fuel cap release ISUZU KB P190 2007 Workshop Repair Manual

6E-258 Engine Control System (4JH1)
Checks Action
Electromagnetic Interference (EMI)
and Electrical Noise Some electrical components/circuits are sensitive to EMI or other types of electrical
noise. Inspect for the following conditions:
• A misrouted harness that is too close to high voltage/high current devices such as
injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the engine control
module (ECM) driven solenoid or switch. These conditions can cause a sharp
electrical surge. Normally, the problem will occur when the malfunctioning
component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as lights,
2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in use,
but do not fail when the accessories are not in use.
• Test for an open diode across the A/C compressor clutch and for other open diodes.
Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the
electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
Important:
DO NOT reprogram the ECM with the SAME software/calibration files that are already
present in the ECM. This is not an effective repair for any type of driveability problem. - A ECM from another vehicle is installed.
- Revised software/calibration files have been released for this vehicle.
• Verify that the ECM contains the correct software/calibration. If incorrect
programming is found, reprogram the ECM with the most current
software/calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/or capture the
failure conditions.
• An alternate method is to drive the vehicle with the DMM connected to a suspected
circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
scan tool Snapshot The scan tool can be set up to take a Snapshot of the parameters available via serial
data. The Snapshot function records live data over a period of time. The recorded data
can be played back and analyzed. The scan tool can also graph parameters singly or
in combinations of parameters for comparison. The Snapshot can be triggered
manually at the time the symptom is noticed, or set up in advance to trigger when a
DTC sets.
An abnormal value captured in the recorded data may point to a system or component
that needs to be investigated further.
Refer to the scan tool user instructions for more information on the Snapshot function.


Hard Start
Checks Action
DEFINITION:The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but
immediately dies.
Preliminary Checks •
Diagnostic System Check - Engine Controls.
• Ensure the driver is using the correct starting procedure.
• Inspect the engine control module (ECM) and fuel injection pump control unit (PCU)
grounds for being clean, tight, and in their proper locations.
• Inspect that the harness connectors are correctly connected.
• Inspect the fuel type and quality.
• Inspect the scan tool Data List in this section.
• Inspect the Service Bulletins for ECM software updates.

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ISUZU KB P190 2007

6C-44 FUEL SYSTEM (4JK1/4JJ1)
Fuel Tube / Quick - Connector Fittings
Precautions
• Do not light a match or create a flame.
• Keep flames away from your work area to prevent
flammable materials from catching fire.
• Disconnect the battery ground cable to prevent
electrical shorts.
• Pre −treat the piping system or associated parts
from thermal damage or from spattering when
welding or similar heat −generating work.

Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electrolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.






140R100032
Legend
1. O-ring
2. Port
3. Connector
4. Plastic Tube


Removal
1. Open the fuel cap to relieve the fuel pressure in
the tank. Use compressed air to remove any dirt
on the fuel quick connect fittings prior to
disconnecting the fittings. W hen disconnecting the
fuel pipe, cover the area with a cloth to prevent
fuel from splashing as the fuel pipe may still have
some pressure in it.





140R100002
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connecto
r
with the other hand while pressing the square
release button of the connector, as illustrated.


