ISUZU KB P190 2007 Workshop Repair Manual

Engine Management – V6 – Diagnostics Page 6C1-2–243

B1S1 Lambda Value (Bank 1 Sensor 1) :1 (= Lambda) 1.000 1.003
B1S2 O2 Sensor (Bank 1 Sensor 2) mV 440 445
B1S2 Short Term Fuel Trim (Bank 1 Sensor 2) % 99.2% 99.2%
B2S1 O2 Sensor (Bank 2 Sensor 1) mA 0.000 0.024
B2S1 Lambda Value (Bank 2 Sensor 1) :1 (= Lambda) 1.003 0.995
B2S2 O2 Sensor (Bank 2 Sensor 2) mV 440 475
B2S2 Short Term Fuel Trim (Bank 2 Sensor 2) % 99.2 99.2
Fuel System 1 Automatic Control Loop — — —
Fuel System 2 Automatic Control Loop — — —
Calculated Load % 100.0 18.8
Engine Coolant Temperature
°C 56 90
B1 Short Term Fuel Trim (Bank 1)
% 0.0 –0.8
B1 Long Term Fuel Trim (Bank 1) % 0.0 0.0
B2 Short Term Fuel Trim (Bank 2) % 0.0 0.8
B2 Long Term Fuel Trim (Bank 2) % 0.0 0.0
Engine Speed RPM 0 588
Vehicle Speed km/h 0 0
Ignition Timing Advance for Cylinder 1
°CA 0 13
Intake Air Temperature
°C 47 32
Mass Air Flow
g/s 0.00 2.75
Absolute TP (Throttle Position) % 14.5
OBD Requirements to which Vehicle is Designed EOBD — —
Distance W hile MIL is Activated km 0 0
8.6 Actuator Tests
Fuel Pump Relay Test
This test allows the Technician to turn the fuel pump on and off.
NOTE
To avoid the possibility of engine flooding and
subsequent catalytic converter damage, Tech 2
will deactivate the fuel pump relay after 2
seconds.
Precondition: Ignition ‘On’, engine ‘Off’.
Electronic Throttle Control Test
This selection from the Tech 2 Actuator Test menu, provides two parameters; the Calculated Throttle Position and the
Desired Throttle Position. As the Technician increases or decreases the throttle opening in 10% increments, each of the
two parameters should be the same.
Preconditions: Ignition ‘On’, engine ‘Off’, vehicle speed is 0 km/h, there are no vehicle speed DTCs set and the ECM is
not performing a throttle learn procedure.
A/C Relay Test
Allows the Technician to turn the air conditioning relay ‘On’ and ‘Off’.

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Engine Management – V6 – Diagnostics Page 6C1-2–244

Precondition: Ignition ‘On’.
Cooling Fan (PWM)
Take care that no-one can access the engine
compartment during these tests!
This test allows the Technician to turn the cooling fan on in increments to its maximum speed.
Precondition: Ignition ‘On’ Air conditioning is ‘Off’..
Alternator L Terminal
This test allows the Technician to turn ‘On’ and ‘Off’, the commanded state of the voltage regulator in the alternator. ‘On’
displays a commanded state of 99%, while ‘Off’ displays a commanded state of 0%.
Precondition: Engine running.
EVAP Purge Solenoid
This test allows the Technician to control the EVAP purge solenoid valve. The normal commanded state is ‘0%’. The
system will increase or decrease the amount of purge by changing the duty cycle of the purge valve in 10% increments
within a range of 0 – 100%. The system will remain in the commanded state until cancelled by Tech 2.
NOTE
The EVAP Purge Solenoid Command parameter
may not change states when using this output
control.
Precondition: Ignition ‘On’, engine ‘Off’.
Engine Speed Control

Other DTCs may set when the Engine Speed
Control function is used. Disregard those
DTCs that set under this condition.
Allows the increase / decrease of the engine speed in 20 – 30 rpm increments from the base idle speed, up to 1,600
rpm.
NOTE
If the engine coolant temperature is below the
prescribed minimum, a message to that effect is
displayed and access to engine speed control is
blocked.
Preconditions: Engine running, engine temperature above 80 °C, transmission in Park or Neutral.

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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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Engine Management – V6 – Diagnostics Page 6C1-2–246

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: The four digit security code must be entered into Tech 2 and the theft deterrent system
must be disarmed and the ignition switched ‘On’ with a programmed remote coded key.
F2: Fuel Trim Reset : This function resets the fuel trim data values learned by the ECM.
F3: Throttle Body Relearn : In this mode, Tech 2 commands the throttle plate from its rest position to full closed
then to about 10% open. This procedure takes approximately 6 – 8 seconds. At the start of this procedure,
the Tech 2, ‘Electronic Throttle Control Learn Counter’ parameter should display ‘0’ then count up to 11, after
the procedure is completed. If the counter does not start at ‘0’, nor display a count of ‘11’ at the conclusion of
the procedure, a fault has occurred and a DTC will set.


