Engine Control System (4JH1) 6E-277
• DO NOT disturb the tool harnesses while
programming. If an interruption occurs during the
programming procedure, programming failure o
r
ECM damage may occur.
• If you are performing the Pass-Thru programming
procedure using a notebook computer without the
power cord, ensure that the internal battery is full
y
charged.
Service Programming System (SPS)
(Remote Procedure)
The Remote Service Programming System (SPS)
method is a three-step process that involves the
following procedures: 1. Connecting the scan tool to the vehicle and obtaining the information from the engine control
module (ECM).
2. Connecting the scan tool to the terminal and downloading a new calibration file from the terminal
into the scan tool memory.
3. Reconnecting the scan tool to the vehicle and uploading the new calibration file into the ECM.
Performing the Remote Procedure 1. Connect the scan tool to the vehicle and obtain the ECM information using the following procedure:
Important:
Ensure the ECM is installed in the vehicle and the batter
y
is fully charged before programming. a. Connect the scan tool to the vehicle data linkconnector (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 at the Main Menu.
f. Select Request Info.
g. If there is already stored in the scan tool, the existing data is displayed on the screen. The
scan tool asks user to keep existing data Keep
Data or Continue to request new vehicle
information from the ECM. If there is no data in
the scan tool, it will immediately start vehicle
identification.
h. Enter the vehicle description by following the on- screen instructions based on stamped VIN o
r
affixed VIN plate on the vehicle.
i. During obtaining information, the scan tool is
receiving information from any modules at the
same time. But only ECM information is
displayed on the screen.
j. Turn OFF all accessories and select Continue.
k. Verify that the correct VIN is entered on the scan tool. If the VIN is incorrect, write down the
correct VIN.
2. Turn OFF the scan tool.
3. Disconnect the scan tool from the vehicle.
4. Turn OFF the ignition.
5. Transfer the data from the terminal to the scan tool using the following procedure:
Important:
The TIS supports service programming with the scan
tool scan tool only. a. Connect the scan tool to the terminal.
b. Launch the TIS application at the terminal.
c. Select the Service Programming System at the main screen.
d. Highlight the following information on the Selec
t
Diagnostic Tool and Programming Process
screen: • Select Diagnostic Tool-Select scan tool.
• Select Programming Process-Identif
y
whether an existing ECM is being
reprogrammed or an ECM is being
replaced with a new one.
• Select ECU Location-Select Vehicle.
e. Select Next.
f. Verify the connections on the Preparing fo
r
Communication screen and select Next.
g. Verify the VIN on the Validate Vehicle Identification Number (VIN) screen and selec
t
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.
h. Highlight Engine on the System Type screen and select Next, if requested.
i. 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
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ISUZU KB P190 2007
6E-280 Engine Control System (4JH1)
EGR Solenid Valve Replacement
Removal Procedure 1. Disconenct the negative battery cable.
2. Disconnect a EGR solenoid valve harness connector.
3. Disconnect two hoses from the EGR solenoid valve.
4. Loosen two bolts and remove the EGR solenoid valve from the bracket.
Installation Procedure
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EGR solenoid valve.
3. Connect two hoses to the EGR solenoid valve.
4. Connect the negative battery cable.
Engine Coolant Temperature (ECT) Sensor
Replacement
1. Removal Procedure
2. Disconnect the negative battery cable.
3. Drain enough engine coolant so that the coolant level will be below the ECT sensor.
4. Disconnect connector from the ECT sensor.
5. Loosen and remove the ECT sensor from the thermostat housing.
Notice: Cool down the engine before above procedures
are carried out.
Installation Procedure
1.
Apply sealer to threads of screw at the ECT
sensor.
2. Tighten the ECT sensor with specified tightening torque.
Tightening Torque • Bolt: 13 N.m (1.3 kgf.m)
3. Connect a ECT sensor connector to the ECT sensor.
4. Fill the engine coolant.
5. Connect the negative battery cable.
Notice: Verify no engine coolant leaking from the
sensor threads after replacement.
Mass Air Flow (MAF) / Intake Air
Temperature (IAT) Sensor Replacement
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect a MAF & IAT sensor connector from the MAF & IAT sensor assembly.
3. Loosen the clips and remove the MAF & IAT sensor assembly from the intake duct housing.
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ISUZU KB P190 2007
Engine Control System (4JH1) 6E-281
Installation Procedure
1. Install the MAF & IAT sensor assembly into intake air duct.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF & IAT sensor assembly.