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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-349
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. Install 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 >
Program ECU.
8. Verify the VIN on the screen if programmed at previously described SPS. If not programmed or
incorrect VIN, input correct VIN.
9. Input 24 digits of each fuel injector ID code.
10. After complete the programming, turn OFF the ignition for 30 seconds.
11. Start the engine and let idle.
12. Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.
G. Supply Pump Relearn 1. Install a scan tool.
2. Start the engine and let idle until engine coolant temperature reads 65 °C (149 °F) or higher while
observing the Supply Pump Status parameter with
a scan tool. The scan tool parameter changes
status Not Learn > Learning > Learned.
3. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.Service Programming System (SPS)
Description
The service programming system (SPS) allows a
technician to program a control module through the
data link connector (DLC). The information transfer
circuit that is used at the DLC is the same serial data
circuit used by the scan tool for retrieving DTCs,
displaying data, clearing DTCs etc. This procedure
offers the ability to install software/ calibrations
matched to a particular vehicle.
Most control modules have two types of memory. The
software/ calibrations reside in the flash memory. The
two types of memory are listed below:
• Electrically Erasable Programmable Read Only Memory (EEPROM)
This type of memory allows selected portions of
memory to be programmed while other portions
remain unchanged.
Certain learned values reside in the EEPROM,
such as:
- The vehicle identification number (VIN)
- The software/ calibrations identification numbers
- The control module security information
• Flash Read Only Memory-Flash Memory Flash memory has increased memory storage
capacity. During programming, all information
within this type of memory is erased, and then
replaced with entirely new information.
Service Programming Methods
The two methods of programming an ECM are listed
below:
• Remote Programming
• Pass Thru Programming
For information on programming an ECM using one of
the methods listed above, refer to Service
Programming System (SPS) (Remote Procedure) or
Service Programming System (SPS) (Pass-Thru
Procedure).
Before Programming a Control Module
Important: DO NOT program an existing ECM with the
identical software/ calibration package. This procedure is not
a short cut to correct the driveability condition. This is an
ineffective repair. An ECM should only be programmed when
the following occurs:
• When a service procedure instructs you to replace the ECM.
• An updated software/ calibrations is released.
Ensure that the following conditions are met before
programming an ECM:
• The scan tool PCMCIA card is programmed with the latest software.
• The TIS 2000 is installed with the latest software.

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ENGINE DRIVEABILITY AND EMISSIONS 6E–109
• The fuel injector(s).
4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using a
Tech 2 Scan Tool.
Following are applicable to the vehicle with
closed Loop System:
If an extremely lean condition occurs, the oxygen
sensor(s) will stop toggling. The oxygen sensor
output voltage(s) will drop below 500 mV. Also, the
fuel injector pulse width will increase.
Important: Make sure the fuel system is not
operating in the “Fuel Cut-Off Mode.”
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly
as the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF.
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
• Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service .
• Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and
personal injury that may result from fuel
spraying on the engine, verify that the fuel rail is
positioned over the fuel injector ports and verify
that the fuel injector retaining clips are intact.
• Pressurize the fuel system by connecting a 20 amp fused jumper between B+ and the fuel
pump relay connector.
• Visually and physically inspect the fuel injector nozzles for leaks.
17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may
cause a 45 to set. Driveability conditions associated with rich conditions can include hard starting
(followed by black smoke) and a strong sulfur smell
in the exhaust.
20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a 44 to
set. Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.
22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure.
Command the fuel pump ON with the scan tool. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
psi) may damage the fuel pressure regulator. Caution: To reduce the risk of fire and personal
injury:
• It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
• A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
Fuel Pressure Relief Procedure
1. Remove the fuel cap.
2. Located on the intake manifold which is at the top right part of the engine.
3. Start the engine and allow it to stall.
4. Crank the engine for an additional 3 seconds.
Fuel Pressure Gauge Installation
1. Remove the fuel pressure fitting cap.
2. Install fuel pressure gauge 5-8840-0378-0 to the fuel feed line located on the upper right side of the
engine.
3. Reinstall the fuel pump relay.

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6E–270 ENGINE DRIVEABILITY AND EMISSIONS
FUEL PRESSURE RELIEF
Caution: To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
Caution: After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fitting with a short towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
out. When the disconnect is completed, place the
towel in an approved container.
1. Remove the fuel filler cap.
2. Remove the fuel pump relay from the underhood relay box.
3. Start the engine and allow it to stall.
4. Crank the engine for about 30 seconds.
5. Disconnect the negative battery cable.
FUEL RAIL ASSEMBLY
Removal Procedure
NOTE:
• Use care when removing the fuel rail assembly in order to prevent damage to the injector al connector
terminal and the injector spray tips.
• Fitting should be capped and holes plugged during servicing to prevent dirt and other contaminants from
entering open lines and passage.
Important: An eight-digit identification number is
stamped on side of the fuel injector. Refer to this
number when you service the fuel rail or when a
replacement part is required.
1. Disconnect 4 injector connectors.
2. Lift side-clip up on the fuel rail.
3. Disconnect fuel pressure regulator hose.
4. Disconnect wiring harness from the bands on the fuel rail.
5. Remove the intake pipe.
6. Loosen flare nut.
A. Lift up the injectors carefully to separate them from intake manifold.
B. Lift up the fuel rail with injectors as assembly. Do not separate the fuel injectors from fuel rail.
C. If an injector become separated from fuel rail, injector backup O-ring and injector retainer clip
must be replaced.
D. Drain residual fuel from fuel rail into an approved container.
7. If removal of fuel pressure regulator is necessary, Refer to Fuel Pressure Regulator Removal
Procedure .