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Engine Management – V6 – Service Operations Page 6C1-3–1

6C1-3
Engine Management – V6 – Service Operations
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.4 Warning
Caution and Notes for correct workshop practices with regard to safety and / or property damage.
1 General Information ............................................................................................................ ...................4
1.1 General Description ............................................................................................................ ................................... 4
1.2 Service Precautions and Requirements........................................................................................... .................... 4
Service Precautions............................................................................................................................................... 4
Service Requirements ........................................................................................................................................... 5
Basic Knowledge Required ....................................................................................................... ......................... 5
Basic Diagnostic Tools Required ......................................................................................................................... 6
1.3 Service Operations Not Covered In This Section................................................................................. ............... 6
Air-conditioning System........................................................................................................................................ 6
Electrical Components .......................................................................................................................................... 6
Fuel System ............................................................................................................................................................ 6
Transmission – Automatic ....................................................................................................... ............................. 7
Transmission – Manual ......................................................................................................................................... 7
1.4 Warning Caution and Notes .................................................................................................................................. 7
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 7
WARNING defined ............................................................................................................................................. 7
CAUTION defined .............................................................................................................................................. 7
NOTE defined..................................................................................................................................................... 7
2 General Service Operations ..................................................................................................... .............9
2.1 Accelerator Pedal Position Sensor .............................................................................................. ........................ 9
Remove ................................................................................................................................................................... 9
Reinstall .................................................................................................................................................................. 9
2.2 Air Cleaner Assembly ............................................................................................................................................ 9
Air Cleaner Upper Housing ...................................................................................................... ............................. 9
Remove .............................................................................................................................................................. 9
Reinstall ........................................................................................................................................................... 10
Air Cleaner Lower Housing Assembly ............................................................................................. .................. 10
Remove ............................................................................................................................................................ 10
Reinstall ........................................................................................................................................................... 11
2.3 Barometric Pressure Sensor..................................................................................................... .......................... 11
Remove ................................................................................................................................................................. 11
Reinstall ................................................................................................................................................................ 12
2.4 Camshaft Position Sensor ....................................................................................................... ........................... 12
Remove ................................................................................................................................................................. 12
Reinstall ................................................................................................................................................................ 13
2.5 Crankshaft Position Sensor ..................................................................................................... ........................... 13
Remove ................................................................................................................................................................. 13
Test ....................................................................................................................................................................... 15
Resistance Check ............................................................................................................... ............................. 15
Reinstall ................................................................................................................................................................ 15
2.6 Engine Coolant Temperature Sensor .............................................................................................. ................... 16
Remove ................................................................................................................................................................. 16
Test ....................................................................................................................................................................... 17
Resistance Check ............................................................................................................... ............................. 17
Reinstall ................................................................................................................................................................ 18
2.7 Engine Control Module.......................................................................................................... .............................. 18
Remove ................................................................................................................................................................. 19

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Engine Management – V6 – Service Operations Page 6C1-3–2

