clutch ISUZU KB P190 2007 Workshop Manual PDF
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 1221 of 6020
Engine Control System (4JH1) 6E-187
Step Action Value(s) Yes No
14 Replace the clutch pedal switch. Refer to Clutch
Pedal Switch Replacement in this section.
Did you complete the replacement?
Go to Step 16
15 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 16
16 1. Reconnect all previously disconnected fuse or
harness connector(s).
2. Clear the DTCs with the scan tool.
3. Turn ON the ignition, with the engine OFF.
4. Observe the Clutch Pedal Switch parameter with the scan tool while fully depressing and releasing
the clutch pedal.
Does the scan tool indicate Applied when the clutch
pedal is applied and Released when the clutch pedal
is released?
Go to Step 17 Go to Step 3
17 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1239 of 6020
Engine Control System (4JH1) 6E-205
Step Action Value(s) Yes No
5 1. Test the engine cooling system for the following
condition. Refer to diagnosis of the engine
cooling system section for testing. • Engine coolant level
• Engine coolant leakage
• Cooling fan belt slippage
• Cooling fan clutch working
• Thermostat working
• W ater pump working
• Radiator clogging
2. Repair or replace 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 the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine and wait until engine is fully warms upped.
5. Observe the ECT parameter with the scan tool.
Is the ECT parameter more than the specified
value? 100°C (212°F)
Go to Step 4 Go to Step 7
7 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1244 of 6020
6E-210 Engine Control System (4JH1)
DTC P1520 (Symptom Code A) (Flash Code 47)
Circuit Description
(Manual Transmission)
The neutral switch is installed on the transmission gea
r
control box. W hen the gear position is neutral, the
switch is closed and the switch signal is provided to the
engine control module (ECM). If the ECM detects the
neutral switch signal is not changed from neutral during
the predetermined engine speed and vehicle speed
range, this DTC will set.
(Automatic Transmission)
The inhibitor switch is installed to the transmission case.
W hen the selector position is P or N range, the switch is
closed and the switch signal is provided to the Emir the
ECM detects the neutral switch signal is not changed
from P or N during the predetermined engine speed and
vehicle speed range, this DTC will set.
Condition for Running the DTC • The ignition switch is ON.
• The engine speed is higher than 1500 RPM.
• The vehicle speed is higher than 63 km/h (39
MPH) (M/T) or 78 km/h (49 MPH) (A/T).
• The clutch pedal is released. (M/T).
Condition for Setting the DTC
• The ECM detects that the neutral switch signal is
continuously ON (neutral or P/N range) during
three consecutive driving cycles.
Action Taken When the DTC Sets
• The ECM illuminates the malfunction indicato
r
lamp (MIL) when the diagnostic runs and fails.
Condition for Clearing the MIL/DTC
Important: • Following conditions must be met two consecutive
driving cycles. (One driving cycle: Ignition switch
ON > Engine run > Vehicle run > Ignition switch
OFF for 10 seconds)
- The engine speed is higher than 1500 RPM
- The vehicle speed is higher than 63 km/h (39 MPH) (M/T) or 78 km/h (49 MPH) (A/T)
- The clutch pedal is released (M/T)
- Other than neutral or P/N range
- After the above procedure is done, a history
DTC clears after 40 consecutive driving cycles
without a fault. Or clear with the scan tool.
Diagnostic Aids
• If an intermittent condition is suspected, refer to
Intermittent Conditions in this section.
DTC P1520 (Symptom Code A) (Flash Code 47)
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or Engine Control Module (ECM)
Connector End Views
Chart for M/T
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 the scan tool. 2. Turn ON the ignition, with the engine OFF.
3. Observe the Neutral Switch parameter with the scan tool while shift to neutral and other
positions.
Does the scan tool indicate ON when the position is
neutral and OFF when other than the neutral?
Go to Diagnostic Aids Go to Step 3
3 1. Turn OFF the ignition. 2. Disconnect the neutral switch harness connector.
