
Weld
splice 6
2BLK
13
3 B-56
ECM
Keyword 2000 0.5
BLK/
GRN
0.3
BLK/
GRN 0.5
BLU 0.5
YEL B-103
J/C 3
B-104
J/C 4
Diagnostic
switch
Diagnostic switch CAN
high CAN
low
Ground Ground 2
0.5
YEL
0.5
BLU 0.5
YELH-18
12
H-18(RHD)
H-48(LHD)
7(RHD)
12(LHD) CAN
low
CAN
high
CANlow
CAN
high
TCM C-94 (5)
EHCU C-67 (11)
SRS control unit B-31 (2)
0.5
VIO/
GRN
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ISUZU KB P190 2007
Page 1632 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-15
DLC and CAN (High output)
RTW76EXF005101
164 5 B-58 71
614
B-58
C-19
Meter(+B)
10A EHCU C-67 (11)
SRS control unit B-31 (2)
Anti-theft control unit B-44 (2)
Fuse/
relay
box
(Cabin)
0.5
RED/
YEL
ICU
IP cluster
DLCICU
H-18
C-2
0.5
BLK
0.5
BLK
0.5
RED/
YEL
+B 2
BLK
B-82
Weld
splice 6 2BLK
13
3 B-56
ECM
Keyword 2000 0.5
BLK/
GRN
0.5
VIO/
GRN
0.3
BLK/
GRN
0.5
BLU0.5
YEL
Diagnostic
switch
Diagnostic switch CAN
high CAN
low
Ground Ground 2
H-18(RHD)
H-48(LHD)
7(RHD)
12(LHD) CAN
low
CAN
high
CANlow
CAN
high
67
66
177
C-58
C-94
56 0.5
BLU
0.5
YEL
B-68
0.5
BLU
4
3
2 4
3
2
C-135
J/C 1
C-136
J/C 20.5
YEL
0.5BLU
0.5YEL
Except
Thailand
equipment TCM A/T
45 H-44 CAN
low
CAN
high
2
8
C-139
0.5
BLU
4
3
2 4
3
2
C-150
J/C 5
C-151
J/C 6 0.5
YEL
0.5
BLU 0.5
YEL 0.5BLU
0.5YEL DRM
(Euro 4
Specification)
CAN low
CAN
high
0.5
BLU
3
1 2 3
1 2
B-103
J/C 3
B-104
J/C 4 0.5
YEL
0.5
BLU 0.5
YEL
22
11
H-6 M/T
Thailand
equipment
11
12
H-18
A/T
Thailand
equipment
21
1
H-7
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ISUZU KB P190 2007
Page 1654 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-37
EGR ValveEngine Coolant Temperature (ECT) Sensor
Connector No.
B-58
Connector Color Black
Test Adapter No. J-35616-2A
Pin No. Wire Color Pin Function
1 BKL/ GRN Diagnostic request switch (ECM)
2 — Not used
3 — Not used
4 BLK Ground
5 BLK Ground
6 BLU CAN high
7 VIO/ GRN Keyword serial data (TCM
[standard output], EHCU [ABS
module] and SRS control unit)
8 — Not used
9 — Not used
10 — Not used 11 YEL/ BLK Diagnostic request switch (TCM)
12 ORN/ WHT Diagnostic request switch (EHCU
[ABS module])
13 RED Diagnostic request switch (SRS
control unit)
14 YEL CAN low
15 — Not used
16 RED/ YEL Battery voltage
LNW46ESH001901
1
4 2
5 3
6
Connector No. E-71
Connector Color Gray
Test Adapter No. J-35616-64A
Pin No. Wire Color Pin Function
1 WHT/ BLU Position sensor 5V reference
2 RED Position sensor low reference
3 GRY Position sensor signal
4 BRN Solenoid drive voltage
5—Not used
6 YEL Solenoid control low side (PWM)
Connector No. E-41
Connector Color Gray
Test Adapter No. J-35616-64A
Pin No. Wire Color Pin Function
1 GRN/ RED Sensor signal
2 WHT Sensor low reference
3 YEL/ BLK Gauge signal
LNW46ESH001701
12
3
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Page 1681 of 6020
6E-64 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
61. Turn OFF the ignition.
2. Disconnect the FRP sensor harness connector.
3. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the FRP sensor (pins 1, 2 and 3
of E-48).
4. Disconnect the ECM harness connector.
5. Inspect for an intermittent, for poor connections and corrosion at the harness
connector of the ECM (pins 47, 48, 68 and 69
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 11 Go to Step 7
7 Replace the FRP sensor. Refer to FRP Sensor
Replacement.
Did you complete the replacement? —
Go to Step 11
—
8Repair the short to ground between the ECM (pins
50 and 70 of E-90) and the FRP regulator (pin 2 of
E-50).
Did you compete the repair? —
Go to Step 11
—
91. Check for normal readings at key up for the
following sensor inputs: Use the Scan Tool
Data List or a known good vehicle to
determine nominal values.
• Engine Coolant Temperature Sensor
• Barometric Pressure (BARO) Sensor
• Boost Pressure Sensor
• Intake Throttle Position Sensor
2. Repair the circuit(s) or replace the sensor as necessary.
Did you find and correct the condition? —
Go to Step 11 Go to Step 10
10 1. Other possible causes for the no-start
condition:
• Engine mechanical timing
• Heavily restricted intake or exhaust plugged solid.
• Poor engine compression.
• Water or gasoline contamination in fuel.
2. Repair as necessary.
Did you find and correct the condition? —
Go to Step 11
—
111. Reconnect all previously disconnected
harness connector(s).