Reinstall ................................................................................................................................................................ 20
ECM Reset ...................................................................................................................... ...................................... 20
2.8 Engine Control Module Bracket Assembly......................................................................................... ............... 21
Remove ................................................................................................................................................................. 21
Reinstall ................................................................................................................................................................ 21
2.9 Engine Oil Level and Temperature Sensor ........................................................................................ ................ 22
Remove ................................................................................................................................................................. 22
Test ....................................................................................................................................................................... 23
Engine Oil Level Sensor Check .................................................................................................. ...................... 23
Reinstall ................................................................................................................................................................ 23
2.10 Engine Oil Pressure Sensor..................................................................................................... ........................... 23
Remove ................................................................................................................................................................. 23
Reinstall ................................................................................................................................................................ 24
2.11 Evaporative Emission (EVAP) Canister Purge Valve Quick Connect Fittings ................................................ 24
Disconnect..................................................................................................................... ....................................... 24
Locking Lever Type ............................................................................................................. ............................. 25
Latch Type ....................................................................................................................................................... 25
Connect ............................................................................................................................................................ 25
2.12 Evaporative Emission Canister Purge Valve ...................................................................................... ............... 26
Remove ................................................................................................................................................................. 26
Test ....................................................................................................................................................................... 27
Resistance Check ............................................................................................................... ............................. 27
Functional Test................................................................................................................................................. 27
Reinstall ................................................................................................................................................................ 28
2.13 Fuel Rail Assembly ............................................................................................................. ................................. 28
Remove ................................................................................................................................................................. 28
Disassemble ......................................................................................................................................................... 30
Fuel Injector ..................................................................................................................................................... 30
Fuel Injector Wiring Harness Assembly.......................................................................................... .................. 32
Reinstall ................................................................................................................................................................ 33
2.14 Heated Oxygen Sensor........................................................................................................... ............................. 33
Service Precautions............................................................................................................................................. 33
Six Wire Sensor................................................................................................................................................ 34
Four Wire Sensor ............................................................................................................... .............................. 35
Test ....................................................................................................................................................................... 37
Heater Resistance Check – Six Wire HO2S........................................................................................ ............. 37
Heater Resistance Check – Four Wire HO2S ....................................................................................... ........... 37
2.15 Ignition Coil .......................................................................................................................................................... 38
Ignition Coils ................................................................................................................. ....................................... 38
Remove ............................................................................................................................................................ 38
Disassemble..................................................................................................................................................... 39
Reassemble ..................................................................................................................................................... 39
Test .................................................................................................................................................................. 39
Reinstall ........................................................................................................................................................... 40
2.16 Intake Air Duct Assembly....................................................................................................... ............................. 40
Remove ................................................................................................................................................................. 40
Reinstall ................................................................................................................................................................ 40
2.17 Intake Air Temperature Sensor .................................................................................................. ......................... 41
Test ....................................................................................................................................................................... 41
Resistance Check ............................................................................................................... ............................. 41
2.18 Knock Sensor, Bank 2 (LHS)..................................................................................................... .......................... 42
Remove ................................................................................................................................................................. 42
Reinstall ................................................................................................................................................................ 43
2.19 Knock Sensor, Bank 1 (RHS) ..................................................................................................... ......................... 43
Remove ................................................................................................................................................................. 43
Reinstall ................................................................................................................................................................ 44
2.20 Mass Air Flow Sensor........................................................................................................... ............................... 45
Handling Precautions .......................................................................................................................................... 45
Remove ................................................................................................................................................................. 45
Reinstall ................................................................................................................................................................ 46

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

2.21 Schrader Valve – Fuel Pressure Gauge Connection Point............................................................................... 47
Remove ................................................................................................................................................................. 47
Reinstall ................................................................................................................................................................ 47
2.22 Spark Plugs .................................................................................................................... ...................................... 48
Service Precautions............................................................................................................ ................................. 48
Remove ................................................................................................................................................................. 48
Inspect .................................................................................................................................................................. 48
Spark Plug Inspection .......................................................................................................... ............................... 49
Poor Spark Plug Performance.................................................................................................... ...................... 49
Analysis of Spark Plug Condition ..................................................................................................................... 51
Reinstall ................................................................................................................................................................ 53
2.23 Throttle Body Assembly......................................................................................................... ............................. 53
Handling Precautions .......................................................................................................................................... 53
Remove ................................................................................................................................................................. 53
Inspect .................................................................................................................................................................. 55
Reinstall ................................................................................................................................................................ 55
3 Specifications ................................................................................................................. ......................57
4 Assembly Lubricants ............................................................................................................ ...............60
5 Torque Specifications ..........................................................................................................................61
6 Special Tools ........................................................................................................................................62


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Engine Management – V6 – Service Operations Page 6C1-3–4

1 General Information
1.1 General Description
This Section describes the correct service procedures to repair and test components of the V6 engine management
system. Emphasis is placed on the proper procedures and repair of components related to this specific system.
For component description, operation and location, refer to 6C1-1 Engine Management – V6 – General Information.
Engine cylinder identification follows the international
standard OBD II. This standard calls for the engine cylinder
bank number one to be identified by the location of cylinder
number one. Therefore the numbering for the V6 engine is:
• 1, 3, 5 – Right-hand side (Bank 1).
• 2, 4, 6 – Left-hand side (Bank 2).
The engine firing order is 1, 2, 3, 4, 5, 6.
Figure 6C1-3 – 1
1.2 Service Precautions and Requirements
Service Precautions

The following safety and precautionary
directions must be followed when servicing
the engine management system otherwise
personal injury and / or improper system
operation may occur:
• If working on a vehicle which has been subjected to an under bonnet thermal incident (fire), wear appropriate
protective clothing to prevent personal injury. Components that contain fluoro-elastomer may produce a corrosive
bi-product when subjected to extreme heat.
• Disconnection of the battery affects certain vehicle electronic systems. Refer to the battery disconnection
procedure in 6D1-3 Battery – V6 before disconnecting the battery.
• Disconnect the battery negative lead when performing the following procedures:
• disconnecting the engine control module (ECM) connectors, or
• charging the battery.
• Disconnect the battery negative lead and the ECM connectors before attempting any electric welding on the vehicle.
• Do not start the engine if the battery terminal is not properly secured to the battery.
• Do not disconnect or reconnect the following while the ignition is switched on or when the engine is running:
• any engine management system component wiring connector, or
• battery terminal leads.

