SECURITY ISUZU KB P190 2007 Workshop Owner's Manual

Engine Cooling – V6 Engine Page 6B1–38

Install

Always wear protective safety glasses when
working with spring-loaded devices. Failure to
do so could result in eye injury.
1 Install the thermostat into the housing (reverse to removal procedure).
2 Ensure that the engine block and thermostat housing mating surfaces are clean and dry.
3 Install a new gasket to the thermostat housing.
4 Install the thermostat housing to the engine block and secure with the attaching bolts (with rubber grommets installed). Tighten all bolts to the correct torque specification.
Thermostat housing to engine
block bolt torque specification ..............................10 N.m
5 Ensure that the heater pipe assembly and thermostat housing mating surfaces are clean and dry.
6 Install new O-rings to the heater pipe assembly.
7 Install heater pipe assembly to thermostat housing and secure with the attaching bolts. Tighten all bolts to the correct torque specification.
Heater pipe assembly to thermostat
housing bolt torque specification ..........................10 N.m
8 Install heater pipe assembly to right-hand cylinder head bolt. Tighten bolt to the correct torque specification. Heater pipe assembly to cylinder
head bolt torque specification ..............................35 N.m

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
9 Reinstall the engine wiring harness, securing the rear harness former to the rear of the engine with the two retaining bolts, tightened to the correct torque specification.
Rear engine harness former
retaining bolts torque specification .......................15 N.m
10 Reinstall the left side engine harness former to the two locating pegs, then push inward to secure.
11 Reinstall the bolt securing the engine harness ground terminal, to the left side of the cylinder block and tighten to the correct torque specification.
Engine harness ground terminal
attaching bolt torque specification ........................12 N.m
12 Reinstall each wiring harness connector to its correct location, ensuring that all security clips are installed correctly.
13 Connect the heater hoses to the heater pipe assembly.
14 Install the coolant inlet pipe. Refer to 3.12 Coolant Inlet Pipe in this Section.
15 Close the radiator drain tap on the lower LHS of the radiator and remove the piece of rubber tubing to the tap outlet.
16 Reinstall the complete intake manifold assembly. Refer to 6A1 Engine Mechanical.
17 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

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Engine Cooling – V6 Engine Page 6B1–53

NOTE
Should the spring clip or the O-ring seal in the
quick connect fitting be damaged during the line
removal process, then the complete fitting must
be replaced.
Reinstall
1 Remove the plugs installed in the transmission cooler line and hose openings and wipe all exposed parts
with a clean shop rag.
• Smear clean automatic transmission fluid on
each cooler line end, then push into the radiator
quick connect fittings. As a security check gently
pull on the connector to ensure correct
engagement.
• As a security check, push and clip each
verification disc into place over the quick-
connect fittings. If difficulty is experienced,
repeat the installation process until the
verification disc can be clipped into place over
the radiator quick-connect fitting.

If the verifier disc does not clip into place,
the quick-connect fitting is not engaged,
rectify this before proceeding.
• Snap the outlet cooler line (4) in the clip (5) of
the radiator fan shroud
• At the transmission end, again clean the line
ends and proceed as detailed in step 2. As a
further security check ensure that each
verification disc can be pushed into place over
the quick connect fitting. If difficulty is
experienced, then the line has not been
completely installed. Remove and repeat the
installation process again until the verification
disc can be clipped into place over the
transmission quick connect fitting
• Ensure that all line clamps are fitted correctly
and that the lines and hoses are correctly routed
and free of obstructions
• Tighten the screw attaching the cooler lines
bracket to the correct torque specifications
• If required, top up the transmission fluid level
(cold)
• Start the engine and check for any fluid leak at
the fittings. If a leak is found, stop the engine
and rectify the leak
Figure 6B1 – 61

Transmission cooler lines bracket
attaching screw torque specification ..................23.0 Nm


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Engine Cooling – V6 Engine Page 6B1–56

Reinstall
Installation of the radiator is the reverse of removal procedures, noting the following points:
1 Before installing radiator, inspect core to ensure that there is no foreign matter in core fins. Clean out between core fins with compressed air, blowing from rear to front.
2 If the vehicle is fitted with an automatic transmission, remove plugs from the removed cooling pipe ends and the two quick connect fittings.
3 After wiping cooler line ends and smearing clean automatic transmission fluid over each flared line end, push into the quick connect fitting to engage. As a security check, tug on each line to ensure correct engagement.
4 Check the transmission fluid level. Refer to the following references as required:
• 7C4 Automatic Transmission
• 4L60E On-vehicle Servicing
5 Install the following hoses:
a. Lower radiator hose, securing with the hose clamp.
b. Upper radiator hose, securing with the hose clamp.
6 Install the radiator cooling fan and shroud assembly. Refer to 3.13Cooling Fan and Shroud Assembly in this Section. Ensure that electrical connectors and the transmission cooler lines are seated correctly in the integral
retainer clips before install upper radiator shroud.
7 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
8 Check for coolant leaks. Refer to 3.7 Pressure Testing in this Section.
9 Reconnect battery ground lead. Refer to 8A Electrical Body & Chassis.
10 Check cooling fan operation. Refer to 6C1-2 Engine Management Diagnostics. Also check for correct rotational direction of cooling fan.

