ISUZU KB P190 2007 Workshop Repair Manual

Engine Management – V6 – Service Operations Page 6C1-3–27

Test

To prevent component damage:
• Use connector test adaptor kit J 35616-A.
• When applying 12 V to a component,
always use a 3 A fused wire.
Resistance Check
1 Using a digital ohmmeter and connector test adaptor
kit J 35616-A, measure the resistance across
terminals 1 and 2.
2 Compare the reading against the specification.
3 If the resistance is not within specification, replace the EVAP canister purge valve.
EVAP canister purge valve
resistance @ 20°C .................................... 24.0 – 28.0 Ω
Figure 6C1-3 – 29
Functional Test
1 Attempt to blow air through the EVAP canister purge
valve inlet port (1). If air passes through the valve, the
valve is faulty and should be replaced.
Figure 6C1-3 – 30

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Engine Management – V6 – Service Operations Page 6C1-3–28

2 Using connector test adaptor kit J 35616-A, connect a
12 V battery, an on / off switch and a 3 A fused wire to
the EVAP canister purge valve terminals as follows:
• Positive lead to terminal 1.
• Negative lead to terminal 2.

Figure 6C1-3 – 31

Do not apply 12 V to the EVAP canister purge
valve continuously for more than three
seconds as the EVAP canister purge valve
will be damaged.
3 Turn the switch on, and listen for an audible click as the EVAP canister purge valve operates. W hilst the switch is in the on position, blow air through the inlet port.
4 If no air passes through the EVAP canister purge valve, check the valve inlet and outlet ports for any obstructions and rectify if necessary. If there are no obstructions, replace the valve.
Reinstall
Reinstallation of the evaporative emission canister purge valve is the reverse of the removal procedure, noting the
following:
1 Connect the purge valve hose quick connect fittings, refer to 2.11 Evaporative Emission (EVAP) Canister Purge Valve Quick Connect Fittings.
2 Road test the vehicle and check for correct operation, taking particular note that no air leaks are evident.
2.13 Fuel Rail Assembly

A depressurised fuel system contains
residual fuel that can be spilled during service
operations, refer to 6C Fuel System – V6 for
further information on handling fuel.
Remove
1 Depressurise the fuel system, refer to 6C Fuel System - V6.
2 Turn the ignition switch off.

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Engine Management – V6 – Service Operations Page 6C1-3–29

NOTE
After removing the upper intake manifold, plug
the lower manifold opening to prevent dirt and
other contaminants from entering.
3 Remove the upper intake manifold assembly, refer to 6A1 Engine Mechanical – V6.
4 Disconnect the fuel feed hose from the fuel rail, refer to 6C Fuel System - V6. Plug the fuel line openings to prevent dirt and other contaminants from entering.
5 Slide the engine wiring harness connector retaining latch (1) in the direction of the arrow to disconnect the
connector from the fuel injector harness.

Figure 6C1-3 – 32

Clean around the area where the fuel
injectors enter the lower intake manifold.
6 Remove the bolt (1), three places, attaching the fuel rail to the lower intake manifold.

Care must be taken when removing the fuel
rail and injector assembly to prevent damage
to the injector spray tips and injector harness
connector terminals.
Support the fuel rail and injector assembly
after removal.
7 Remove the fuel rail and injector assembly.
8 Plug all fuel line and manifold openings after removal to prevent dirt and other contaminants from entering.
Figure 6C1-3 – 33

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Engine Management – V6 – Service Operations Page 6C1-3–30

Disassemble
Fuel Injector
Remove
For each fuel injector:
1 Slide the fuel injector wiring connector locking tab (1) upwards in the direction of the arrow.
2 Disconnect the connector from the fuel injector.
Figure 6C1-3 – 34
3 Using a flat blade screwdriver, remove the fuel injector retaining clip (1) from the fuel injector (2). Discard the
retaining clip.

Figure 6C1-3 – 35

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Engine Management – V6 – Service Operations Page 6C1-3–31

4 Remove the fuel injector (1) from the fuel rail.
5 Remove and discard the fuel injector seals (2).
6
As required, repeat for the remaining injectors and test
each fuel injector, refer to the Test in this Section.
Figure 6C1-3 – 36
Test

To prevent component damage use connector
test adaptor kit J 35616-A.
1 Connect a digital ohmmeter using connector test adaptor kit J 35616-A to the fuel injector.
2 Measure the resistance across terminals A and B.
3 Compare the reading against the specification.
Fuel injector resistance @ 20°C ............... 11.4 – 12.6 Ω
4 If the resistance is not within specifications, replace
the fuel injector.
Figure 6C1-3 – 37
Reinstall
Reinstallation of the fuel injector is the reverse of the removal procedure, noting the following:
1 Install new fuel injector seals and lubricate with clean engine oil.
2 Install a new fuel injector retaining clip, refer to Figure 6C1-3 – 35.