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Engine Management – V6 – Service Operations Page 6C1-3–5

• Ensure the correct procedure for disconnecting and connecting engine management system wiring connectors is
always followed.
• Ensure that all wiring connectors are fitted correctly.
• The engine management system wiring connectors are designed to fit only one way; there are indexing tabs and
slots on both halves of the connector. Forcing the connector into place is not necessary if it is being installed with
the correct orientation. Failure to take care to match the indexing tabs and slots correctly can cause damage to the
connector, the module, or other vehicle components or systems.
• Never touch the connector pins of any electronic component, such as an ECM, as electrostatic discharge (ESD)
damage may result.
• W hen steam or pressure cleaning engines, do not direct the cleaning nozzle at engine management system
components.
• Never subject the ECM to temperatures less than -40 ° C and greater than 125 ° C.
• Prior to disconnection or removal of any components associated with the fuel system, clean the area around any
connection points to avoid possible contamination of the fuel system.
• A depressurised fuel system contains fuel in the fuel system and fuel lines that can be spilled during service
operations. To reduce the chance of personal injury, cover the fittings with a shop towel to absorb any fuel spillage
prior to performing the service operation. Once the service operation has been completed, place the towel in an
approved container for disposal.
• To avoid accidental fuel discharge, it is advisable to disconnect the battery and remove the fuel pump relay if the
fuel line between the fuel pump and the fuel rail is to be disconnected / open for an indefinite period.
• Always tighten fasteners to the correct tightening torque, and where indicated in the service procedure, follow the
correct tightening sequence, precautions and recommendations to prevent premature failure of the fastener or
component.
• After removing components, such as the upper or lower intake manifold, front engine pipe, heated oxygen sensor,
etc. always plug any openings to prevent dirt and other contaminants from entering.
• Do not use silicone based assembly lubricants as damage to the heated oxygen sensors may result.

Use of incorrect electrical test equipment
when performing engine management service
procedures could result in incorrect results or
component damage.
• Use only the test equipment specified in the diagnostic tables. Use of other test equipment may either give
incorrect results or damage serviceable components, refer to, 6C1-2 Engine Management – V6 – Diagnostics.
• After completing the required service operations, road test the vehicle to ensure correct engine management
system operation.
Service Requirements
Basic Knowledge Required

A lack of basic understanding of electronics,
electrical wiring circuits and use of electrical
circuit testing tools when performing certain
service procedures could result in incorrect
results or damage to components.
In addition, a general understanding of the engine management system and its component operation is essential to
prevent misdiagnosis and component damage.

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

Basic Diagnostic Tools Required

Use of incorrect electrical circuit diagnostic
tools when performing certain service
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:
• Test lamp, refer to 8A Electrical – Body and Chassis for further information.
• Digital multimeter with 10 M Ω ohms impedance, refer to 8A Electrical – Body and Chassis for further information.
• Connector test adapter kit Tool No. J35616-A.
1.3 Service Operations Not Covered In This
Section
There are situations where components and/or procedures related to the powertrain management system are covered in
other Sections of the service documentation. To aid technicians in locating the necessary service procedures for these
components and/or procedures, refer to the stated references.
Air-conditioning System
For A/C pressure switch replacement procedure, refer to 2A Heater and Air-conditioning.
Electrical Components
For the following electrical system component replacement procedures, refer to the appropriate Sections as follows:
• Extended brake pedal travel switch and stop lamp switch service operations, refer to 5C Brakes.
• Fuse and relay locations, refer to 8A Electrical-Body and Chassis.
• Cruise control switch assembly service operations, refer to 8C Cruise Control – HFV6.
• Powertrain interface module PIM removal and installation procedure, refer to 6E1 Powertrain Interface Module – V6.
• Neutral start and back-up lamp switch, refer to 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing.
• Vehicle speed sensor service operations, refer to:
− 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing
− 7B1 Manual Transmission – V6
Fuel System
For the following fuel system component replacement procedures, refer to 6C Fuel System – V6.
• Fuel system cleaning,
• Fuel system leak and pressure test,
• Fuel feed hose to fuel rail replacement,
• Fuel line quick connect fittings,
• Evaporative emission control canister,
• Fuel filter,
• Fuel hose / pipes layout,
• Fuel pump motor assembly and fuel pressure regulator assembly,
• Fuel sender assembly service operations.

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