ignition ISUZU KB P190 2007 Workshop Repair Manual

Engine Management – V6 – Service Operations Page 6C1-3–55

Inspect
The following throttle body inspection procedure may be carried out with the throttle body installed on the vehicle. Prior to
performing a throttle body on-vehicle inspection:
• Turn the ignition switch off.
• Disconnect the throttle body wiring harness connector. Refer to Remove in this Section.
• Remove the air intake duct, refer to 2.16 Intake Air Duct Assembly.

To avoid serious personal injury, never
attempt to rotate the throttle plate manually
whilst the throttle body harness connector is
connected to the throttle body.
1 Fully open the throttle plate by hand and inspect the throttle body bore and throttle plate for any deposits.

When cleaning / inspecting the throttle body:
• Do not subject the throttle body assembly
to an immersion cleaner or a strong
solvent. Damage to the throttle position
sensor and / or sealed throttle shaft
bearings will result.
• Never use a wire brush or scraper to clean
the throttle body. A wire brush or sharp
tool may damage the throttle body
components.
2 Use a clean shop towel and a spray type hydro-carbon cleaner to clean the throttle body bore and throttle plate. If necessary, use a parts cleaning brush to remove heavy deposits.
3 Inspect the throttle body for a binding throttle plate by fully opening and closing the throttle plate by hand. It should open and close smoothly.
4 Inspect the throttle body for a bent or damaged throttle plate, cracks, corrosion, or distortion in the throttle body housing.
NOTE
The throttle body contains no serviceable parts
and should not be disassembled. If the throttle
body is damaged it must be replaced as an
assembly.
5 If the throttle body is affected by any of the above conditions, it must be replaced.
6 If an on-vehicle throttle body inspection was performed, perform the following:
• Reinstall the air intake duct, refer to 2.16 Intake Air Duct Assembly.
• Reconnect the throttle body wiring harness connector, refer to Reinstall in this Section.
• Road test the vehicle and check for correct operation, taking particular note that no air leaks are evident.
Reinstall
Reinstallation of the throttle body assembly is the reverse of the removal procedure, noting the following:
1 Ensure the throttle body and upper intake manifold mating surfaces are clean and free of foreign material.
2 Install a new throttle body to upper intake manifold gasket.

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Engine Management – V6 – Service Operations Page 6C1-3–60

4 Assembly Lubricants
Camshaft Position (CMP) Sensor O-ring ........................................... Engine Oil
Crankshaft Position (CKP) Sensor .................................................... Engine Oil
Evaporative Emission (EVAP) Canister Purge Valve
Quick Connect Fitting ........................................................................ Engine Oil
Fuel Feed Hose Quick Connect Fitting .............................................. Engine Oil
Fuel Injector Seals............................................................................. Engine Oil
Heated Oxygen Sensor (HO2S) – All .............................. Anti-seize Compound
Ignition Coil Boot .......................................................................Talcum Powder
Ignition Coil Sealing Rubber .............................................................. Engine Oil

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Engine Management – V6 – Service Operations Page 6C1-3–61

5 Torque Specifications
Fuel Rail Attaching Bolt ............................................................... 8.0 – 12.0 Nm
Accelerator Pedal Position Sensor Support Bracket
Attaching Nut ............................................................................... 8.5 – 11.5 Nm
Air Cleaner Lower Housing Attaching Bolt................................. 18.0 – 22.0 Nm
Barometric Pressure Sensor Attaching Bolt ................................ 8.0 – 12.0 Nm
Camshaft Position Sensor Attaching Bolt .................................... 8.0 – 12.0 Nm
Crankshaft Position Sensor Attaching Bolt .................................. 8.0 – 12.0 Nm
Engine Coolant Temperature Sensor ................................................... 22.0 Nm
Engine Control Module Attaching Bolt ......................................... 8.0 – 12.0 Nm
Ground Terminal Attaching Screw.......................................................... 4.5 Nm
Engine Control Module Bracket Assembly
Attaching bolt (6mm Bolt) ............................................................ 8.0 – 12.0 Nm
Engine Control Module Bracket Assembly
Attaching bolt (8mm Bolt) .......................................................... 20.0 – 25.0 Nm
Engine Oil Pressure Sensor ...................................................... 12.0 – 14.0 Nm
Heated Oxygen Sensor ............................................................. 40.0 – 50.0 Nm
Ignition Coil Attaching Bolt........................................................... 7.0 – 11.0 Nm
Air Intake Duct Retaining Clamp ................................................... 1.5 – 2.5 Nm
Knock Sensor Attaching Bolt ..................................................... 21.0 – 25.0 Nm
Mass Air Flow Sensor Attaching Nut ............................................. 1.8 – 2.2 Nm
Spark Plug ................................................................................. 16.0 – 20.0 Nm
Throttle Body Assembly Attaching Bolt........................................ 8.0 – 12.0 Nm

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ISUZU KB P190 2007

Charging System – V6 Page 6D1-1-5

• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is
ignored, the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.