3. Turn ON the ignition, with the engine OFF.
4. Observe the Neutral Switch parameter with the scan tool.
Does the scan tool indicate ON?
Go to Step 4 Go to Step 5
4 1. Test the neutral switch input signal circuit between the engine control module (ECM) (pin
87 of C-57 connector) and the neutral switch (pin
1 of E-11 connector) 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 7 Go to Step 6
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ISUZU KB P190 2007
Page 1245 of 6020
Engine Control System (4JH1) 6E-211
Step Action Value(s) Yes No
5 Replace the neutral switch. Refer to Neutral Switch
Replacement in Transmission Section.
Did you complete the replacement?
Go to Step 7
6 Important: Replacement ECM must be
programmed.
Replace the ECM. Refer to Engine Control Module
(ECM) Replacement in this section.
Did you complete the replacement?
Go to Step 7
7 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with the scan tool.
Important: Following conditions must be met two
consecutive driving cycles before clear with the scan
tool. (One driving cycle: Ignition switch ON > Engine
run > Vehicle run > Ignition switch OFF for 10
seconds) • The engine speed is higher than 1500 RPM
• The vehicle speed is higher than 63 km/h
(39 MPH)
• The clutch pedal is released
• Other than neutral
3. Turn ON the ignition, with the engine OFF.
4. Observe the Neutral Switch parameter with the scan tool while shift to neutral and other
positions.
Does the scan tool indicate ON when the position is
neutral and OFF when other than the neutral?
Go to Step 8 Go to Step 3
8 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
Chart for A/T
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Select the “JR405E Automatic Transmission” in the system selection menu.
5. Monitor the Read Diagnostic Trouble Code (DTC) Info As Stored By ECU with the scan tool.
Does the transmission control module (TCM) DTC
P0705 set?
Go to Applicable
DTC in Automatic Transmission Section Go to Step 3
3 1. Install the scan tool. 2. Turn ON the ignition, with the engine OFF.
3. Observe the Neutral Switch parameter with the scan tool while shift to P or N and other
positions.
Does the scan tool indicate ON when the position is
P or N and OFF when other than the P or N?
Go to Diagnostic Aids Go to Step 4
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ISUZU KB P190 2007
Page 1247 of 6020
Engine Control System (4JH1) 6E-213
DTC P1520 (Symptom Code B) (Flash Code 47)
Circuit Description
The neutral switch is installed on the transmission gea
r
control box. W hen the gear position is neutral, the
switch is closed and the switch signal is provided to the
engine control module (ECM). If the ECM detects the
neutral switch signal is not changed from other than
neutral during the predetermined engine speed and
vehicle speed range, this DTC will set. This DTC runs
only manual transmission.
Condition for Running the DTC
• The ignition switch is ON.
• The engine speed is higher than 665 RPM
• The vehicle speed is lower than 2 km/h (1.2 MPH).
• The clutch pedal is released after once depressed.
Condition for Setting the DTC • The ECM detects that the neutral switch signal is
continuously OFF (other than neutral) during three
consecutive driving cycles.
Action Taken When the DTC Sets • The ECM illuminates the malfunction indicato
r
lamp (MIL) when the diagnostic runs and fails.
Condition for Clearing the MIL/DTC
Important: • Following conditions must be met two consecutive
driving cycles. (One driving cycle: Ignition switch
ON > Engine run > Ignition switch OFF for 10
seconds)
- The engine speed is higher than 665 RPM
- The vehicle speed is lower than 2 km/h (1.2 MPH)
- The clutch pedal is released after once depressed
- Neutral position
- After the above procedure is done, a history
DTC clears after 40 consecutive driving cycles
without a fault. Or clear with the scan tool.
Diagnostic Aids
• If an intermittent condition is suspected, refer to
Intermittent Conditions in this section.
