2007 ISUZU KB P190 heating

Engine Control System (4JH1) 6E-253
Step Action Value(s) Yes No
31 1. Turn OFF the ignition.
2. Inspect for an intermittent and for poor connections at the thermo relay terminals (pins
1, 2, 3 and 4 of X-15 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 37
32 1. Turn OFF the ignition. 2. Inspect for an intermittent and for poor connections at the harness connector of the
pressure switch (pins 1 and 2 of C-24 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 38
33 1. Turn OFF the ignition. 2. Inspect for an intermittent and for poor connections at the harness connector of the
electronic thermostat (pins 1, 2, 3 and 4 of C-55
connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 39
34 1. Turn OFF the ignition. 2. Inspect for an intermittent and for poor connections at the harness connector of the A/C
switch (pins 10 and 11 of B-57 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 40
35 1. Turn OFF the ignition. 2. Inspect for an intermittent and for a poor connection at the harness connector of the
blower motor switch (pin 1 of B-13 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 41
36 1. Turn OFF the ignition. 2. Inspect for an intermittent and for a poor connection at the harness connector of the ECM
(pin 33 of C-56 connector).
3. Repair the connection(s) as necessary.
Did you find and correct the condition? 

Go to Step 43 Go to Step 42
37 Replace the thermo relay. Did you complete the replacement? 

Go to Step 43 
38 Replace the pressure switch. Refer to Heating and
Air Conditioning section.
Did you complete the replacement? 

Go to Step 43 
39 Replace the electronic thermostat. Refer to Heating
and Air Conditioning section.
Did you complete the replacement? 

Go to Step 43 
40 Replace the A/C switch. Refer to Heating and Air
Conditioning section.
Did you complete the replacement? 

Go to Step 43 
41 Replace the blower motor switch. Refer to Heating
and Air Conditioning section.
Did you complete the replacement? 

Go to Step 43 
42 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 43 

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ISUZU KB P190 2007

6E-254 Engine Control System (4JH1)
Step Action Value(s) Yes No
43 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 Char 1 of 2 Step 4 Refer to Applicable
Diagnostic Chart in Heating & Air Conditioning Section



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6E-260 Engine Control System (4JH1)
Checks Action
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Improper mechanical timing (timing gear)
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to the Engine Electrical
section.
• Inspect the glow plug control (preheating) system operation.
• Inspect for slow cranking speed.
• Inspect for weakened batteries.


Rough, Unstable, or Incorrect Idle And Stalling
Checks Action
DEFINITION:Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or restricted.
Replace as necessary.
• 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.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool Data
List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake Air
Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine, check for
high resistance on the low reference circuit and signal circuit or for a skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON. FT
sensor is internal to the PCU and it is part of the fuel injection pump assembly.
• Use the scan tool to compare the MAF Sensor parameter with the Desired MAF
parameter. Start the engine and warm up (allow engine coolant temperature to reach at
least 60°C [140°F]). The MAF Sensor parameter must follow the Desired MAF parameter
within 100 mg/strk. If not, inspect the air intake system, EGR system components and
contaminated, skewed or slow MAF sensor.
• Inspect the crankshaft position (CKP) sensor is tight and the flywheel circumference is
not damaged.

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6E-274 Engine Control System (4JH1)
Checks Action
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 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.
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Improper mechanical timing
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
• Inspect for any excessive fuel entering combustion chamber.
• Inspect for coolant entering the combustion chamber.
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to the Engine Electrical
section.
• Inspect the glow plug control (preheating) system operation.



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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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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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ENGINE MECHANICAL (4JK1/4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.

Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.

Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled
under every possible driving condition.

Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening o
r
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantit
y
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.


Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.

Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.

Functional inspection
Inspection/adjustment of valve clearance 1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead cente
r
(TDC).





RTW 76ASH001301
Legend
1. TDC



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-57
6. Remove the M6 bolt from the idle gear A.
7. Install the gear case cover. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).


RTW 56ASH020101
Legend
1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)




RTW 56ASH012101
8. Install the vacuum pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the oil pipe (feed side and return side) o
f
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.




LTW 56ASH000101

10. Install the crank pulley.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure fo
r
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.



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