engine 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 1028 of 6020
ENGINE ELECTRICAL 6D – 27
RTW46DSH003701
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two commutator segments.
2 Repear Step 1 at different segments of the armature core.
There should be continuity between all segments of the commutator.
If there is not, the armature must be replaced.
RTW46DSH003801
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field winding end or brush.
2 Hold the other circuit tester probe against the bare surface of the yoke body.
There should be no continuity. If there is continuity, the field coil is grounded.
The yoke must be replaced.
RTW46DSH003901
2. Use the circuit tester to check the field winding
continuity.
1 Hold one circuit tester probe against the “M ”
terminal lead wire.
2 Hold the other circuit tester probe against the field winding brush.
There should be continuity. If there is no continuity, the yoke must be replaced.
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Page 1029 of 6020
6D – 28 ENGINE ELECTRICAL
BRUSH AND BRUSH HOLDER
1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)
RTW46DSH004001
RTW46DSH004101
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.
3. Inspect the brushes for excessive wear. If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.
OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise. It should turn smoothly.
3. Try to rotate the pinion in the opposite direction. The pinion should lock.
065RY00035
RTW46DSH004401
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
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Page 1030 of 6020
ENGINE ELECTRICAL 6D – 29
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring
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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 1033 of 6020
6D – 32 ENGINE ELECTRICAL
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M ”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.
RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.
RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
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Page 1034 of 6020
ENGINE ELECTRICAL 6D – 33
PRE-HEATING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.
VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.
825R300046
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94 − 114
GLOW PLUG
LNW21KSH001401
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9
EGR SYSTEM 4JA1T (L)
Refer to 6F-9. (EGR system diagram)
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Page 1035 of 6020
Engine Control System (4JH1) 6E-1
SECTION 6E
ENGINE CONTROL SYSTEM (4JH1)
TABLE OF CONTENTS
Specifications ..................................................... 6E-4
Schematic And Routing Diagrams ..................... 6E-5 Vacuum Hose Routing Diagram...................... 6E-5
Engine Controls Schematics ........................... 6E-7
Component Locator ............................................ 6E-18 Engine Controls Component Views ................ 6E-18
Engine Control Module (ECM) Connector
End Views ...................................................... 6E-22
Engine Control Connector End Views ............. 6E-25
Diagnostic Information And Prosedures............. 6E-30 Engine Control System Check Sheet .............. 6E-30
Diagnostic Starting Point - Engine Controls .... 6E-31
Breaker Box .................................................... 6E-32
Diagnostic System Check - Engine Controls .. 6E-33
Scan Tool Data List ......................................... 6E-36
Scan Tool Data Definitions.............................. 6E-37
Scan Tool Output Controls .............................. 6E-40
Scan Tool Does Not Power Up ....................... 6E-41
Scan Tool Does Not Communicate with Keyword
2000 Device ................................................... 6E-42
Lost Communication with The Engine Control
Module (ECM) ............................................... 6E-44
Engine Cranks but Does Not Run ................... 6E-47
Diagnostic Trouble Code (DTC) List ............... 6E-50
DTC P0100 (Symptom Code 7)
(Flash Code 65) ............................................. 6E-66
DTC P0100 (Symptom Code 9)
(Flash Code 65) ............................................ 6E-68
DTC P0100 (Symptom Code B)
(Flash Code 65) ............................................ 6E-70
DTC P0100 (Symptom Code C)
(Flash Code 65) ............................................ 6E-73
DTC P0105 (Symptom Code 1)
(Flash Code 34) ............................................ 6E-75
DTC P0105 (Symptom Code 2)
(Flash Code 34) ............................................ 6E-78
DTC P0105 (Symptom Code 7)
(Flash Code 34) ............................................ 6E-81
DTC P0105 (Symptom Code 9)
(Flash Code 34) ............................................ 6E-83
