torque ISUZU KB P190 2007 Workshop Repair Manual

ENGINE FUEL (C24SE) 6C-15
Filler Neck
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck
assembly is restored.
• Each joint area of the hose (to restore axial
direction and insertion length of the hose)
• Each fasten area of the clamp (to restore axial
direction and position of the clamp)
• Each bolt in the clamp (to restore fasten length
of bolt in the clamp)
• The band clip (to restore position and fasten
length of the band clip)
NOTE: Cover end of each hose and pipe to prevent an
y
dust entering.
Installation
1.
Align each marking and restore the following point.
• Each joint area of the hose (Restore axial
direction and insertion length of the hose)
• Each fasten area of the clamp (Restore axial
direction and position of the clamp)
• Each bolt in the clamp (Restore fasten length o
f
bolt in the clamp)
Torque: 2.5 N ･
･･
･
m (0.25 kg ･
･･
･
m / 2 lb ft) … filler neck
side except flat deck model. • The band clip (Restore position and fasten
length of the band clip)
2. Install the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.


Fuel Gauge Unit
Removal and Installation
As for removal and installation of the Fuel Gauge Unit,
refer to “Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sende
r
assembly.


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ISUZU KB P190 2007

ENGINE FUEL (C24SE) 6C-17
Main Data and Specifications
Torque Specification
N⋅
⋅⋅
⋅
m (kg ⋅
⋅⋅
⋅
m/ lb ft)



RTW 46CLF000601


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6D1-2 ENGINE ELECTRICAL

Battery
General Description
There are six battery fluid caps on top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small vent
holes on the side. These vent holes permit the escape of small
amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire service life
of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive charge, resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge than a conventional type battery.



Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


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ISUZU KB P190 2007

6D2-2 IGNITION SYSTEM



General Description
Ignition is done by the Ignition Module that fires.
Since the cylinder on exhaust stroke requires less energy to
fire its spark plug, energy from the ignition coils can be utilized
to fire the mating cylinder on compression stroke.
A notch in the timing disc on the crankshaft activates the crank
angle sensor which then sends information such as firing order
and starting timing of ignition coil to the ECM.
By receiving signals such as crank position, engine speed,
water temperature and Manifold Absolute Pressure (MAP), the
ECM controls the ignition timing.




Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.



Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to
electronic ignition system (El system).





Ignition Coil
Removal
1. Disconnect battery ground cable.
2. Disconnect the Ignition coil connector.
3. Remove the ignition coil.



Installation
1. Install the ignition coil.
Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque.
Torque: 20 N ⋅m (2.0 kgf ⋅m)
2. Connect battery ground cable.


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6D2-4 IGNITION SYSTEM


Cleaning Spark Plugs
• Clean spark plugs with a spark plug cleaner.
• Raise the ground electrode to an angle of 45 to 60 degrees.
if electrode is wet, dry it gefore cleaning.
•
After spark plug is thoroughly cleaned, check insulator for
presence of cracks.




• Clean threads and metal body with a wire brush.
• File the electrode tip if electrode is extremely worn.
• Bend the ground electrode to adjust the spark plug gap.



Installation
1. Spark plugs
• Tighten spark plugs to the specified torque.
Torque: 20 N ⋅m (2.0 kgf ⋅m)












Crankshaft Angle Sensor
Removal
1. Disconnect battery ground cable
2. Disconnect the wiring connector from crankshaft angle sensor.
3. Remove crankshaft angle sensor from cylinder block.
Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation, apply small amount of engine oil to the O-ring.
Torque: 6 N ⋅m (0.6 kgf ⋅m)
2. Reconnect wiring connector to crankshaft angle sensor.



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IGNITION SYSTEM 6D2-5
Main Data and Specifications General Specifications
Ignition System
Ignition Form Electronic Ignition System (El system) with Crankshaft angle Sensor
Spark Plug
Type
No. of Coils and Type Coil Location Torque Electronic Spark Control
2 Solid State
Engine-mounted
20 N ⋅m (2.0 kgf ⋅m)


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6D3-2 STARTING AND CHARGING SYSTEM


Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion shaft.
W hen the starter switch is turned on, the contacts of magnetic
switch are closed, and the armature rotates. At the same time,
the plunger is attracted, and the pinion is pushed forward by
the shift lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. W hen the engine
starts and the starter switch is turned off, the plunger returns,
the pinion is disengaged from the ring gear, and the armature
stops rotation. W hen the engine speed is higher than the
pinion, the pinion idles, so that the armature is not driven.




Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.

Diagnosis
Condition Possible cause Correction
Starter does not run Charging failure Repair charging system
Battery Failure Replace Battery
Terminal connection failure Repair or replace terminal connector
and/or wiring harness
Starter switch failure Repair or replace starter switch
Starter failure Repair or replace starter


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ISUZU KB P190 2007

STARTING AND CHARGING SYSTEM 6D3-3


Starter
Removal
1. Remove the battery ground cable.
2. Remove harness connectors (1) and (2).


3. Remove bolts from starter.


Installation
1. Install starter assembly.
2. Install mounting bolts and tighten bolts to specified torque.
Torque: 51 N ⋅
⋅⋅
⋅
m (5.2 kgf ⋅
⋅⋅
⋅
m)
3. Connect harness.
4. Reconnect the battery ground cable.


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STARTING AND CHARGING SYSTEM 6D3-9



Generator Power
1. Adjust load resistor, if the required load currents are not attained.
2. The shape of the voltage curves on oscilloscope curve should be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not attained, o
r
if the oscilloscope picture shows variations, the alternator
should be overhauled.

Regulated Voltage Circuit Diagram

Legend
1 Battery
2 Ignition Lock
3 Charge Telltale
4 Resistor, for attainment of load current with the battery set in series
5 Voltmeter
6 Ammeter
7 Generator




Installation
1. Install generator assembly and bring generator assembly to the position to be installed.
2. Install generator assembly and tighten to the specified torque.
Torque:
Long bolt: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m)
Short bolt: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m)
3. Connect wiring harness connector.
4. Move drive belt tensioner to loose side using a wrench, then install drive belt to normal position.
5. Reconnect battery ground cable.


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6D3-18 STARTING AND CHARGING SYSTEM
Reassembly
Generator
(a) Press new bearing onto slipring end of the rotor taking care to aplly the force to the bearing inner race only, otherwise
the bearing will be noisy and it's life will be shortened.
(b) Fit a new bearing to the drive end housing, fit the bearing plate, and four retaining screws, press the rotor into the
bearing, using a support tool to take the thrust against the
bearing inner.
The support is fitted from the pulley side of the bearing. In this way the thrust is not taken by the drive end housing.
(c) To fit pulley, mount an 8mm Allen key in the vice with the short end upwards, place a 24mm ring spanner on the shaft
nut, position the internal hexagon of the rotor shaft onto the
Allen key, tighten the nut to the required torque(See torque
chart)
(d) Inspect the bearing support ring for signs of damage, if in doubt replace the ring by pressing it into the housing b
y
hand, do not use excessive force.
(e) To refit the rectifier, fit new mica washers to the positive heatsink B+ bolt and retaining screw each washer must
have heatsink compound applied to both surfaces before
fitting.
Fit the three retaining screws to the rectifier then install into slipring end housing. Tighten the B+ bolt to the reuired
torque.
(f) To refit the stator, make sure the spigot surface are clean and free from damage, fit the stator into the slipring end
housing noting the correct lead connection positioning. Fit
the stator leads into the wire loops in the recrifier. Using a
pair of pliers squeeze the loop to retain the stator lead prior
to soldering. Repeat for each lead in turn, solder the leads
into position using 60/40 resin cored solder. Make sure the
leads will be clear of the internal fan when the rotor is
assmebled into the stator.
(g) Carefully install the rotor into the stator/slipring end housing assembly, noting the alignment of the housings and through
bolt holes. Fit the through bolts making sure the stator is
seated correctly, tighten the through bolts to the correct
torque setting (uneven torque can produce magnetic noise
levels above normal).
(h) Fitting the regulator. Compress the brushes into the brush holder by hand, slip the regulator through the opening in the
rear of the slipring end housing until the brushes come in
contact with the slipring. Press the regulator towards the
slipring until the holes are aligned then fit the retaining
screws and tighten.



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