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 9


A small amount of fuel may be released when
connecting the fuel pressure gauge to the fuel
pressure test point. Cover the fittings with a
shop towel to absorb any fuel spillage before
connecting the fuel pressure gauge. After the
fuel pressure test procedure, place the soiled
towel in an approved container for disposal.
3 At the fuel pressure test point, remove the Schrader valve sealing cap.
4 Connect the fuel pressure gauge (1) (tool No. J 34730–1A) to the fuel gauge Schrader fitting
adapter (2) (tool No. AU453), then install to the fuel
pressure test port (3). W rap a shop towel around the
fitting while connecting the fuel pressure gauge to
avoid and/or capture any fuel spillage.
5 Route the bleed hose of the fuel gauge into an approved fuel container.


Figure 6C – 5

After connecting the fuel pressure gauge and
pressurising the fuel system, inspect for fuel
leaks at the fuel pressure gauge and the fuel
pressure test point.
6 Either: Using Tech 2, enable the fuel pump to pressurise the fuel system, refer to 0C Tech 2. Inspect for fuel leaks at the
fuel pressure gauge and fuel pressure test point, then bleed the air from the fuel pressure gauge.
or: Reinstall the fuel pump relay and fuel pump fuse, then open the fuel gauge bleed valve (4) to bleed the air from the
fuel pressure gauge, refer to Figure 6C – 5.
7 Remove and place the soiled shop towel in an approved container.
Test
1 Start the engine and record the fuel pressure.
2 Turn the ignition switch off.
3 If required, perform any tests and/or diagnostic procedures:
• For the fuel system leak test, refer to 3.3 Fuel Leak Test.
• For the fuel injector leak-down test (for vehicles fitted with a V6 engine, refer to 6C1-3 Engine Management –
V6 – Service Operations.
4 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
Removal
1 Turn the ignition switch off.
2 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.

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Fuel System – V6 Page 6C – 12


A small amount of fuel may be released when
pressing on the Schrader valve. Cover the
fitting with a shop towel to absorb any fuel
spillage before removing the Schrader valve
sealing cap. Place the soiled towel in an
approved container for disposal.
7 At the fuel pressure test point (2), remove the Schrader valve sealing cap (1), refer to Figure 6C – 7.

Figure 6C – 7
Legend
1 Schrader Valve Sealing Cap
2 Pressure Test Point 3 Schrader Valve

Wear safety glasses when performing the fuel
pressure relief procedure.
8 Place a shop towel around the Schrader valve to soak up the expelled petrol.
9 Use a small screwdriver to press the Schrader valve down (3).
10 Remove the soiled shop towel and place in an approved container.
Repressurise
1 Reinstall the fuel pump relay and fuel pump fuse.
2 Perform the following procedure to inspect for leaks at the fuel pressure test point: a Turn the ignition switch on for two seconds.
b Turn the ignition switch off for 10 seconds.
c Turn the ignition switch on.
d Check for leaks at the fuel pressure test point.
3 Tighten the fuel filler cap.
4 Start the engine and recheck for leaks.
5 Reinstall the Schrader valve sealing cap.

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Fuel System – V6 Page 6C – 20

8 From behind the fuel filler door (1), unscrew the fuel
filler cap (4) and cover the end of the fuel filler neck
with a suitable material to prevent foreign objects from
entering the fuel tank.
9 Remove the screw (2) securing the fuel filler neck (3) to the fuel filler pocket.
10 Remove the front half of the right-hand rear wheelhouse liner, refer to 10 Cab.