DTC P0110 (Symptom Code 1)
(Flash Code 23) ............................................ 6E-85
DTC P0110 (Symptom Code 2)
(Flash Code 23) ............................................ 6E-88
DTC P0115 (Symptom Code 1)
(Flash Code 14) ............................................ 6E-90
DTC P0115 (Symptom Code 2)
(Flash Code 14) ............................................ 6E-93
DTC P0180 (Symptom Code B)
(Flash Code 15) ............................................ 6E-95
DTC P0215 (Symptom Code A)
(Flash Code 52............................................... 6E-96
DTC P0215 (Symptom Code B)
(Flash Code 52) ............................................ 6E-98
DTC P0215 (Symptom Code C)
(Flash Code 52) ............................................ 6E-100
DTC P0215 (Symptom Code D)
(Flash Code 52) ............................................ 6E-102
DTC P0216 (Symptom Code A,B)
(Flash Code 54) ............................................ 6E-103
DTC P0243 (Symptom Code 3)
(Flash Code 64) ............................................ 6E-107
DTC P0243 (Symptom Code 4)
(Flash Code 64) ............................................ 6E-111
DTC P0243 (Symptom Code 5)
(Flash Code 64) ............................................. 6E-114
DTC P0243 (Symptom Code 6)
(Flash Code 64) ............................................. 6E-118
DTC P0243 (Symptom Code 8)
(Flash Code 65) ............................................. 6E-121
DTC P0251 (Symptom Code 6)
(Flash Code 53) ............................................ 6E-123
DTC P0251 (Symptom Code 7)
(Flash Code 53) ............................................ 6E-125
DTC P0251 (Symptom Code 9, A, B, C)
(Flash Code 53) ............................................ 6E-127
DTC P0251 (Symptom Code E)
(Flash Code 53) ............................................ 6E-129
DTC P0335 (Symptom Code B, D)
(Flash Code 43) ............................................ 6E-130
DTC P0335 (Symptom Code E)
(Flash Code 43) ............................................. 6E-134
DTC P0380 (Symptom Code 4)
(Flash Code 66) ............................................ 6E-136
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Page 1036 of 6020
6E-2 Engine Control System (4JH1)
DTC P0380 (Symptom Code 8)
(Flash Code 66) ............................................6E-139
DTC P0381 (Symptom Code 4)
(Flash Code 67) ............................................6E-141
DTC P0381 (Symptom Code 8)
(Flash Code 67) ............................................6E-144
DTC P0400 (Symptom Code 3)
(Flash Code 32) ............................................6E-146
DTC P0400 (Symptom Code 4)
(Flash Code 32) ............................................6E-149
DTC P0400 (Symptom Code 5)
(Flash Code 32) ............................................6E-152
DTC P0400 (Symptom Code 8)
(Flash Code 32) ............................................6E-155
DTC P0500 (Symptom Code 1, A)
(Flash Code 24) ............................................6E-157
DTC P0500 (Symptom Code B)
(Flash Code 24) ............................................6E-160
DTC P0560 (Symptom Code 1)
(Flash Code 35) ............................................6E-166
DTC P0560 (Symptom Code 2)
(Flash Code 35) ............................................6E-167
DTC P0560 (Symptom Code A)
(Flash Code 35) ............................................6E-169
DTC P0561 (Symptom Code A)
(Flash Code 18) ............................................6E-171
DTC P0561 (Symptom Code B)
(Flash Code 18) ............................................6E-173
DTC P0602 .....................................................6E-174
DTC P0606 (Symptom Code A, B)
(Flash Code 28) ............................................6E-175
DTC P0645 (Symptom Code 4)
(Flash Code 46) ............................................6E-176
DTC P0645 (Symptom Code 8)
(Flash Code 46) ............................................6E-179
DTC P0703 (Symptom Code A, B)
(Flash Code 25) ............................................6E-181
DTC P0704 (Symptom Code 6)
(Flash Code 57) ............................................6E-185
DTC P1105 (Symptom Code 1)
(Flash Code 86) ............................................6E-188
DTC P1105 (Symptom Code 2)
(Flash Code 86) ............................................6E-189
DTC P1120 (Symptom Code 1)
(Flash Code 21) ............................................6E-190
DTC P1120 (Symptom Code 7)
(Flash Code 21) ............................................6E-193
DTC P1120 (Symptom Code 9)
(Flash Code 21) ............................................6E-195
DTC P1120 (Symptom Code D)
(Flash Code 21) ............................................ 6E-197
DTC P1120 (Symptom Code E)
(Flash Code 21) ............................................ 6E-200
DTC P1173 (Symptom Code 3)
(Flash Code 22) ............................................ 6E-204
DTC P1173 (Symptom Code 7, A)
