Isuzu KB P190. Manual - part 485

 

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Isuzu KB P190. Manual - part 485

 

 

ENGINE CONTROL SYSTEM (4JK1/4JJ1)   6E-323

Symptoms - Engine Controls

Symptoms - Engine Controls

Important Preliminary Inspections Before Starting

Perform Diagnostic System Check - Engine Controls
before using the symptom tables, and verify that all of
the following are true:

• The ECM and malfunction indicator lamp (MIL)/

service vehicle soon (SVS) lamp are operating
correctly.

• The scan tool data is within the normal operating

range. Refer to Scan Tool Data List in this section.

• Verify the customer concern and locate the correct

symptom in the table of contents. Inspect the items
indicated under that symptom.

Visual and Physical Inspection

Several of the symptom procedures ask for careful
visual and physical inspection. This step is extremely
important. The visual and physical inspection can lead
to correcting a problem without further inspections, and
can save valuable time. Ensure that:

• The ECM grounds are clean, tight, and in their

proper location.

• The vacuum hoses are not split or kinked, and

properly connected. Inspect thoroughly for any
type of leak or restriction.

• The air intake ducts are not collapsed or damaged.

• The exhaust pipes are not collapsed or damaged.

• The engine harness wiring and terminals are

properly connected and are not pinched or cut.

Intermittent

Important: Inspect for improper installation of electrical
components if an intermittent condition exists. Inspect
for aftermarket add-on electrical equipment devices,
lights, and cellular phones. Verify that no aftermarket
equipment is connected to the controller area network
(CAN) or other serial data circuit.

Important: The problem may or may not turn ON the
MIL/ SVS lamp or store a DTC. Faulty electrical
connections or wiring cause most intermittent
problems. Perform a careful visual and physical
inspection of the suspect connectors for the following
conditions:

• Improperly mated connector halves

• Terminals that are not seated

• Terminals that are damaged or improperly formed

Reform or replace connector terminals in the problem
circuit in order to ensure proper contact tension.
Remove the terminal from the connector body in order
to inspect for poor terminal wire connection.
Road test the vehicle with the DMM connected to the
suspected circuit. An abnormal reading that occurs
when the malfunction occurs is a good indication that
there is a malfunction in the circuit being monitored.
Use the scan tool in order to help detect intermittent
conditions. Useful features of the Tech 2 scan tool
include the following:

• Trigger the Snapshot feature in order to capture

and store engine parameters when the malfunction
occurs. Review this stored information in order to
see the specific running conditions that caused the
malfunction.

• Freeze Frame/ Failure Record can also aid in

locating an intermittent condition. Review and
capture the information in the Freeze Frame/
Failure Record associated with the intermittent
DTC being diagnosed. Drive the vehicle within the
conditions that were present when the DTC
originally set.

• Use the Plot Function on the scan tool in order to

plot selected data parameters. Review this stored
information to aid in locating an intermittent
problem. Refer to the scan tool Users Guide for
more information.

Use the data recording module (DRM) in order to help
detect intermittent conditions. The DRM has ability to
store engine log data when an event of DTC. Maximum
three log data can be stored in the DRM memory. If
more than maximum number of storage is set, oldest
log data is overwritten. However, if same DTC is set
within eight hours that DTC is not stored in the DRM
memory.
The manual trigger function is to store the log data by
an arbitrary operation of the driver when an event of
wrong vehicle performance that is instead of an event
of DTC. If the driver presses and releases the manual
trigger switch once, that time becomes a trigger and
one log data before and behind the trigger is stored in
the DRM memory. When there is a space in the DRM
memory, log data is stored in that space. However,
when more than maximum number of storage is set,
oldest log data is overwritten.
Refer to the DRM Users Guide for more information.

Important: If the intermittent condition exists as a start
and then stall, test for DTCs relating to the vehicle theft
deterrent system. Test for improper installation of
electrical options such as lights, cellular phones, etc..
Any of the following may cause an intermittent MIL/
SVS lamp with no stored DTC:

• The ECM grounds are loose or dirty. Refer to

Engine Controls Schematics.

6E-324   ENGINE CONTROL SYSTEM (4JK1/4JJ1)

• The MIL/ SVS lamp circuit intermittently shorted to

ground

• Electrical system interference caused by a

malfunctioning relay, ECM driven solenoid, or
switch. The electrical component can cause a
sharp electrical surge. Normally, the problem will
occur when the malfunctioning component is
operating.