4. Connect the negative battery cable.
Turbocharger Solenoid Valve Replacement
[High Altitude Spec]
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect a harness connector from the turbocharger solenoid valve.
3. Disconnect two hoses from the turbocharge
r
solenoid valve.
4. Loosen a nut and remove the turbocharger solenoid valve from the bracket.
RTW 66ESH004001
Legend
1. Vaccum Pressure Sensor
2. To Turbocharger
3. EGR Solenoid Valve
4. To Vacuum Regulating Valve
5. Turbocharger Solenoid Valve
Installation Procedure
1. Set the turbocharger solenoid valve on the bracke
t
and tighten a nut.
2. Connect a harness connector to the turbocharge
r
solenoid valve.
3. Connect two hoses to the turbocharger solenoid valve.
4. Connect the negative battery cable.
Vacuum Pressure Sensor Replacement
[High Altitude Spec]
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect a harness connector from the vacuum pressure sensor.
3. Loosen a bolt and remove the vacuum pressure sensor from the bracket.
RTW 66ESH004001
Legend
1. Vaccum Pressure Sensor
2. To Turbocharger
3. EGR Solenoid Valve
4. To Vacuum Regulating Valve
5. Turbocharger Solenoid Valve
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ISUZU KB P190 2007
6E-282 Engine Control System (4JH1)
Installation Procedure 1. Set the vacuum pressure sensor on the bracket and tighten a bolt.
2. Connect a harness connector to the vacuum pressure sensor.
3. Connect the negative battery cable.
Vehicle Speed Sensor (VSS) Replacement
Removal Procedure
M/T & A/T (4W D) 1. Disconnect the negative battery cable.
2. Disconnect a harness connector from the vehicle speed sensor (VSS).
3. Remove the VSS from the transmission.
A/T (2W D)
1. Disconnect the negative battery cable.
2. Disconnect a harness connector from the vehicle speed sensor (VSS).
3. Loosen a bolt and remove the VSS from the transmission.
Installation Procedure
M/T & A/T (4W D) 1. Install the VSS at the transmission.
2. Connect a harness connector to the VSS.
3. Connect the negative battery cable.
M/T & A/T (4W D) 1. Set the VSS at the transmission and tighten a bolt.
2. Connect a harness connector to the VSS.
3. Connect the negative battery cable.
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ISUZU KB P190 2007
Engine Control System (4JH1) 6E-283
Description And Operation
Engine Control Module (ECM) Description
RTW 66ESH001201
The engine control module (ECM) is designed to
withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. W hen testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a digital multi meter (DMM). The ECM should remain
connected to the ECM harness.
The ECM is located on the floor panel. The ECM mainl
y
controls the following.
• The fuel system control
• The exhaust gas recirculation (EGR) system
control
• The preheating (glow) system control
• The A/C compressor control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensor s. The ECM controls the systems that
affect vehicle performance. The ECM performs the
diagnostic function of the system. The ECM can
recognize operational problems, alert the driver through
the malfunction indicator lamp (MIL), and store
diagnostic trouble codes (DTCs). DTCs identify the
system faults to aid the technician in making repairs.
ECM Voltage Description
The ECM supplies a buffered voltage to various
switches and sensor s. The ECM can do this because
resistance in the ECM is so high in value that a test
lamp may not illuminate when connected to the circuit.
An ordinary shop voltmeter may not give an accurate
reading because the voltmeter input impedance is too
low. Use a 10-megaohm input impedance DMM, to
ensure accurate voltage readings. The input and/o
r
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special drivers.
The ECM controls most components with electronic
switches which complete a ground circuit when turned
ON.
Aftermarket Electrical and Vacuum Equipment
Aftermarket or add-on electrical and vacuum equipment
is defined as any equipment which connects to the
vehicle's electrical or vacuum systems that is installed
on a vehicle after the vehicle leaves the factory. No
allowances have been made in the vehicle design fo
r
this type of equipment. No add-on vacuum equipment
should be added to this vehicle. Add-on electrical
equipment must only be connected to the vehicle's
electrical system at the battery power and ground. Add-
on electrical equipment, even when installed to these
guidelines, may still cause the powertrain system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such as
portable telephones and audios. Therefore, the first
step in diagnosing any powertrain fault is to eliminate all
aftermarket electrical equipment from the vehicle. Afte
r
this is done, if the fault still exists, the fault may be
diagnosed in the normal manner.