1.3 System Operation
Operation
W ith the ignition switch in the ON position and the engine at rest, current is supplied via the regulator to generator
connector E-4 pin 1 and to the engine control module ECM connector E-60 pin 43. This initiates current flow (within the
regulator) from the generator connection P-9, to the brushes and rotor winding, to ‘excite’ the circuit.
The current in the rotor winding creates magnetic fields between adjacent rotor poles.
W ith the engine running, the rotor spins, the stator windings cut through this field and induce voltage. As the engine
speed is increased, this induced voltage increases. Current then flows through the three-phase diode bridge in the
rectifier to convert the AC voltage to DC. This is supplied to the generator connector P-9 output and then to the battery
terminal via fuse SBF1.
The regulator monitors the voltage to the battery. W hen this voltage reaches approximately 14.5 V, the regulator opens
the circuit through the rotor winding, causing the generator output voltage to drop. W hen the regulator senses a voltage
below a preset voltage, the regulator closes the circuit through the rotor winding and voltage to the battery again
increases. This cycle repeats very rapidly.

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Charging System – V6 Page 6D1-1-6

Alternator Warning
NOTE
All generator faults are displayed as
Check Alternator W arning on the instrument
cluster MFD, refer to 8A Electrical Body and
Chassis.
The ECM monitors the voltage on connector E-60 pin 21 and pin 43.
The voltage at the generator connector E-4 pin 2 will remain low when a fault condition is detected in the generator or
associated external circuits. The voltage remains low (while the ignition switch is on) until the fault is repaired.
NOTE
For more information on the alternator warning
refer to 8A Electrical Body and Chassis.
Fault conditions include the following:
• open circuit or excessive voltage drop in circuit 1,
• open circuit in the generator phase connection,
• overcharging conditions,
• short circuit in the regulator output stage,
• open circuit in the rotor winding,
• poor contact between the rectifier and the regulator, and / or
• high resistance in the fusible link assembly.

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Charging System – V6 Page 6D1-1-7

2 Diagnosis
2.1 Diagnostic General Information
Basic Diagnostic Tools Required

Use of incorrect electrical circuit diagnostic
tools when performing the generator
diagnostic procedures could result in
incorrect diagnostic results or damage to
components.
The following electrical circuit testing tools are required to perform the diagnostic procedures detailed in this Section:
• digital multimeter with 10 mega ohms impedance, and
• connector test adapter kit Tool No. KM609.
For further information on the use of these tools, refer to 8A Electrical Body and Chassis.
2.2 Tech 2 Data List
The Tech 2 displays the status of certain charging system parameters.
To view the data list:
1 Connect Tech 2 to the DLC.
2 On Tech 2 select: Engine / V6 Engine / Data Display / Data List / Electrical/Theft Data .
Tech 2 Parameter Units Displayed Typical Display Values
Alternator L Terminal D Percentage Various
2.3 Diagnostic Systems Check
Step Action Yes No
1 1 Connect Tech 2 to the DLC.
2 Ignition ON, engine OFF.
3 On Tech 2 select: Engine / V6 Engine / Diagnostic Trouble codes / Read
DTC’s.
Are there any set DTC’s? Go to the
appropriate DTC table in 6C1-2 Engine
Management – V6 – Diagnostics. Refer to 2.5
Charging
System Inoperative / Malfunctioning

Reference to following information will assist when diagnosing charging circuit faults:
• for battery testing, refer to 6D1-3 Battery – V6,
• for wiring diagram details, refer to Figure 6D1-1 2, and
• for electrical component locations, refer to 8A Electrical Body and Chassis.

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Charging System – V6 Page 6D1-1-10

3 Minor Service Operations
3.1 Safety Precautions
Observe the following precautions. Failure to observe these precautions will result in serious damage to the generator.
• Only use the generator and voltage regulator in a negative ground system.
• Always refer to 1.2 W ARNING, CAUTION and NOTES before disconnecting the battery.
• W hen installing a battery, fit the positive (+) cable to the battery before fitting the negative cable.
• W hen a slave battery is used for starting purposes, ensure that both batteries are connected in parallel. That is,
positive terminals connected and negative terminals connected.
• Only use jumper leads that have surge protection.
• Disconnect both battery cables when charging the battery. This isolates the generator from the battery and from
the external charging equipment.
• Do not operate the generator within an open circuit or without a battery in the circuit.
• Do not disconnect the battery while the generator is running.
• Do not attempt to polarise the generator.
• Do not connect generator connector E-4 pin 1 to 12 V (the battery or ignition circuits).
• Some battery powered timing lights can produce high transient voltages when connected or disconnected.
Only disconnect or connect timing lights when the engine is switched off.

Ensure the generator connector E-4 pin 1 has
a maximum sinking current of 50mA.
3.2 Maintenance
Regular Checks
Check the following at regular intervals:
• generator terminals – for corrosion and loose connections,
• wiring – for continuity and damaged insulation,
• mounting bolts – for tightness,
• drive belt – for alignment and wear, and
• drive pulley – for damage and warping.
NOTE
The drive-belt adjustment for the engine
ancillaries (i.e. generator and water pump) is
provided by a spring-loaded tensioner. Therefore,
the drive belt does not require manual
adjustment.
Lubrication
High tolerance bearings are used in this generator. If the bearings are removed during the generator disassembly, new
bearings must be installed to restore the generator to original specification. The ball bearings supporting the rotor shaft
are pre-lubricated and sealed. Do not attempt to lubricate these during servicing.

