ISUZU KB P190 2007 Workshop Repair Manual

Starting System – V6 Page 6D1-2–13

Step Action Yes No
16 1 Scroll to Starter Relay
2 Ensure the transmission is in park (P) or neutral (N).
3 W hile monitoring Tech 2, turn the ignition switch to START.
Does Tech 2 display the following:
Off with the ignition switch in the ON position,
On with the ignition switch in the START position?
Go to Step 18 Go to Step 17
17 1 Disconnect the ECM connector C – 56.
2 Using a multimeter set to measure voltage, back probe between the harness connector C – 56 pin 32 and ground.
3 W ith the aid of an assistant, monitor the voltage on the multimeter.
• Place the transmission in park (P), the multimeter should
display 0 V
• Place the transmission in neutral (N), the multimeter should
display 0 V
Does the multimeter display as described? Refer to 6C1 - 3
Engine
Management – V6 – Service Operations
for further diagnosis.
Go to Step 21 For vehicles fitted
with the 4 speed automatic
transmission refer
to 7C2 Automatic Transmission –
4L60E – On-vehicle Servicing for further
diagnosis of the
park / neutral and back-up switch.

Go to Step 21
18 Test the starter relay.
Refer to 6C1-2 Engine Management – V6 – Diagnostics.
Is the starter relay serviceable? Go to Step 19 Repair or replace
as required
Go to Step 21
19 1 Using a multimeter set to measure voltage, back probe between
the harness connector P – 3 pin 1 and ground.
2 W ith the aid of an assistant, monitor the voltage on the multimeter.
• Turn the ignition switch to START, the multimeter should
display 7.0 V
Does the multimeter display as described? Repair or replace
the starter motor as required.
Refer to 4
Major
Service Operations.
Go to Step 21 Go to Step 20
20 Check for short to ground or open circuit from connector P – 3 pin 1
and the starter relay connector X-13 pin 2.
W as the circuit serviceable? Go to Step 2 Repair as required
(refer to Note 2).
Go to Step 21
21 Operate the system in order to verify the repair.
Did you correct the condition? System OK Go to Step 2
When all diagnosis and repairs are completed, check the system for correct operation.

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–14

Diagnostic Table – Slow Cranking, Solenoid Clicks or Chatters
Step Action Yes No
1
Did you review 1.3 System Operation? Go to Step 2 Go to 1.3
System
Operation.
2 Did you read 2.3 Diagnostic Systems Check Go to Step 3 Go to 2.3
Diagnostic Systems Check.
3 Perform the 3.3 On-Vehicle Testing.
Did you correct the condition? Go to Step 4 Repair or replace
the starter motor.
Refer to 4
Major
Service Operations.
Go to Step 4
4 Operate the system in order to verify the repair.
Did you correct the condition? System OK Go to Step 2
When all diagnosis and repairs are completed, check the system for correct operation.

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–15

3 Minor Service Operations
3.1 Safety Precautions
Observe the following precautions. Failure to observe these precautions can result in serious damage to components.
• Refer to 1.1 W ARNING, CAUTION and NOTES in this Service Information before disconnecting the battery.
• Use the starter motor on a negative ground system only.
• W hen installing a battery, attach the positive (+) cable to the battery first. Then attach the negative cable.
• W hen using a slave battery for starting purposes, ensure that both batteries are connected in parallel, that is.
positive to positive terminals and negative to negative terminals.
• Only use jumper leads that have surge protection.
3.2 Maintenance
Regular Checks
Check the following at regular intervals:
• Starter motor terminals – for corrosion and loose connectors.
• W iring – for damaged insulation.
• Mounting bolts – for tightness.
• Battery terminals – for clean and secure connections.
3.3 On-Vehicle Testing
NOTE
The battery must be fully charged and in
serviceable condition before beginning these
tests, refer to 8A Electrical Body and Chassis.

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–16

Engine Compartment Relay And Fuse Panel


Figure 6D1-2 – 4

1 Remove fuses SBF5 and SBF9 from the engine compartment fuse panel to disable the ignition and prevent the engine from starting, refer to 8A Electrical Body and Chassis.
2 Chock the wheels.
3 For vehicles fitted with automatic transmission ensure the transmission is in P (park) or N (neutral) and the hand brake is applied.
4 Ensure the engine is at room temperature or normal operating temperature and in good working order.
Bad Connection Test
A bad connection appears as a voltage reading when the multimeter leads are connected to two different positive (or
negative) connections.
1 Using a multimeter set to measure voltage, connect the multimeter’s positive lead to the positive battery post.
2 Connect the multimeter’s negative lead to the starter motor M terminal.
3 Record the voltage that displayed during cranking.
4 Repeat this with the multimeter’s negative lead connected to the solenoid switch connector P – 4 pin B (circuit 1).
5 Also repeat this connecting the multimeter’s negative lead to the battery cable strands.
6 Restore all connections that show a significant resistance (voltage reading).

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–17

Starter Motor Ground Test
1 Using a multimeter set to measure voltage, connect
the multimeter’s positive lead (1) to the negative
battery post.

Connect the lead to the actual battery post
and not to the cable or connector.
2 Connect the multimeter’s negative lead (2) to the starter motor housing.
3 Record the voltage that displayed during cranking.
4 Repeat this connecting the multimeter’s negative lead to the battery cable strands.
5 Restore all ground connections that show a significant resistance.
Figure 6D1-2 – 5
Switching Circuit Test
1 Using a multimeter set to measure voltage, connect
the multimeter’s negative lead (1) to the solenoid
switch connector P – 3 pin 1.
2 Connect the multimeter‘s positive lead (2) to the positive battery post.
3 Crank the engine.
4 Record the voltage that displayed during cranking.
Maximum switching
circuit voltage difference.........................................2.5 V
5 If the voltage is above the specification, test the solenoid switching circuit to locate the cause of the
high resistance and restore the connection.
Figure 6D1-2 – 6

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–18

Cranking Voltage Test
1 Using a multimeter set to measure voltage, attach
the multimeter’s negative lead to ground and the
multimeter’s positive lead to starter solenoid
connector P – 3 pin 1 (3) of the solenoid switch.