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Engine Management – V6 – General Information Page 6C1-1–18

3.12 Immobiliser System
The vehicle incorporates an immobiliser system. After the ignition switch is turned to the ON position, and the powertrain
interface module (PIM) has authenticated the immobiliser control unit (ICU), the PIM sends an encrypted security code to
the engine control module (ECM). The ECM compares the received security code with its own security code, and if it is
valid, the ECM enables the vehicle to be started. For further information and diagnosis of the immobiliser system, refer to
11A Immobiliser.
For further information on the PIM, refer to 6E1 Powertrain Interface Module – V6.

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Engine Management – V6 – Diagnostics Page 6C1-2–57

DTC Description Diagnostic Table
P1629 Immobiliser Fuel Enable Signal Not Received 7.30 DTC P0513, P0633, P1629, P1632,
P1677, P1678 or P1679
P1632 Immobiliser Fuel Disable Signal Received 7.30 DTC P0513, P0633, P1629, P1632,
P1677, P1678 or P1679
P1648 W rong Security Code Entered 7.43 DTC P1648
P1668 Alternator L Terminal Circuit Malfunction 7.44 DTC P1668, P2500 or P2501
P1677 Immobiliser Function not Enabled 7.30 DTC P0513, P0633, P1629, P1632,
P1677, P1678 or P1679
P1678 Engine Control Module Identification Failed 7.30 DTC P0513, P0633, P1629, P1632,
P1677, P1678 or P1679
P1679 Immobiliser Environment Identification Failed 7.30 DTC P0513, P0633, P1629, P1632,
P1677, P1678 or P1679
P1845 Engine Torque Reduction Malfunction 7.45 DTC P1845
P2096 Post Catalyst O2 Sensor Fuel Trim Below Lower Limit
(Bank 1) 7.46 DTC P2096 or P2098
P2097 Post Catalyst O2 Sensor Fuel Trim Above Upper Limit
(Bank 1) 7.47 DTC P2097 or P2099
P2098 Post Catalyst O2 Sensor Fuel Trim Below Lower Limit
(Bank 2) 7.46 DTC P2096 or P2098
P2099 Post Catalyst O2 Sensor Fuel Trim Above Upper Limit
(Bank 2) 7.47 DTC P2097 or P2099
P2100 Throttle Control Motor Malfunction
7.29 DTC P0506, P0507, P0638, P1551,
P2100, P2101, P2119 or P2176
P2101 Throttle Control Position Range / Performance 7.29 DTC P0506, P0507, P0638, P1551,
P2100, P2101, P2119 or P2176
P2105 Throttle Control Forced Engine Shutdown 7.48 DTC P2105
P2107 Throttle Control Malfunction 7.49 DTC P2107
P2119 Closed Throttle Position Range / Performance 7.29 DTC P0506, P0507, P0638, P1551,
P2100, P2101, P2119 or P2176
P2122 Accelerator Pedal Position Sensor 1 Voltage Low 7.50 DTC P2122, P2123, P2127, P2128 or P2138
P2123 Accelerator Pedal Position Sensor 1 Voltage High 7.50 DTC P2122, P2123, P2127, P2128 or P2138
P2127 Accelerator Pedal Position Sensor 2 Voltage Low 7.50 DTC P2122, P2123, P2127, P2128 or P2138
P2128 Accelerator Pedal Position Sensor 2 Voltage High 7.50 DTC P2122, P2123, P2127, P2128 or P2138
P2138 Accelerator Pedal Position Sensor 1-2 Correlation 7.50 DTC P2122, P2123, P2127, P2128 or P2138
P2176 Throttle Control Lower Position not Learned 7.29 DTC P0506, P0507, P0638, P1551,
P2100, P2101, P2119 or P2176
P2177 Fuel Trim Lean during Cruising/Acceleration (Bank 1) 7.51 DTC P2177 or P2179
P2178 Fuel Trim Rich during Cruising/Acceleration (Bank 1) 7.52 DTC P2178 or P2180
P2179 Fuel Trim Lean during Cruising/Acceleration (Bank 2) 7.51 DTC P2177 or P2179
P2180 Fuel Trim Rich during Cruising/Acceleration (Bank 2 7.52 DTC P2178 or P2180
P2187 Fuel Trim Lean during Idling/Deceleration (Bank 1) 7.53 DTC P2187 or P2189
P2188 Fuel Trim Rich during Idling/Deceleration (Bank 1) 7.54 DTC P2188 or P2190