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Charging System – V6 Page 6D1-1-11

3.3 On-vehicle Testing
Generator On-vehicle Checks
Prerequisites
Before testing the generator output, ensure that:
• all generator circuit connections are clean and tight,
• the generator is always connected to the battery during testing (to prevent damage to the diodes),
• the battery is fully charged, and
• the specific gravity does not vary more than 0.025 between cells. (It is recommended the average specific gravity
is 1.260 or higher). Refer to 6D1-3 Battery – V6.
Carry out a load test on the battery to determine its ability to supply and accept current. This is a good indicator of the
general condition of the battery. For details of battery testing, refer to 6D1-3 Battery – V6.
Inspect the drive belt and tensioner markings to determine if the drive belt is within operating limits. Replace the belt if it
is excessively worn or outside the operating range of the tensioner.
For further details, refer to 6A1 Engine Mechanical – V6.
Generator Test
Regulating Voltage Test
NOTE
Leave the generator E-4 wiring harness
connector connected, as it provides initial field
excitation.
1 Ensure the ignition switch is in the OFF position and all electrical equipment is turned off.

Refer to 1.2 WARNING, CAUTION and
NOTES before disconnecting the battery.
2 Disconnect the battery ground cable P-5 at the battery.
3 Disconnect the generator positive lead P-9 from the generator . Connect the positive lead of a multimeter
set to measure current (1) to P-9 (2).
4 Connect that multimeter’s negative lead to the disconnected generator positive lead (3).
5 Connect the positive lead of a multimeter set to measure voltage (4) to P-9 (5).
6 Connect that multimeter’s negative lead to a good ground connection on the generator housing (6).

Insulate the terminal of the generator
positive lead P-9 to prevent contact with any
metal part of the vehicle. If the terminal is
grounded, damage to the charging circuit
can result when the battery is reconnected.
Figure 6D1-1 3

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Charging System – V6 Page 6D1-1-16


Reinstall
Reinstallation of the generator is the reverse of the removal procedure, noting the following:
1 Tighten all fasteners to the correct torque specification.
2 Reconnect the battery ground lead.
3 Start the engine.
4 Check the generator warning indicator operation.
5 Check the drive belt is correctly routed and aligned.
6 Check the generator output. Refer to 3.3 On-vehicle Testing.
7 Check the voltage regulator operation. Refer to 3.3 On-vehicle Testing.
8 Turn the ignition switch off.
Generator mounting bolts ........................... (1) 58.0 Nm
Generator mounting bolts ........................... (2) 58.0 Nm
Generator mounting bolts ........................... (4) 58.0 Nm
Battery harness to P-9 pin B nut
torque specification ...................................7.1 – 13.3 Nm

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–4

• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.
1.2 Components
Starting System Components
The main components of the starting system are:
• battery,
• wiring,
• ignition switch,
• theft deterrent engine crank inhibitor (a function of the theft deterrent system),
• park / neutral and back-up switch (on vehicles with 4 speed automatic transmission),
• engine control module (ECM),
• start relay,
• solenoid switch, and
• starter motor.
Starter Motor and Solenoid Switch Components
Solenoid Switch
The solenoid switch is used to activate the DC motor and has two windings; the pull-in winding and the hold-in winding.
The pull-in winding has heavier wire and is grounded through the DC motor winding and brushes. The hold-in winding is
grounded through the solenoid casing.
Planetary Drive Train
The planetary drive train consists of an internally toothed ring gear and three planetary gear wheels, which rotate on
sleeve bearings on the planetary drive shaft. The ring gear is keyed into the drive-end housing and is made from
high-grade polyamide with mineral additives.
W hen the starter motor operates, the armature turns the planetary gears inside the fixed planetary ring gear. This drives
the planetary shaft at a reduced speed ratio which turns the drive assembly. A fork lever in the drive-end housing forces
the drive assembly forward to engage with the flexplate / flywheel ring gear on the engine and transmit cranking torque.
An internal clutch allows the drive assembly pinion gear to rotate freely when the engine starts. This prevents the
armature from being driven at excessive speed by the engine.
Armature
The armature shaft is supported at each end by oil absorbent, sintered metal bushes; one in the commutator end shield
and one in the planetary drive shaft. The front end of the armature has a gear profile. This meshes with the three
planetary gear wheels. These in turn, mesh with the internal teeth of the ring gear.
Brushes
A brush plate supports four commutator brushes. This plate is fixed to the commutator end shield with two retaining
screws. Two negative brushes are grounded to the pole housing. The two positive brushes are insulated from the pole
housing and connected to the solenoid switch M terminal, refer to Figure 6D1-2 – 1.

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