Do not crank the engine for more than
30 seconds at a time. Allow 2 minutes for
the starter motor to cool down between
tests.
3 Crank the engine.
4 Record the voltage that displayed during cranking.
Minimum cranking
voltage.................................................................9.0 V
5 Remove and repair or replace the starter motor and solenoid switch if the voltage is below the
specifications and cranks poorly. Refer to 4
Major Service Operations. Figure 6D1-2 – 7

Current Draw Test
1 Using a multimeter set to measure voltage, attach the multimeter’s positive lead to the positive battery post.
2 Attach the same multimeter’s negative lead to the negative battery post.
3 Using a multimeter set to measure current, attach the multimeter’s positive lead to the battery post.
4 Connect the negative lead of the multimeter set to measure current to a battery loading device, for example a carbon pile.
5 Connect the free lead of the battery loading device to the negative battery terminal.
6 Set the battery loading device to maximum resistance (open).
7 Crank the engine.
8 Record the voltage that displayed during cranking.
9 W ith the ignition in the OFF position, adjust the battery loading device so the reading of the multimeter set to measure voltage matches the reading recorded in the last step.
10 Record the current draw from the battery loading device.
11 Set the battery loading device back to ‘open’.
12 Check the current draw is within specifications.
Cranking current range ................................ 100 – 140 A
13 Remove and repair or replace the starter motor and solenoid switch if the current draw is outside the specification. Refer to 4 Major Service Operations.

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–19

4 Major Service Operations

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 00
Warnings, Cautions and Notes before
disconnecting the battery.
4.1 Starter Motor
Remove

The starter motor is in close proximity to the
left-hand side exhaust manifold and engine
pipe. Allow the engine to cool before
attempting to remove the starter motor.
1 Refer to 1.1 W ARNING, CAUTION and NOTES in this Service Information before disconnecting the battery.
2 Disconnect the battery ground lead.
3 Raise the front of the vehicle. For jacking locations, refer to 0A General Information.
4 Put safety stands in place.
5 Fit the front lifting bracket: EN–46114 (1) to the engine, then hook the chains from the engine hoist
onto the front lifting bracket.



Figure 6D1-2 – 8


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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–20

6 Fit the rear lifting brackets: EN–46114 (1) to the
engine, then hook the chains from the engine hoist
onto the rear lifting bracket.
7 Remove the oil level indicator tube, Refer to 6A1 Engine Mechanical – V6.

Figure 6D1-2 – 9
8 Remove the left hand side knock sensor (1) from the engine block.


Figure 6D1-2 – 10
9 Remove the left hand side engine mount, then using the engine hoist raise the engine to give sufficient
clearance to remove the starter motor.
Figure 6D1-2 – 11

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–21

10 Unclip the oil level sensor harness from the heat shield
(1).
11 Remove the heat shield attaching screw (2).
12 Remove the lower starter motor attaching bolt (3).
13 Remove the heat shield.
14 Remove the upper starter motor retaining bolt (3).
15 Remove the starter motor from the engine block and lower the starter motor as far as possible to gain
access to the wiring harness connections.


Figure 6D1-2 – 12
16 Remove the wiring harness connector P – 3 (1) from the solenoid switch (2).
17 Remove the flange nut (3) and battery connector P – 4 (4) from the solenoid switch.
18 Remove the starter motor from the vehicle.

Figure 6D1-2 – 13
Reinstall
Reinstallation of the starter motor is the reverse of the removal procedure noting the following:
1 Tighten all fasteners to the correct torque specification.
Solenoid switch connector P – 4 nut (B+)
torque specification ............................................10.0 Nm
Starter motor heat shield lower bolts
torque specification ............................................23.0 Nm
Starter motor heat shield upper screw
torque specification .....................................3.0 – 5.0 Nm
Starter motor mounting bolt
torque specification ............................................45.0 Nm
Knock sensor bolt
torque specification ............................................23.0 Nm
2 Check the starter motor operates correctly.


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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–22

4.3 Starter Motor Bench Tests
Preliminary Checks
1 Check the drive assembly is fully retracted.
2 Check the drive assembly pinion turns freely on the planetary drive shaft.
3 Perform the No Load Test (as outlined in this Section) if the drive assembly is not fully retracted.
4 Disassemble and service the starter motor if it fails the No Load test, refer to 4.4 Starter Motor Disassemble and
Reassemble in this Section.
Pull-in Test
1 Clamp the starter motor, by the mounting lug in the drive-end housing, in a vice with soft jaws.
2 Remove the nut (1) and washer (2) from the solenoid switch M terminal (3).
3 Remove the braided cable (4) from the solenoid switch M terminal.
Figure 6D1-2 – 14
4 Connect the starter motor to an auxiliary battery, as follows:
a Connect the test lead (1) between the battery negative post to the solenoid switch M terminal
(3).
b Connect the test lead (2) battery positive post.
5 Momentarily hold the free end of test lead (2) to solenoid switch terminal P – 3.
6 Check the solenoid switch activates and the drive assembly moves outward.
7 Disassemble and service the starter motor if the solenoid switch activates but the drive assembly
does not move, refer to 4.4 Starter Motor
Disassemble and Reassemble in this Section.
8 Replace the solenoid switch if it does not activate (there is no sound or movement).
Figure 6D1-2 – 15

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ISUZU KB P190 2007