Fuel filler neck attaching screw
torque specification ..............................................5.0 Nm
Figure 6C – 18
11 Unclip the fuel filler door release cable (1) from the retainer on the fuel filler neck (2).
Figure 6C – 19
12 Lower the fuel filler neck and breather hose assembly.
13 Loosen the clamp (2) and disconnect the fuel tank breather hose (3) from the fuel filler neck (1).
Figure 6C – 20

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Fuel System – V6 Page 6C – 22

Reinstall
Reinstallation of the fuel tank is the reverse of the removal procedure, noting the following:
1 Lift the fuel tank into position reinserting the fuel tank inlet and breather hoses into the body opening. Raise the fuel tank into place and rest the front of the tank on the crossmember.
2 Replace the fuel pump electrical connector, be sure to engage the locking tab.
3 Fit the fuel tank mounting straps in the following order, refer to Figure 6C – 17, a Loosely reattach the rear fuel tank mounting strap and bolt (8 & 9), refer to Figure 6C – 17.
b Loosely attach the front mounting strap and bolt (1 & 2), refer to Figure 6C – 17.
c Ensure that the fuel tank is located in the correct position then,
d Tighten the rear mounting strap bolt (8), Figure 6C – 17.
e Tighten the front mounting strap bolt (1), Figure 6C – 17.
4 Tighten all fuel tank mounting strap bolts to the correct torque specification.
Fuel tank mounting strap bolts
torque specification ............................................68.0 Nm

Install the fuel filter with the flow arrow on its
body pointing in the same direction as the
fuel flow to the front of the vehicle.
5 Install the disconnected quick-connect fittings to the fuel supply line at the front of the fuel tank and the evaporative line quick-connect fitting at the rear of the fuel tank. Refer to 4.1 Fuel Lines And Quick Connect Fittings, for the
correct component routeing.
6 Lower the vehicle to a comfortable working height and reinstall the clamp (1) to the fuel filler neck and reconnect the rubber fuel tank inlet hose (2) and tighten the clamp, refer to Figure 6C – 21.
7 Reinstall the fuel tank breather hose (3) to the fuel filler neck (1) and tighten the clamp (2), refer to Figure 6C – 20.
8 Clip the fuel filler door release cable (1) to the retainer on the fuel filler neck (2), refer to Figure 6C – 19.
9 Locate the fuel filler neck (3) to the filler pocket and attach with the securing screw (2), remove the cover material from the fuel filler neck inlet and refit the fuel filler cap (4), refer to Figure 6C – 18.
10 Reinstall the front half of the right-hand rear wheelhouse liner, refer to 10 Cab.
11 Before starting the vehicle, perform a fuel system leak test, refer to 3.3 Fuel Leak Test.



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Engine Management – V6 – Service Operations Page 6C1-3–47

2.21 Schrader Valve – Fuel Pressure Gauge
Connection Point

If the Schrader valve is to be removed but not
replaced immediately, it is advisable to
disconnect the battery to avoid possible fuel
discharge if an accidental attempt is made to
start the engine.
Disconnection of the battery affects vehicle
electronic systems. Refer to 6D1-3 Battery –
V6 before disconnecting the battery.
Remove
1 Depressurise the fuel system, refer to 6C Fuel System - V6.
2 Turn the ignition off.

A small amount of fuel may be released when
servicing the fuel pressure test point. To
reduce the chance of personal injury, cover
the fuel pressure test point with a shop towel
to absorb any fuel spillage when the Schrader
valve sealing cap and Schrader valve are
removed. After the procedure, place the towel
in an approved container for disposal.
3 Remove the Schrader valve sealing cap (1).
4 Remove the Schrader valve (2) using a standard valve core removal tool.
Figure 6C1-3 – 65
Reinstall
Reinstallation of the Schrader valve is the reverse of the removal procedure, noting the following:
1 Inspect the fuel rail and quick connect fitting for leaks, refer to 6C Fuel System - V6.
2 Road test the vehicle and check for correct operation.

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