• There are any open diodes.

Important: The following symptom tables contain
groups of possible causes for each symptom. The
order of these procedures is not important. If the scan
tool readings do not indicate the problems, then
proceed in a logical order, easiest to check or most
likely to cause first. In order to determine if a specific
vehicle is using a particular system or component, refer
to Engine Controls Schematics for an application.
Use the following tables when diagnosing a symptom
complaint:

• Intermittent Conditions

• Hard Start

• Rough, Unstable, or Incorrect Idle and Stalling

• High Idle Speed

• Cuts  Out

• Surges

• Lack of Power, Sluggishness or Sponginess

• Hesitation, Sag or Stumble

• Abnormal Combustion Noise

• Poor Fuel Economy

• Excessive Smoke (Black Smoke)

• Excessive Smoke (White Smoke)

ENGINE CONTROL SYSTEM (4JK1/4JJ1)   6E-325

Intermittent Conditions

Checks

Action

Definition:
The problem is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom cannot currently be duplicated, if the problem is not DTC related.

Preliminary Checks

• Refer to Symptoms - Engine Controls before starting.

Harness/ Connector

Many intermittent open or shorted circuits are affected by harness/ connector
movement that is caused by vibration, engine torque, bumps/ rough pavement, etc.
Test for this type of condition by performing the applicable procedure from the following
list:

• Move related connectors and wiring while monitoring the appropriate scan tool data.

• Move related connectors and wiring with the component commanded ON, and OFF,

with the scan tool. Observe the component operation.

• With the engine running, move related connectors and wiring while monitoring

engine operation.

If harness or connector movement affects the data displayed, component/ system
operation, or engine operation, inspect and repair the harness/ connections as
necessary.

Electrical 

Connections 

or 

Wiring

Poor electrical connections, terminal tension or wiring problems cause most
intermittent. To perform the following inspections:

• Poor mating of the connector halves, or terminals improperly seated in the

connector body.

• Improperly formed or damaged terminals. Test for poor terminal tension.

• Poor terminal to wire connections including terminals crimped over insulation. This

requires removing the terminal from the connector body.

• Corrosion/ water intrusion. Pierced or damaged insulation can allow moisture to

enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Look for swollen and stiff sections of wire in the suspect circuits.

• Wires that are broken inside the insulation.

• Harness for pinched, cut or rubbed through wiring.

• Ensure that the wiring does not come in contact with hot exhaust components.

Control Module Power and Grounds 
Component Power and Grounds

Poor power or ground connections can cause widely varying symptoms.

• Test all control module power supply circuits. Many vehicles have multiple circuits

supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/ component connectors, fuses, and any intermediate connections
between the power source and the module/ component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.

• Test all control module ground and system ground circuits. The control module may

have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and
in splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.

6E-326   ENGINE CONTROL SYSTEM (4JK1/4JJ1)

Temperature Sensitivity

• An intermittent condition may occur when a component/ connection reaches normal

operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.

• Freeze Frame, Failure Records or Snapshot Data may help with this type of

intermittent conditions, where applicable.

• If the intermittent is related to heat, review the data for a relationship with the

following:

- High ambient temperatures.

- Underhood/ engine generated heat.

- Circuit generated heat due to a poor connection, or high electrical load.

- Higher than normal load conditions, towing, etc..

• If the intermittent is related to cold, review the data for the following:

- Low ambient temperatures-In extremely low temperatures, ice may form in a

connection or component. Test for water intrusion.

- The condition only occurs on a cold start.

- The condition goes away when the vehicle warms up.

• Information from the customer may help to determine if the trouble follows a pattern

that is temperature related.

Electromagnetic Interference (EMI) 
and Electrical Noise

Some electrical components/ circuits are sensitive to EMI or other types of electrical
noise. Inspect 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 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 any 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:

- An ECM from another vehicle is installed.

- Revised software/ calibration files have been released for this vehicle.

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.

• 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.

• Freeze Frame/ Failure Records data, where applicable, contains the conditions that

were present when the DTC set.

- Review and record Freeze Frame/ Failure Records data.

- Operate the vehicle under the same conditions that were noted in Freeze

Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.

• 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.

Checks

Action

 

 

 

 

 

 

 

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