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Engine Management – V6 – Diagnostics Page 6C1-2–140

Circuit Description
The engine control module (ECM), the powertrain interface module (PIM) and the immobiliser control unit (ICU) are
integral parts of the vehicle immobiliser system. The immobiliser system authenticates the security code programmed
into each of these modules to prevent unauthorised vehicle operation. This authentication process includes the following
steps:
1 At predetermined situations, the ICU sends a security code to the PIM.
2 W hen the ignition is switched ON, the PIM receives and compares this security code from the ICU against the security code programmed into the PIM.
3 Once the PIM receives the correct security code from the ICU, it sends a security code to the ECM.
4 The ECM receives and compares this security code from the PIM against the security code programmed into the ECM.
5 The authentication process is complete once the ECM receives the correct security code from the PIM within the specified time frame.
6 The ECM allows normal vehicle operation.
NOTE
If any of these authentication processes fail, the
vehicle will not start and DTCs will set. For further
information on the immobiliser system, refer to
11A Immobiliser.
Conditions for Running the DTC
Conditions for running the DTC are:
• The ignition is switched on.
• The ignition voltage is 10.0 – 16.0 V.
Conditions for Setting the DTC
P0513
The ECM receives an incorrect response from the PIM during the immobiliser authentication process.
P0633
An attempt is made to start the engine before the immobiliser function has been programmed into a new PIM.
P1629
The ECM has not received a fuel enable password from the ICU.
P1632
The ECM receives an incorrect response from the PIM during the immobiliser authentication process.
P1677
An attempt is made to start the vehicle after the ECM was reset.
P1678
The ECM does not receive a valid response from the PIM when an attempt is made to start the engine.
P1679
The ECM receives a message from the PIM stating that it can't authenticate to the ICU.

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Engine Management – V6 – Diagnostics Page 6C1-2–165

Step Action Yes
No
10 1 Using Tech 2, clear the DTCs.
2 Switch off the ignition for 30 seconds.
3 Start the engine.
4 Operate the vehicle within the conditions for running the DTC.
Does DTC P0850 fail this ignition cycle? Go to Step 2 Go to Step 11
11 Using Tech 2, select the DTC display function.
Does Tech 2 display any DTCs? Go to the
appropriate DTC
Table in this Section System OK
When all diagnosis and repairs are completed, check the system for correct operation.
7.43 DTC P1648
DTC Descriptor
This diagnostic procedure supports DTC P1648 – W rong Security Code Entered.
Circuit Description
Tech 2 is used to program the engine control module (ECM). Before any programming, a security code must be entered
into Tech 2. The ECM will check if the code entered is correct before continuing. If the security code is incorrect, DTC
P1648 sets.
Conditions for Running the DTC
Conditions for running the DTC are:
• The ignition is switched on.
• The ignition voltage is 10.0 – 16.0 V.
Conditions for Setting the DTC
An incorrect security code is entered into Tech 2 when attempting to program the ECM.
Action Taken When the DTC Sets
W hen the DTC sets, the malfunction indicator lamp (MIL) is not displayed.
Conditions for Clearing the DTC
The immobiliser security code is a Type ‘C’ DTC. Refer to 1.4 Diagnostic Trouble Codes in this Section, for action
taken when a Type ‘C’ DTC sets and conditions for clearing Type ‘C’ DTCs.
Additional Information
• Refer to 6C1-1 Engine Management –V6 – General Information for details of the ECM operation.
• Refer to 6C1-3 Engine Management –V6 – Service Operations for details on resetting the ECM.
• Since fault condition in a wiring connector may trigger DTCs, always test the connectors related to this diagnostic
procedure for shorted terminals or poor wiring connection before replacing any component. Refer to 8A Electrical -
Body and Chassis for information on electrical fault diagnosis.
• For an intermittent fault condition, refer to 5.2 Intermittent Fault Conditions in this Section.
• To assist diagnosis, refer to 3 W iring Diagrams and Connector Charts in this Section, for the system wiring
diagram and connector charts.