2. Turn OFF the ignition for 30 seconds.
3. Attempt to start the engine.
Does the engine start and continue to run? —
Go to Step 12 Go to Step 2
12 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 1691 of 6020
6E-74 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0087 (Flash Code 225)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. In case of fuel
rail overpressure, a pressure limiter valve threaded into
the fuel rail will open to release overpressure and
return fuel back to the fuel tank. If the ECM detects that
the fuel rail pressure went excessively high, then
sharply decreased, this DTC will set indicating high fuel
pressure, which activated the pressure limiter valve.
Condition for Running the DTC • DTCs P0192 and P0193 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the pressure limiter valve is activated with overpressure (more than 190 MPa
[27,600 psi]) in the fuel rail.
Action Taken When the DTC Sets • 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. • The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Diagnostic Aids • An intermittently sticking FRP regulator may have allowed the fuel pressure to become high enough
to open the pressure limiter valve.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Notice: • If the fuel tank is empty or near empty, air might be allowed to go into the fuel system. With air in the
fuel system, smooth flow of fuel into the supply
pump is interrupted and this DTC may set. Perform
bleeding of fuel system after refilling.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0087
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 P0088, P0089, P0091, P0092, P0192,
P0193, P0201 - P0204, P1064, P1065, P124B or
P2146 - P2151 set? —
Go to Applicable DTC Go to Step 3
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Page 1696 of 6020
ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-79
DTC P0088 (Flash Code 118)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail.
If the ECM detects that the fuel pressure went
excessively high for a certain length of time, this DTC
will set (First Stage). If the ECM detects that during the
same ignition cycle the fuel pressure rose even higher
than the amount to set DTC P0088 for a certain length
of time, the engine is stopped (Second Stage). If the
engine is stopped, the fuel pressure was too high and
the pressure limiter valve did not active or did not active
quick enough.
Condition for Running the DTC • DTCs P0192 and P0193 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC
First Stage • The ECM detects that the fuel rail pressure is more than 197 MPa (28,600 psi) for longer than 5
seconds.
Second Stage
• The ECM detects that the fuel rail pressure is more than 200 MPa (29,000 psi) for longer than 5
seconds.
Action Taken When the DTC Sets
First Stage • 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.
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Second Stage • 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.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
• The ECM stops engine running when the vehicle speed is lower than 5 km/h (3 MPH) for 5 seconds.
The engine will run after the key is cycled when the
ignition has been tuned OFF for longer than 10
seconds.
Condition for Clearing the DTC
First Stage • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Second Stage
• 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 • An intermittently sticking Fuel Rail Pressure regulator may have allowed the fuel pressure to
become high enough to set this DTC.
• Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at idle is
around 27 to 33 MPa (3,900 to 48,00 psi) after
warm up.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0088
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
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Page 1701 of 6020
6E-84 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0089 (Flash Code 151)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. If the ECM
detects that fuel pressure is a certain pressure higher
than the desired pressure, this DTC will set.
Condition for Running the DTC • DTCs P0091, P0092, P0192, P0193, P0652, P0653, P0201 - P0204, P1064, P1065, P124B and
P2146 - P2151 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the actual fuel rail pressure is more than 20 to 40 MPa (2,900 to 5,800 psi)
over the desired pressure for longer than 20
seconds. Action Taken When the DTC Sets
• 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.
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection.
• The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Diagnostic Aids • An intermittently sticking FRP regulator may have allowed the fuel pressure to become high enough
to set this DTC.
• Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at idle is
around 27 to 33 MPa (3,900 to 4,800 psi) after
warm up.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0089
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 P0091, P0092, P0192, P0193, P0201 -
P0204, P0219, P1064, P1065, P124B or P2146 -
P2151 set? —
Go to Applicable DTC Go to Step 3
3 1. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 4 Go to Step 5
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Page 1707 of 6020
6E-90 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
DTC P0093 (Flash Code 227)
Description
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by two plungers, all of
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. If the ECM
detects that the fuel rail pressure is certain pressure
low as compared with the engine speed, this DTC will
set.
Condition for Running the DTC • DTC P0087, P0091, P0092, P0192, P0193, P0652, P0653, P0201 - P0204, P1064, P1065,
P124B and P2146 - P2151 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the actual fuel rail pressure is lower than 15 MPa (2,180 psi) for longer than 5
seconds.
Action Taken When the DTC Sets • 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.
• The ECM limits fuel injection quantity.
• The ECM inhibits pilot injection. • The ECM inhibits cruise control.
Condition for Clearing the DTC • Refer to DTC Type Definitions for Condition for Clearing the MIL/ DTC - Type A.
Diagnostic Aids • An intermittently sticking FRP regulator may have allowed the fuel pressure to become low enough to
set this DTC.
• Normal Fuel Rail Pressure readings on the scan tool with the engine running in neutral at idle is
around 27 to 33 MPa (3,900 to 4,800 psi) after
warm up.
• A skewed FRP sensor value can set this DTC. The FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the key ON and engine OFF after the
engine has stopped running for a minimum of 1
minute.
Notice: • This DTC most likely indicates a loss of fuel pressure by a fuel leak from the high pressure
side. Inspect the high pressure side fuel leakage
between the fuel supply pump and fuel injector
first.
• If the fuel tank is empty or near empty, air might be allowed to go into the fuel system. With air in the
fuel system, smooth flow of fuel into the supply
pump is interrupted and this DTC may set. Perform
bleeding of fuel system after refilling.
Schematic Reference: Fuel System Routing Diagram
and Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P0093
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
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