DTC P1520 (Symptom Code B) (Flash Code 47)
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or Engine Control Module (ECM)
Connector End Views
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 the scan tool. 2. Turn ON the ignition, with the engine OFF.
3. Observe the Neutral Switch parameter with the scan tool while shift to neutral and other
positions.
Does the scan tool indicate ON when the position is
neutral and OFF when other than the neutral?
Go to Diagnostic Aids Go to Step 3
3 1. Turn OFF the ignition. 2. Inspect the ECM (10A) fuse (EB-4) in the engine room fuse block.
Is the ECM (10A) fuse (EB-4) open?
Go to Step 4 Go to Step 5
4 Replace the ECM (10A) fuse (EB-4). If the fuse continues to open, repair the short to ground on one
of the circuits that is fed by the ECM (10A) fuse (EB-
4) or replace the shorted attached component fed by
the ECM (10A) fuse (EB-4).
Did you complete the repair?
Go to Step 13
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ISUZU KB P190 2007
Page 1249 of 6020
Engine Control System (4JH1) 6E-215
Step Action Value(s) Yes No
13 1. Reconnect all previously disconnected harness
connector(s).
2. Clear the DTCs with the scan tool.
Important: Following conditions must be met two
consecutive driving cycles before clear with the scan
tool. (One driving cycle: Ignition switch ON > Engine
run > Ignition switch OFF for 10 seconds) • The engine speed is higher than 665 RPM
• The vehicle speed is lower than 2 km/h (1.2
MPH)
• The clutch pedal is released after once
depressed
• Neutral position
3. Turn ON the ignition, with the engine OFF.
4. Observe the Neutral Switch parameter with the scan tool while shift to neutral and other
positions.
Does the scan tool indicate ON when the position is
neutral and OFF when other than the neutral?
Go to Step 14 Go to Step 3
14 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed? Go to Diagnostic
Trouble Code (DTC) List System OK
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ISUZU KB P190 2007
Page 1276 of 6020
6E-242 Engine Control System (4JH1)
DTC A/C Compressor System Check
Description
W hen air conditioning (A/C) and blower fan are
selected, and if the system has a sufficient refrigerant
charge. A 12-volt signal is supplied to the A/C request
input of the Engine Control Module (ECM). The A/C
request signal may be temporarily canceled during
system operation by the electronic thermostat in the
evaporator to prevent the evaporator icing. Also, it is
cancelled when the pressure switch detected abnormal
pressure in the line. W hen the A/C request signal is
received by the ECM, the ECM supplies a ground from
the A/C compressor relay if the engine operating
conditions are within acceptable ranges. W ith the A/C
compressor relay energized, voltage is supplied to the
compressor clutch coil. The ECM will enable the
compressor clutch to engage whenever A/C has been
selected with the engine running and enable conditions
are met.
Condition for Running the A/C Compressor:
• The engine is running.
• The A/C switch is ON.
• The engine coolant temperature (ECT) is less than
105 °C(221 °F).
A/C Compressor System Check
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or Engine Control Module (ECM)
Connector End Views
Chart 1 of 2
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 the scan tool. 2. Turn OFF the ignition for 30 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Monitor the Diagnostic Trouble Code (DTC) Information of the engine control system with the
scan tool and check whether following DTC(s) is
set: • P0115 (Symptom Code 1 & 2)
• P0645 (Symptom Code 4 & 8)
Are any of the above DTC(s) set?
Refer to Applicable DTC Go to Step 3
3 1. Turn ON the ignition, with the engine OFF.
2. Turn ON the blower motor switch.
Does the blower motor turn ON and operate
correctly?
Go to Step 4 Refer to Applicable
Diagnostic Chart in Heating & Air Conditioning Section
4 1. Turn OFF the blower motor switch. 2. Keep the A/C switch OFF.
Does the A/C Request Signal parameter indicate
OFF?
Go to Step 5 Go to Chart 2 of 2
with heater Step 1 OR
Go to Chart 2 of 2
without heater Step 1
5 1. Start the engine and let the engine idle. 2. Keep the blower motor switch OFF.