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Engine Management – V6 – Diagnostics Page 6C1-2–166

Test Description
The following numbers refer to the step numbers in the diagnostic table:
4 This step tests the ECM ground circuits and supply voltage.
DTC P1648 Diagnostic Table
Step Action Yes No
1 Has the Diagnostic System Check been performed?
Go to Step 2 Refer to
4.4 Diagnostic
System Check in this Section
2 1 Switch off the ignition for 30 seconds.
2 Using Tech 2, select the DTC display function.
NOTE
Do not attempt to perform any Tech 2 function that
requires the ECM security code to be entered.
Does DTC P1648 fail this ignition cycle? Go to Step 4 Go to Step 3
3 Using Tech 2, attempt a programming function that requires the ECM
security code to be entered. Refer to 6C1-3 Engine Management –V6
– Service Operations for details on resetting the ECM.
Has the programming function been successfully performed? System OK Go to Step 4
4 1 Test all ECM ground circuits for a high resistance or an open
circuit fault condition. Refer to 8A Electrical - Body and Chassis
for information on electrical fault diagnosis.
2 Test the ECM ignition supply voltage circuit for a high resistance, open circuit or short to ground fault condition. Refer
to 8A Electrical - Body and Chassis for information on electrical
fault diagnosis.
Has any fault been found and rectified? Go to Step 6 Go to Step 5
5 Replace the ECM. Refer to 6C1-3 Engine Management –V6 – Service
Operations for details on replacing the ECM.
Has the repair been completed? Go to Step 6 —
6 1 Using Tech 2, clear the DTCs.
2 Switch off the ignition for 30 seconds.
Does DTC P1648 fail this ignition cycle? Go to Step 2 Go to Step 7
7 Using Tech 2, select the DTC display function.
Does Tech 2 display any DTCs? Go to the
appropriate DTC
Table in this Section System OK
When all diagnosis and repairs are completed, clear all DTCs and check the system for correct operation.
7.44 DTC P1668, P2500 or P2501
DTC Descriptors
This diagnostic procedure supports the following DTCs:
• DTC P1668 – Generator L Terminal Circuit Malfunction
• DTC P2500 – Generator L Terminal Low Voltage
• DTC P2501 – Generator L Terminal High Voltage

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Engine Management – V6 – Diagnostics Page 6C1-2–225

F5: EVAP Purge Solenoid
F6: Engine Speed Control
F7: Starter Relay Test
F8: Fuel Injector Balance
F5: Additional Functions
W hen this selection is made from the Tech 2 screen, an additional two choices are provided:
F0: System Identification: In this mode, Tech 2 will display the engine identification screen.
F1: Security Information: W hen selected, this mode displays various engine management data parameters relating to the security system.
F6: Programming
W ithin this selection, there are five programming selections available:
F0: Immobiliser Link to ECM/PIM
F1: Reset ECU
F2: Fuel Trim Reset
F3: Reset Engine Oil Life
F4: Throttle Body Relearn

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Engine Management – V6 – Diagnostics Page 6C1-2–245

Starter Motor Relay Test
The engine will crank and start during the
starter relay test.
Allows the Technician to turn the starter relay ‘On’, thereby activating the starter motor and cranking the engine.
Preconditions: Apply park brake, firmly apply foot brake, ignition ‘On’, engine ‘Off’, transmission in Park or Neutral.
Fuel Injector Balance
This test allows the Technician to check the fuel flow through each injector when the engine is not running. The
sequence of events are:
1 Install a fuel pressure gauge to the fuel rail.
2 Select ‘Fuel Injector Balance Test’, from the ‘Actuator Test’ menu on Tech 2
3 Activate the fuel injector balance test with Tech 2. This action activates the fuel pump and stabilises the fuel delivery system fuel pressure. The fuel pump is then turned off.
4 Note the stabilised fuel rail pressure.
5 W hen the pump is turned ‘Off’, the injector is activated for a pre-determined time.
6 The fuel pressure drop is then noted from the fuel pressure gauge.
NOTE
For a detailed procedure and analysis of fuel
injector condition, refer to 5.3 Fuel Injector
Balance Test.
8.7 Programming
F0: ICU Link to ECM/PIM : Should the ECM, PIM or ICU be replaced, the modules must be security linked to
each other. If this linking procedure is not performed, the vehicle will not crank nor run. For additional
information relating to Tech 2 and the linking procedure, refer to 11A – Immobiliser.
NOTE
After an ECU reset, the ignition switch must be
turned Off for at least 10 seconds and then
turned On for at least one minute, before
attempting communication between Tech 2 and
the ECU.
Preconditions: TIS approval (TIS 2000 Security Access) must be obtained, the four digit security number
entered into Tech 2 and the theft deterrent system disarmed. Then the ignition must be turned ‘On’, using a
programmed remote coded key.
F1: Reset ECU : This function erases the security link between the Engine Control Module (ECM) and the
Powertrain Interface Modules (PIM). If this procedure is performed, the engine will not crank nor run. A ICU
Link to ECM/PIM procedure will need to be performed. For additional information relating to the ICU Link to
ECM/PIM procedure, refer to 11A – Immobiliser.

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