(Flash Code 22) ............................................ 6E-206
DTC P1335 (Symptom Code A)
(Flash Code 43) ............................................ 6E-207
DTC P1345 (Symptom Code A)
(Flash Code 41) ............................................ 6E-209
DTC P1520 (Symptom Code A)
(Flash Code 47) ............................................ 6E-210
DTC P1520 (Symptom Code B)
(Flash Code 47) ............................................ 6E-213
DTC P1605 (Symptom Code C, D, E)
(Flash Code 55) ............................................ 6E-216
DTC P1610 (Symptom Code A)
(Flash Code 56) ............................................ 6E-217
DTC P1611 (Symptom Code A)
(Flash Code 56) ............................................ 6E-218
DTC P1612 (Symptom Code A)
(Flash Code 56) ............................................ 6E-219
DTC P1613 (Symptom Code A)
(Flash Code 56) ............................................ 6E-220
DTC P1614 (Symptom Code A)
(Flash Code 56) ............................................ 6E-221
DTC P1625 (Symptom Code A)
(Flash Code 76) ............................................ 6E-222
DTC P1625 (Symptom Code B)
(Flash Code 76) ............................................ 6E-224
DTC P1630 (Symptom Code A, B)
(Flash Code 51) ............................................ 6E-226
DTC P1650 (Symptom Code A)
(Flash Code 44) ............................................ 6E-227
DTC P1650 (Symptom Code B)
(Flash Code 44) ............................................ 6E-230
DTC P1651 (Symptom Code A, B)
(Flash Code 45) ............................................ 6E-231
DTC P1690 (Symptom Code 4)
(Flash Code 77) ............................................ 6E-234
DTC P1690 (Symptom Code 8)
(Flash Code 77) ............................................ 6E-237
Glow Control System Check ........................... 6E-239
A/C Compressor System Check ..................... 6E-242
Symptoms - Engine Controls ............................. 6E-255 Symptoms - Engine Controls .......................... 6E-255
Intermittent Conditions .................................... 6E-256
Hard Start ........................................................ 6E-258
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Page 1037 of 6020
Engine Control System (4JH1) 6E-3
Rough, Unstable, or In co rr ect Idle And
Stallin g........................................................... .6E -260
Cut Out, Mi sses.............................................. .6E -262
Su rge s/Chuggle s............................................ .6E -263
La ck of Po wer, Sluggi shne ss, Spongine ss .... .6E -266
He sitation, Sag, Stu mble................................ .6E -268
Fuel Kno ck /Co mbu stion Noi se ....................... .6E -270
Poor F uel E cono my........................................ .6E -271
E xc ess ive S moke (B la ck S m oke) ................. .6E -272
E xc ess ive S moke (W hite S moke) ................. .6E -273
Repair In str u ctions ............................................ .6E -275
Engine Control Module (ECM) Replacement ..6E-275
Service Programming System (SPS)
Description .....................................................6E-276
Service Programming System (SPS)
(Remote Procedure) ......................................6E-277
Service Programming System (SPS)
(Pass-Thru Procedure) ..................................6E-278
Accelerator Pedal Position (APP) Sensor
Replacement ..................................................6E-279
Crankshaft Position Sensor (CKP) Sensor
Replacement ..................................................6E-279
EGR Solenoid Valve Replacement .................6E-280
Engine Coolant Temperature Coolant
(ECT) Sensor Replacement ...........................6E-280
Mass Air Flow (MAF) / Intake Air Temperature
Sensor Replacement......................................6E-280
Turbocharger Solenoid Valve Replacement
[High Altitude Spec] ........................................6E-281
Vacuum Pressure Sensor Replacement
[High Altitude Spec] ........................................6E-281
Vehicle Speed Sensor (VSS) Replacement ....6E-282
Description And Operation .................................6E-283 Engine Control Module (ECM) .......................6E-283
Engine Control Component Description ..........6E-284
Fuel Injection System Description ...................6E-288
Low Pressure Fuel Circuit Description ............6E-290
High Pressure Fuel Circuit Description ...........6E-291
Timing Control Device Description ..................6E-294
Exhaust Gas Recirculation (EGR) System
Description .....................................................6E-297
Turbocharger Description................................6E-298
Special Tools And Equipment ............................6E-299 Special Tools and Equipment .........................6E-299
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