3. Keep the A/C switch OFF.
Does the A/C compressor clutch keep OFF
(disengage)?
Go to Step 6 Go to Step 11
6 1. Turn ON the blower motor switch. 2. Keep the A/C switch OFF.
Does the A/C compressor clutch keep OFF
(disengage)?
Go to Step 7 Go to Chart 2 of 2
with heater Step 7 OR
Go to Chart 2 of 2
without heater Step 4
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Page 1277 of 6020
Engine Control System (4JH1) 6E-243
Step Action Value(s) Yes No
7 1. Turn OFF the blower motor switch.
2. Turn ON the A/C switch.
Does the A/C compressor clutch keep OFF
(disengage)?
Go to Step 8 Go to Chart 2 of 2
with heater Step 8 OR
Go to Chart 2 of 2
without heater Step 10
8 1. Turn ON the blower motor switch. 2. Keep the A/C switch ON.
Does the A/C compressor clutch ON and OFF
(engage and disengage) periodically within the
Condition for Running the A/C Compressor?
Go to Step 9 Go to Step 10
9 Does the air flow cool enough.
System OK Refer to Applicable
Diagnostic Chart in Heating & Air Conditioning Section
10 Does the A/C Relay Command parameter indicate ON at previous step?
Go to Step 14 Go to Chart 2 of 2
with heater Step 9 OR
Go to Chart 2 of 2
without heater Step 11
11 1. Turn OFF the ignition. 2. Disconnect the A/C compressor clutch harness connector (E-3).
3. Start the engine.
Does the A/C compressor clutch ON (engage)?
Go to Step 22 Go to Step 12
12 1. Turn OFF the ignition. 2. Remove the A/C compressor relay from the engine room relay block.
3. Connect a test lamp between the A/C compressor clutch voltage supply circuit (pin 2 of
X-14 connector) and a known good ground.
4. Turn ON the ignition, with the engine OFF.
Does the test lamp illuminate?
Go to Step 13 Go to Step 21
13 Repair the short to battery or ignition voltage on the A/C compressor voltage feed circuit between the
A/C compressor relay (pin 2 of X-14 connector) and
the A/C compressor (E-3).
Did you complete the repair?
Go to Step 23
14 1. Turn OFF the ignition.
2. Remove the A/C compressor relay from the engine room fuel block.
3. Connect a test lamp between the voltage feed circuit of the relay switch side terminal (pin 1 of
X-14 connector) and known good ground.
4. Turn ON the ignition, with the engine OFF.
Does the test lamp illuminate?
Go to Step 15 Go to Step 17
15 1. Keep the ignition ON, with the engine OFF. 2. Disconnect the test lamp.
3. Connect a 3-amp fused jumper wire between both switch side terminals of the A/C compressor
relay (pins 1 and 2 of X-14 connector).
Does the A/C compressor clutch click (engage)?
Go to Step 19 Go to Step 16
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ISUZU KB P190 2007
Page 1278 of 6020
6E-244 Engine Control System (4JH1)
Step Action Value(s) Yes No
16 1. Keep the ignition ON, with the engine OFF.
2. Keep 3-amp fused jumper wire with connected.
3. Disconnect A/C compressor clutch harness connector.
4. Connect a test lamp between A/C compressor voltage feed circuit (E-3) and a known good
ground.
Does the test lamp illuminate?
Go to Step 20 Go to Step 18
17 Repair the open circuit or high resistance on the relay switch side voltage feed circuit between the
A/C compressor relay (pin 1 of X-14 connector) and
the A/C (10A) fuse (EB-13).
Did you complete the repair?
Go to Step 23
18 Repair the open circuit or high resistance on the
relay switched voltage supply circuit between the
A/C compressor relay (pin 2 of X-14 connector) and
the A/C compressor clutch (pin 1 of E-3 connector).
Did you complete the repair?
