battery ISUZU KB P190 2007 Workshop Workshop Manual

TROUBLESHOOTING 6 – 3
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions. The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1 –1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch. Does the starter switch work? —

Go to Step 2 Repair or
replace the
starter switch
2 Check the starter relay. Does the starter relay work? —

Go to Step 3 Repair or
replace the
starter relay
3 Check the magnetic switch. Does the magnetic switch work? —

Go to Step 4 Repair or
replace the magnetic switch
4 Check the pinion gear condition on the starter motor. Was the condition normal? —

Go to Step 5 Replace the
pinion gear
5 Check the brush wear or brush spring weakness. Was the condition normal? —

Replace the
starter motor assembly Repair or
replace the
brush or brush spring

1-2 Starter motor operates but engine does not turn over
Step Action Value(s) Yes No
1 Check the engine internal seizure. Was the engine seized? —

Repair or
replace seized parts Check other
DTC by Tech 2 and go to
indicated DTC


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ISUZU KB P190 2007

6 – 16 TROUBLESHOOTING
14. Battery Charging and Noise Problem
Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? —
Repair or
replace the
brush and/or the slip ring. Go to Step 3
3 Inspect the stator coil on the generator.
Was there an open circuit or the scorching on the
stator coil? —

Replace the stator coil. Go to Step 4
4 Inspect the rotor coil on the generator.
Was there an open circuit or the scorching on the
rotor coil? —

Replace the rotor coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? —
Replace the
rectifier Go to Step 6
6 Inspect the IC regulator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

14-2 Battery Overcharging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the terminal circuit.
Were the B and F terminals shorted? —
Repair the
short circuit. Go to Step 3
3 Check the regulating voltage.
Was the IC regulator voltage excessive? —
Replace the IC
regulator. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? —
Repair or
replace the
brush holder assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? —
Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? —
Repair or
replace the
brush and/or the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —

Repair the loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 19
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? —
Replace the
brush or repair the
commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty?
—

Clean contact face Go to Step 4
4 Was the pinion clutch slipped? — Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil.
Was there an open circuit or a short circuit in the
armature field coil? —
Repair or
replace the
armature field coil. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

15-2 Incorrect pinion and ring gear engagement
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken? —

Replace the wron parts. Go to Step 3
3 Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect? —
Adjust or
replace the movement parts. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 5
Engine model
Item 4JA1T (L)
4JA1TC
Cooling system
W ater pump type Centrifugal
Thermostat type W ax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage × No. of units 80D26L × 1

95D31L × 1 (OPT)
Generator capacity V-A12 – 60
12 – 80
Starter motor output V-kW12 – 2.3
Turbocharger model
Turbine type
Compressor type *IHI RHF 4H
Mixed flow type
Backward & rake

*IHI: Ishikawajima-Harima Heavy Industries., Ltd.


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ENGINE MECHANICAL 6A – 7

Engine model
Item 4JH1TC
Cooling system
W ater pump type
Thermostat type
Air cleaner type

Battery type/voltage × No. of units



Generator capacity V-A
Starter motor output V-kW
Turbocharger model Turbine type
Compressor type
Centrifugal
W ax pellet with jiggle valve
Dry paper element (except for Euro3 spec) Viscous paper element (for Euro3 spec)
80D26L × 1
95D31L × 1 (OPT)
75D26R × 2 (OPT for EC, MT)
80D26R × 2 (OPT for EC, AT)
12 – 60/12 – 80 12 – 2.3
*IHI RHF5
Mixed flow type Radial-inflow
Backward & rake type Radial-outflow
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.

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ENGINE MECHANICAL 6A – 37

REMOVAL AND INSTALLATION
Read this section carefully before performing any removal and installation procedure. This section gives
you important points as well as the order of operation. Be sure that you understand everything in this section before
you begin.


Removal

P1010011
1. Battery
1) Disconnect the battery cable and the grounding cable from the battery terminals.
2) Remove the battery clamp. Take care not to accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.



2. Engine Hood Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.



3. Supporting the Vehicle 1) Jack up the vehicle.
2) Place chassis stands at the front and the rear of the vehicle.


4. Under cover (for 4x4 model) 5. Rear propeller shaft 1) Remove the propeller shaft flange yoke at the rear differential.
2) Remove the center bearing retainer bolts.
3) Remove the propeller shaft together with the center bearing from the transmission mainshaft spline.


F06R300006 P1010002

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6B – 16 ENGINE COOLING

P1010064
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





PTW 46BSH000101
5. Remove fan guide(1), clips(2) on both sides and the bottom
lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.




RTW 36BMH000101
7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking
care not to damage the radiator core with a fan blade.


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ISUZU KB P190 2007

6B – 18 ENGINE COOLING




110RS005
• Check the rubber hoses for swelling.

Installation
1. Install radiator assembly (9) with hose, taking care not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the engine.




RTW 36BMH000101
6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.

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ISUZU KB P190 2007

6C – 2 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS
Description Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor
VE type Bosch distributor VP44 type
Governor type
Mechanical variable
(Half speed oil pressure) Electrical controled
Timer type
Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
19.1 (195) 19.0 (194) 19.5 (199) Injection nozzle designed operating
pressure MPa (kg/cm2) 1st
2nd 25.0 (255)
33.5 (328) 33.8 (331)
Main fuel filter type Disposable cartridge paper element


Precautions
When working on the fuel system, there are several things
to keep in mind:
•
Any time the fuel system is being worked on,
disconnect the negative battery cable except fo
r
those tests where battery voltage is required.
•
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O” rings. Replace if required.
•
Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.

NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.


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ISUZU KB P190 2007