torque ISUZU KB P190 2007 Workshop Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 1023 of 6020
6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Disconnect the magnetic switch cable at the terminal bolts.
3. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
4. Remove the starter motor from the engine.
Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
85 (8.7/63)
3. Reconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
4. Reconnect the battery cable and the ground cable at the battery terminals.
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Page 1031 of 6020
6D – 30 ENGINE ELECTRICAL
RTW46DSH005601
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic switch as illustrated.
2. Insert the shift lever into the plunger hole of the magnetic switch.
RTW46DSH005701
7. Gear Case
3,8. Dust Cover 1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
Dust Cover Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
8 (0.8/5.4)
10. Pinion Assembly
Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041
RTW46DSH004501
21. Brush Holders
1. Install the brushes into the brush holder with raising the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of the yoke and the brush holder.
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Page 1032 of 6020
ENGINE ELECTRICAL 6D – 31
24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
8.1 (0.83/6.00)
065RY00044
RTW46DSH002601
25. Lead Wire
Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque N ⋅m (kg ⋅m/lb ⋅ft)
8.6 (0.88/6.40)
RTW46DSH005801
Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)
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Page 1290 of 6020
6E-256 Engine Control System (4JH1)
Important:
The following symptom tables contain groups o
f
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
• Cuts Out, Misses
• Surge/Chuggles
• Lack of Power, Sluggishness, or Sponginess
• Hesitation, Sag, Stumble
• Fuel Knock/Combustion Noise
• Poor Fuel Economy
• Excessive Smoke (Black Smoke)
• Excessive Smoke (W hite Smoke)
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.
• W ith 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.
Refer to Electrical Connections or W iring.
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Page 1298 of 6020
6E-264 Engine Control System (4JH1)
Checks Action
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Ensure the driver understands the torque converter clutch (TCC) operation.
• Ensure the driver understands the A/C compressor operation.
• Use the scan tool in order to make sure the Vehicle Speed parameter reading
matches the vehicle speedometer.
• 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 Mass Air Flow (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.
• Use the scan tool to observe the Accelerator Pedal Position. Accelerator Pedal
Position parameter should change linearly from 0% to 100% according to the
accelerator pedal operation. Also inspect the Accelerator Pedal Position indicating
angle when the accelerator pedal is steady. If the indicating angle fluctuates, check
for an intermittent open, high resistance in the circuits or for a skewed sensor.
• Inspect the crankshaft position (CKP) sensor is tight and the flywheel circumference
is not damaged.
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Page 1299 of 6020
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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Page 1302 of 6020
6E-268 Engine Control System (4JH1)
Checks Action
Engine Mechanical Check 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
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
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 engine overheat condition. Refer to the Engine Cooling section.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation (A/T only).
Hesitation, Sag, Stumble
Checks Action
DEFINITION:The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur
at any vehicle speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe
enough, the condition may cause the engine to stall.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect for a proper transmission shift pattern and down shift operation.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Inspect the scan tool Data List in this section.
• Inspect the engine control module (ECM) and fuel injection pump control unit (PCU)
grounds for being clean, tight, and in their proper locations.
• 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.
• Use the scan tool to observe the Accelerator Pedal Position Accelerator Pedal
Position. Accelerator Pedal Position parameter should change linearly from 0% to
100% according to the accelerator pedal operation.
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Page 1304 of 6020
6E-270 Engine Control System (4JH1)
Checks Action
Engine Mechanical Check 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
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
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.
Fuel Knock/Combustion Noise
Checks Action
DEFINITION:A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with the throttle opening.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Ensure the vehicle has an actual problem.
• Inspect for smoke associated with the combustion noise.
• Inspect the fuel quality (cetane index).
• 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.
Fuel System Checks •
If excessive smoke is present, check for an injection nozzle(s).Remove each glow
plug from the cylinder head and inspect the tip of the glow plugs for wet by fuel. Use
the cylinder compression gauge. Proper compression is more than 2100 kPa (309
psi). If poor compression is observed, inspect the engine mechanical.
• 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.
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Page 1309 of 6020
Engine Control System (4JH1) 6E-275
Repair Instructions
Engine Control Module (ECM) Replacement
Engine Control Module (ECM) Replacement
Procedure
Important:
If the ECM is to be replaced the following programmed
contents MUST be reprogrammed into the new ECM. • Vehicle identification number (VIN).
• Latest software/calibrations if released. Refer to
Service Programming System (SPS) Description
and Service Programming System (SPS) (Remote
Procedure) or Service Programming System (SPS)
(Pass-Thru Procedure) in this section
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the seat left-hand side.
3. Roll up the floor carpet.
4. Remove four bolts from the ECM cover.
5. Disconnect the two connectors from the ECM.
Installation Procedure
1. Connect the two connectors to the ECM.
2. Put on the ECM to the floor panel.
3. Tighten the ECM cover by four bolts with specified tightening torque.
Tightening torque
• Bolts: 8.0 - 12.0 N.m (0.8 - 1.2 kgf.m)
4. Lay the floor carpet exactly.
5. Put on the seat to the floor panel and tighten with specified tightening torque.
Tightening torque • Bolts: 40.0 N.m (4.1 kgf.m)
6. Connect the negative battery cable.
Vehicle Identification Number (VIN) Programming
Procedure
Important: If the ECM from another vehicle is installed, VIN is no
t
programmed by the scan tool. Use the SPS to change
the original VIN. Refer to Service Programming System
(SPS) Description and Service Programming System
(SPS) (Remote Procedure) or Service Programming
System (SPS) (Pass-Thru Procedure) in this section.
Important:
If an updated software/calibrations is released, DO NOT
program the VIN now. The VIN is programmed at SPS
procedure. Refer to Service Programming System
(SPS) Description and Service Programming System
(SPS) (Remote Procedure) or Service Programming
System (SPS) (Pass-Thru Procedure) in this section.
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Page 1313 of 6020
Engine Control System (4JH1) 6E-279
Important:
Refer to Service Bulletins before service programming is
performed if the bulletins are listed along with the
calibration files.
Important:
Select Cancel if you receive a message stating that the
calibration selected is already the current calibration in
the scan tool and reprogramming with the same
download is not allowed.
14. Select Reprog.
15. The Transfer Data screen will appear until the progress bar reaches 100%.
Important:
The vehicle fitted with automatic transmission, Check
Trans lamp may blink while programming the ECM since
communication between the ECM and TCM is
interrupted. Clear DTC in any module afte
r
programming. 16. Select Close on the Programming Complete
screen.
17. Turn OFF the scan tool.
18. Disconnect the scan tool from the vehicle.
Accelerator Pedal Position (APP) Sensor
Replacement
Removal Procedure 1. Disconnect the negative battery cable.
2. Disconnect the APP sensor connector.
3. Loosen two screws and remove APP sensor from the throttle body.
Installation Procedure 1. Temporary tighten the APP sensor by two screws. 2. Connect a APP sensor connectors to the
APP
sensor.
3. Connect the Tech2 to the vehicle.
4. Connect the negative battery cable.
5. Select "Data Display" with the Tech2.
6. Check the APP sensor data and adjust the
APP
sensor.
7. Tighten two screws.
Crankshaft Position (CKP) Sensor
Replacement
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect connector from the CKP sensor.
3. Loosen a bolt and remove the CKP sensor from the clutch housing.
Installation Procedure
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified tightening torque.
Tightening Torque
• Bolts: 8.0 - 12.0 N.m (0.8 - 1.2 kgf.m)
3. Connect a CKP sensor connector to the CKP sensor.
4. Connect the negative battery cable.
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