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Engine Management – V6 – Service Operations Page 6C1-3–32

Fuel Injector Wiring Harness Assembly
Remove
1 For each fuel injector wiring harness connector, slide
the locking tab (1) upwards in the direction of the
arrow and disconnect the connector from the fuel
injector.
Figure 6C1-3 – 38
2 Unclip the fuel injector harness assembly (1), three places, from the fuel rail.
Figure 6C1-3 – 39
3 Using a flat blade screwdriver, prise the fuel injector harness upper tray retainer (1), eight places, from the
lower tray locking tang (2).
4 Remove the fuel injector harness from the lower tray.
Figure 6C1-3 – 40

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Engine Management – V6 – Service Operations Page 6C1-3–33

Reinstall
Reinstallation of the fuel injector wiring harness assembly is the reverse of the removal procedure, noting the following:

Ensure there is no undue strain placed on the
fuel injector wiring harness (1) once it has
been positioned in the tray (2).
1 Lay the fuel injector wiring harness in the lower tray.
2 Clip the upper and lower fuel injector harness trays together, ensuring that all eight retainers are correctly
seated.
Figure 6C1-3 – 41
Reinstall
Reinstallation of the fuel rail assembly is the reverse of the removal procedure, noting the following:
1 Lubricate the fuel injector O-rings with engine oil.
2 Carefully reinstall the fuel rail and injector assembly.

Ensure the fuel injectors are correctly seated
in the lower intake manifold, and the fuel rail
attaching brackets are correctly located prior
to tightening the attaching bolts.
3 Reinstall the fuel rail attaching bolts and tighten to the correct torque specification. Fuel rail attaching bolt
torque specification ..................................8.0 – 12.0 Nm
4 Reconnect the fuel feed hose to the fuel rail, refer to 6C Fuel System - V6.
5 Inspect the fuel rail and quick connect fitting for leaks, refer to 6C Fuel System - V6.
6 Road test the vehicle and check for correct operation.
2.14 Heated Oxygen Sensor

To avoid the possibility of personal injury,
allow the exhaust pipe to cool to ambient
temperature (less than 50 °
°°
°
C) before
attempting to remove the oxygen sensor.
Service Precautions
• Handle the HO2S carefully. Do not drop it, and keep it free of grease, dirt and other contaminants. Do not use
cleaning solvents of any type on the HO2S.
• Do not repair the HO2S or any of its parts. Replace the HO2S if any damage is evident.
• The HO2S may be difficult to remove when the engine is cold. Excessive force may damage the threads in the
exhaust manifold or exhaust pipe.

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Engine Management – V6 – Service Operations Page 6C1-3–34

• If the HO2S has been removed, but not replaced, anti-seize compound must be applied to the threads prior to
installation. New HO2S will already have the anti-seize compound applied.
• For vehicles with the six wire HO2S sensor, under no
circumstances should the protective cover (1) be
removed, or the gortex filter (2) be covered and / or
sealed.
Figure 6C1-3 – 42
Six Wire Sensor
The replacement procedure for Bank 1 and Bank 2 six wire heated oxygen sensor (HO2S) are typically the same, with
the following procedure being specific to Bank 1.
Remove
1 Turn the ignition switch off.
2 Unclip the HO2S wiring harness connector assembly (1) from the ignition coil wiring harness tray, refer to Figure 6C1-3 – 43. View A refers to Bank 1, and View B refers to Bank 2.
3 Slide the connector locking tang (2) away from the harness connector.
4 Separate the harness connector (3).

Figure 6C1-3 – 43
5 Raise the front of the vehicle and support on safety stands. Refer to 0A General Information for location of the jacking points.

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Engine Management – V6 – Service Operations Page 6C1-3–35

6 Unscrew the HO2S (1) from the exhaust pipe and
remove.
7 If required, test the HO2S, refer to the Test in this Section.

Figure 6C1-3 – 44
Reinstall
Reinstallation of the heated oxygen sensor (HO2S) is the reverse of the removal procedure, noting the following:
1 Ensure the protective cover (1) is securely in place, and the gortex filter (2) has not been covered or
sealed.
Figure 6C1-3 – 45

A special anti-seize compound is used on the
HO2S threads. A new HO2S will already have
the anti-seize compound applied to the
threads.
If a HO2S has been removed, but not replaced,
an anti-seize compound must be applied to
the threads prior to installation.
2 Coat the cleaned threads of the HO2S with anti-seize compound.
3 Tighten the HO2S to the correct torque specification.
Heated oxygen sensor
torque specification .................................40.0 – 50.0 Nm
4 Road test the vehicle and check for correct operation, taking particular note that no exhaust leakage is evident.
Four Wire Sensor
The replacement procedure for Bank 1 (RHS) and Bank 2 (LHS) four wire heated oxygen sensor (HO2S) are typically the
same, with the following procedure being specific to Bank 2.

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Engine Management – V6 – Service Operations Page 6C1-3–36

Remove
1 Turn the ignition switch off.
2 Raise the vehicle and support on safety stands, refer to 0A General Information for location of the jacking points.
3 Unclip the HO2S wiring harness (1) from the transmission.
4 Depress the harness connector retaining clip (2) and separate the harness connectors.
5 Unscrew the HO2S (3) from the exhaust pipe and remove.
6 If required, test the HO2S, refer to the Test in this Section.
Figure 6C1-3 – 46
Reinstall
Reinstallation of the heated oxygen sensor (HO2S) is the reverse of the removal procedure, noting the following:

A special anti-seize compound is used on the
HO2S threads. A new HO2S will already have
the anti-seize compound applied to the
threads.
If a HO2S has been removed, but not replaced,
then anti-seize compound must be applied to
the threads prior to installation.
1 Coat the cleaned threads of the sensor with anti-seize compound.
2 Tighten the HO2S to the correct torque specification.
Heated oxygen sensor
torque specification .................................40.0 – 50.0 Nm
3 Road test the vehicle and check for correct operation, taking particular note that no exhaust leakage is evident.

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