Electrostatic Discharge Damage
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused b
y
electrostatic discharge. By comparison, as much as
4,000 volts may be needed for a person to feel even the
zap of a static discharge. There are several ways for a
person to become statically charged. The most
common methods of charging are by friction and
induction. •
An example of charging by friction is a person
sliding across a vehicle seat.
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ISUZU KB P190 2007
Engine Control System (4JH1) 6E-295
The timing control valve (TCV) acts as a variable
throttle, using the rapid opening and closing (cycling)
of the valve needle in the TCV.
At normal operation,
the TCV controls the pressure acting on the annula
r
chamber so that the hydraulic stopper cam move to
any position, from the retard position to the advance
position. At this time, the duty ratio is set by the fuel
injection pump control unit (PCU).
When control current flows to the TCV coil, the valve
needle opens and the fuel annular chamber flows
through the orifice to the feed pump inlet.
Consequently, the pressure of the annular chambe
r
decreases and the hydraulic stopper is moved to the
retard side.
When control current to the TCV coil is cut, the valve
needle closes and the return passage is closed.
Consequently, the pressure of the annular chambe
r
increases and the hydraulic stopper is moved to the
advance side.
Pump Camshaft Position (CMP) Sensor
RTW 66ESH003301
Legend
1. Pump Camshaft Position (CMP) Sensor
2. Flexible Connecting Harness
3. Drive Shaft
4. Pump Camshaft Position (CMP) Sensor Retaining Ring
5. Sensor W heel
W hen the drive shaft rotates, the pump camshaft
position (CMP) sensor receives signal form the senso
r
wheel, and an electric pulse is sent through the flexible
connecting harness to the fuel injection pump control
unit (PCU). From these signals the PCU can determine
the average pump speed and the momentary pump
speed. The pump CMP sensor is mounted to the cam
ring. Thus, the relationship between the cam ring and
the pump CMP sensor signal is constant. The pump
CMP sensor signal is utilized for the following purposes:
• To determine the momentary angular position o
f
the cam ring.
• To calculate the actual speed of the fuel injection
pump.
• To determine the actual timing plunger position.
RTW 66ESH003401Legend
1. Pump Camshaft Position (CMP) Sensor Signal
2. Crankshaft Position (CKP) Sensor Signal
3. Fuel Injection Solenoid Valve Control Pulse
4. Fuel Injection Solenoid Needle Valve Lift
5. Cam Lift (Cam Profile)
6. Pulse Count
7. Fuel Injection Solenoid Valve Close
8. Fuel Injection Solenoid Valve Open
9. Start of Pressure Delivery
10. End of Pressure Delivery
11. Pressure Delivery Angle
12. Effective Stroke
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ISUZU KB P190 2007
Engine Control System (4JH1) 6E-299
Special Tools and Equipment
Special Tools and Equipment
Illustration Tool Number/
Description
Illustration Tool Number/
Description
5-8840-2835-0 /
J-35616-A
Connector Test Adapter Kit
(W ith Test Lamp)
5-8840-0607-0 /
J-34142-B
Test Lamp
5-8840-0285-0 /
J-39200
Digital Multimeter
5-8840-0279-0 /
J-23738-A
Vacuum Pump
Tech2 Kit
Breaker Box
Adapter Harness
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ISUZU KB P190 2007
ENGINE MECHANICAL (4JK1/4JJ1) 6A-3
ISUZU DIESEL ENGINE (4JK1/4JJ1)
Service Precautions
Matters that require attention in terms of
maintenance
To prevent damage to the engine and ensure reliabilit
y
of its performance, pay attention to the following in
maintaining the engine:
• W hen lifting up or supporting the engine, do not
apply a jack on the oil pan.
W hen taking down the engine on the ground, do not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, fo
r
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between the oil pan and the oil pump strainer, it can
damage the oil pan and the oil strainer.
• W hen the air duct or air cleaner is removed, cove
r
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
• W hen maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, fo
r
instance, watch out for short circuits and others.
•
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
• W hen valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings o
r
crankshaft journal bearings are removed, put them
in order and keep them.
• W hen installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
•
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.
• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• W hen assembling or installing parts, fasten them
with the prescribed tightening torque so that the
y
are installed properly.
Matters that require attention in specifically dealing
with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, the
y
are highly sensitive to foreign matter and, if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.
W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.
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ISUZU KB P190 2007