Go to Step 23
19 1. Turn OFF the ignition.
2. Inspect for an intermittent and for poor connections at the A/C compressor relay
terminals (pins 3 and 5 of X-14 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 23 Go to Step 21
20 1. Turn OFF the ignition. 2. Inspect for an intermittent and for a poor connection at the harness connector of the A/C
compressor clutch (E-3).
3. Repair the connection(s) as necessary.
Did you find and correct the condition?
Go to Step 23 Go to Step 22
21 Replace the A/C compressor relay. Did you complete the replacement?
Go to Step 23
22 Replace the A/C compressor. Refer to Heating and
Air Conditioning section.
Did you complete the replacement?
Go to Step 23
23 1. Reconnect all previously disconnected fuse,
relay or harness connector(s).
2. Turn OFF the ignition for 30 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Turn ON the blower motor switch.
Does the blower motor turn ON and operate
correctly?
Go to Step 4 Refer to Applicable
Diagnostic Chart in Heating & Air Conditioning Section
Chart 2 of 2 with heater
Step Action Value(s) Yes No
1 1. Turn OFF the ignition.
2. Replace the thermo relay with the horn relay or replace with a known good relay.
3. Turn OFF the blower motor switch.
4. Turn OFF the A/C switch.
5. Turn ON the ignition, with the engine OFF.
Does the A/C Request Signal parameter indicate
OFF?
Go to Step 33 Go to Step 2
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Page 1284 of 6020
6E-250 Engine Control System (4JH1)
Step Action Value(s) Yes No
7 Repair the short to ground between the pressure
switch (pin 2 of C-24 connector) and the electronic
thermostat (pin 2 of C-55 connector).
Did you complete the repair?
Go to Step 43
8 1. Test the electronic thermostat switching circuits
shorted each other. (pins 1 and 2 of C-55
connector).
2. Repair the circuits as necessary.
Did you find and correct the condition?
Go to Step 43 Go to Step 39
9 1. Test the electronic thermostat circuit between the electronic thermostat (pin 4 of C-55 connector)
and the A/C switch (pin 11 of B-57 connector) for
a short to ground.
2. Repair the circuits as necessary.
Did you find and correct the condition?
Go to Step 43 Go to Step 40
10 1. Test the ground circuit among the electronic thermostat (pin 1 of C-55 connector), the blower
motor switch (pin 1 of B-13 connector) and the
A/C switch (pin 10 of B-57 connector) for a short
to ground.
2. Repair the circuits as necessary.
Did you find and correct the condition?
Go to Step 43 Go to Step 41
11 Inspect the A/C (10A) fuse (EB-13) in the engine room fuse block.
Is the A/C (10A) fuse (EB-13) open?
Go to Step 12 Go to Step 13
12 1. Replace the A/C (10A) fuse (EB-13). If the fuse continues to open, repair the short to ground on
a circuit fed by the fuse or check for a shorted
attached component.
2. Repair the short to ground or replace the component as necessary.
Did you complete the repair?
Go to Step 43
13 1. Turn OFF the ignition.
2. Remove the thermo relay from the engine room relay block.
3. Connect a test lamp between the voltage feed circuit (pins 2 and 3 of X-15 connector) and a
known good ground.
4. Turn ON the ignition, with the engine OFF.
Does the test lamp illuminate on both circuits?
Go to Step 14 Go to Step 23
14 1. Turn OFF the ignition. 2. Reinstall the thermo relay.
3. Remove the radiator grille in order to access the pressure switch.
4. Disconnect the pressure switch harness connector (C-24).
5. Connect a 3-amp fused jumper wire between the pressure switch harness (pin 1 of C-24
connector) and a known good ground.
6. Turn ON the ignition, with the engine OFF.
Does the thermo relay click (engage)?
Go to Step 15 Go to Step 17
15 Does the A/C Clutch Switch parameter indicate ON?
Go to Step 18 Go to Step 16
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