2007 ISUZU KB P190 lock

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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-276 Engine Control System (4JH1)
1. Connect the scan tool to the vehicle DLC, with theengine and the scan tool OFF.
2. Turn ON the scan tool.
3. Select Diagnostic > appropriate vehicle identification > Powertrain > 4JH1-TC >
Programming > Program VIN.
4. Input correct VIN reading from stamped VIN o
r
affixed VIN plate on the vehicle.
Select Lock ECU and lock the programmed VIN.

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 be
the scan tool for retrieving diagnostic trouble codes
(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 Onl
y
Memory (EEPROM).
This type of memory allows selected portions o
f
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 engine control
module (ECM) are listed below: • Remote Programming
• Pass Thru Programming
For information on programming an ECM using one o
f
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: • W hen a service procedure instructs you to replace
the ECM. W hen the ECM from another vehicle is
installed, VIN must be changed. And change
vehicle information as necessary such as type o
f
transmission.
• 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.
• The hardware key is plugged into the compute
r
port.
• Vehicle system voltage:
- There are no charging system concerns. All charging system concerns must be repaired
before programming the ECM.
- The battery voltage is greater than 12 volts bu
t
less than 16 volts. The battery must be fully
charged before programming the ECM.
-
A battery charger is NOT connected to the
vehicles battery. Incorrect system voltage o
r
voltage fluctuations from a battery charger may
cause programming failure or ECM damage.
- Turn OFF or disable any system that may put a load on the vehicles battery. Turn OFF o
r
disable systems such as:
◊ Heating, ventilation, and air conditioning
(HVAC) systems
◊ Headlights
◊ Room lights
◊ Accessory equipment
• The ignition switch is in the proper position. The
scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position o
f
the ignition switch during the programming
procedure unless instructed to do so.
• All tool connections are secure:
- The RS-232 cable
- The connection at the DLC
- The voltage supply circuits


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ISUZU KB P190 2007

6H – 6 ACCELERATOR CONTROL




RTW 46HMH000201

























Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90 °.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if
any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should not be damage or
corrosion.

Installation
1. Install the accelerator control cable to accelerator control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90 °
until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.

NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.




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ISUZU KB P190 2007

6A-2 ENGINE MECHANICAL (4JK1/4JJ1)
Special Tools ...................................................6A-110
Flywheel .............................................................6A-111 Components ....................................................6A-111
Removal ..........................................................6A-111
Inspection ........................................................6A-113
Installation .......................................................6A-113
Torque Specifications......................................6A-115
Special Tools ...................................................6A-115
Gear Case Assembly .........................................6A-116 Components ....................................................6A-116
Removal ..........................................................6A-117
Installation .......................................................6A-118
Torque Specifications......................................6A-119
Crankshaft Front Oil Seal ...................................6A-120 Components ....................................................6A-120
Removal ..........................................................6A-120
Installation .......................................................6A-121
Torque Specifications......................................6A-122
Special Tools ...................................................6A-122
Crankshaft Rear Oil Seal ...................................6A-123 Components ....................................................6A-123
Removal ..........................................................6A-124
Installation .......................................................6A-124
Special Tools ...................................................6A-125
Crankshaft ..........................................................6A-126 Components ....................................................6A-126
Removal ..........................................................6A-127
Disassembly ....................................................6A-127
Reassembly.....................................................6A-128
Inspection ........................................................6A-128
Installation .......................................................6A-132
Torque Specifications......................................6A-135
Cylinder Block ....................................................6A-136 Components ....................................................6A-136
Removal ..........................................................6A-136
Inspection ........................................................6A-137
Installation .......................................................6A-139
Lubrication System .............................................6A-140 Service Precautions ........................................6A-140
Functional Check ............................................6A-141
Oil Filter Cartridge ..............................................6A-143 Components ....................................................6A-143
Removal ..........................................................6A-143
Installation .......................................................6A-143
Special Tools ...................................................6A-144
Oil Filter Assembly and Oil Cooler .....................6A-145 Components ....................................................6A-145
Removal ..........................................................6A-145
Disassembly ....................................................6A-146
Reassembly.....................................................6A-147 Installation ....................................................... 6A-147
Crank Case and Oil Pan .................................... 6A-150 Components .................................................... 6A-150
Removal .......................................................... 6A-151
Disassembly .................................................... 6A-152
Reassembly .................................................... 6A-152
Installation ....................................................... 6A-153
Torque Specifications...................................... 6A-155
Oil Pump ............................................................ 6A-156 Components .................................................... 6A-156
Removal .......................................................... 6A-156
Disassembly .................................................... 6A-157
Reassembly .................................................... 6A-158
Inspection ........................................................ 6A-158
Installation ....................................................... 6A-159
Oil Pressure SW ................................................ 6A-161 Components .................................................... 6A-161
Removal .......................................................... 6A-162
Inspection ........................................................ 6A-162
Installation ....................................................... 6A-162
Circuit check.................................................... 6A-162
Air Cleaner Element ........................................... 6A-163 Removal .......................................................... 6A-163
Cleaning .......................................................... 6A-163
Installation ....................................................... 6A-163

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ISUZU KB P190 2007

6A-60 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.




RTW 76ASH001301
Legend
1. TDC


2. Remove the engine cover.
3. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
4. Install the M5 lock bolt of fixing sub gear.






RTW 56ASH007101


5. Remove the baffle plate (1).





RTW 56ASH006301
6. Remove the camshaft bearing cap and camshaft.
• Check the engraved making on the camshaft
bearing caps.






RTW 56ASH018401



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