start ISUZU KB P190 2007 Workshop Repair Manual

Engine Management – V6 – Service Operations Page 6C1-3–47

2.21 Schrader Valve – Fuel Pressure Gauge
Connection Point

If the Schrader valve is to be removed but not
replaced immediately, it is advisable to
disconnect the battery to avoid possible fuel
discharge if an accidental attempt is made to
start the engine.
Disconnection of the battery affects vehicle
electronic systems. Refer to 6D1-3 Battery –
V6 before disconnecting the battery.
Remove
1 Depressurise the fuel system, refer to 6C Fuel System - V6.
2 Turn the ignition off.

A small amount of fuel may be released when
servicing the fuel pressure test point. To
reduce the chance of personal injury, cover
the fuel pressure test point with a shop towel
to absorb any fuel spillage when the Schrader
valve sealing cap and Schrader valve are
removed. After the procedure, place the towel
in an approved container for disposal.
3 Remove the Schrader valve sealing cap (1).
4 Remove the Schrader valve (2) using a standard valve core removal tool.
Figure 6C1-3 – 65
Reinstall
Reinstallation of the Schrader valve is the reverse of the removal procedure, noting the following:
1 Inspect the fuel rail and quick connect fitting for leaks, refer to 6C Fuel System - V6.
2 Road test the vehicle and check for correct operation.

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Engine Management – V6 – Service Operations Page 6C1-3–49

1 Replace any plug that has cracked and / or broken insulation or loose electrodes.
2 Inspect the spark plugs for defects. Refer to Analysis of Spark Plug Condition in this Section for identification of the condition of spark plugs.
3 Ensure the threads are clean and in good order.
4 Use a round wire feeler gauge to check the spark plug gap. If the gap is not within specifications, replace the
spark plug.
Spark plug gap ........................................... 1.1 – 1.2 mm
Figure 6C1-3 – 68
Spark Plug Inspection
Poor Spark Plug Performance
A spark plug can perform poorly due to wear, dirt, carbon fouling, excessive electrode wear, a broken insulator or
excessive gap.
Worn or Dirty Plugs
W orn or dirty plugs can give satisfactory operation while the vehicle is idling, but break down under load.
This can cause:
• poor fuel economy,
• power loss,
• acceleration loss,
• difficult starting, or
• poor engine performance.
Carbon Fouling
Carbon fouling is indicated by black carbon deposits. The black deposits are usually the result of slow-speed driving and
short runs. In these circumstances, the optimum engine operating temperature is seldom reached.
Fouling can also be caused by:
• worn piston rings,
• faulty ignition,
• rich fuel mixture, or
• spark plugs that are rated too cold.
Excessive Electrode Wear
This often indicates:
• the engine is operating at high speeds,
• the engine is operating at levels that are consistently greater than normal,
• a plug that is rated too hot,
• excessively lean fuel mixture, or

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Engine Management – V6 – Service Operations Page 6C1-3–53

Reinstall
Reinstallation of the spark plug is the reverse of the removal procedure, noting the following:

• Discard the spark plug if it has been
dropped.
• Do not use anti-seize compound or similar
lubricant on the spark plug threads.
1 Using a suitably sized rubber tube attached to the spark plug terminal post, hand start each spark plug into the cylinder head thread.

Failure to tighten a spark plug to the correct
torque specification may result in premature
spark plug failure, and / or engine damage.
2 Tighten the spark plug/s to the correct torque specification. Spark plug torque specification ...............16.0 – 20.0 Nm
3 Road test the vehicle and check for correct operation.
2.23 Throttle Body Assembly
Handling Precautions

Under no circumstances should the clip (1),
six places, retaining the cover plate (2) to the
throttle body be removed. If the cover is
removed, the vacuum seal between the cover
plate and the throttle body will be broken.
This will allow the ingress of foreign particles
and / or moisture and render the throttle body
unserviceable
The throttle body must not be subjected to
any form of shock such as dropping it. If the
throttle body is subjected to shock, damage
may result to the fragile motor magnets
within the throttle body.
Figure 6C1-3 – 70
Remove
1 Turn the ignition switch off.

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Charging System – V6 Page 6D1-1-10

3 Minor Service Operations
3.1 Safety Precautions
Observe the following precautions. Failure to observe these precautions will result in serious damage to the generator.
• Only use the generator and voltage regulator in a negative ground system.
• Always refer to 1.2 W ARNING, CAUTION and NOTES before disconnecting the battery.
• W hen installing a battery, fit the positive (+) cable to the battery before fitting the negative cable.
• W hen a slave battery is used for starting purposes, ensure that both batteries are connected in parallel. That is,
positive terminals connected and negative terminals connected.
• Only use jumper leads that have surge protection.
• Disconnect both battery cables when charging the battery. This isolates the generator from the battery and from
the external charging equipment.
• Do not operate the generator within an open circuit or without a battery in the circuit.
• Do not disconnect the battery while the generator is running.
• Do not attempt to polarise the generator.
• Do not connect generator connector E-4 pin 1 to 12 V (the battery or ignition circuits).
• Some battery powered timing lights can produce high transient voltages when connected or disconnected.
Only disconnect or connect timing lights when the engine is switched off.

Ensure the generator connector E-4 pin 1 has
a maximum sinking current of 50mA.
3.2 Maintenance
Regular Checks
Check the following at regular intervals:
• generator terminals – for corrosion and loose connections,
• wiring – for continuity and damaged insulation,
• mounting bolts – for tightness,
• drive belt – for alignment and wear, and
• drive pulley – for damage and warping.
NOTE
The drive-belt adjustment for the engine
ancillaries (i.e. generator and water pump) is
provided by a spring-loaded tensioner. Therefore,
the drive belt does not require manual
adjustment.
Lubrication
High tolerance bearings are used in this generator. If the bearings are removed during the generator disassembly, new
bearings must be installed to restore the generator to original specification. The ball bearings supporting the rotor shaft
are pre-lubricated and sealed. Do not attempt to lubricate these during servicing.

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Charging System – V6 Page 6D1-1-12


7 Reconnect the battery ground cable P-5.
8 Fit a loading device (7) across the battery terminals, e.g. an adjustable carbon pile.

The loading device must have a minimum
power consumption of 1000 W.
9 Record the voltage reading before starting the engine. (This reading should increase when the engine is running, indicating generator output.).
10 Start the engine.
11 Increase the engine speed to the value outlined in the chart below.
12 Using the reading from the multimeter set to measure current, adjust the loading device to apply a load within the range outlined in the chart below.
13 Using the multimeter set to measure voltage, check the generator output voltage against the specification.
Engine RPM ........................................................... 1300
Load ................................................................ 5.0 – 10 A
Output Voltage ........................................... 13.8 – 15.4 V

Load Regulation Test
NOTE
The decrease in the voltage recorded during this
test should not exceed 0.5 V from the readings
obtained for the Regulating Voltage Test. If the
decrease in the regulating voltage is greater than
0.5 V, the regulator is defective. Replace the
regulator.
14 Increase the engine speed to the value outlined in the chart below.
15 Using the reading from the multimeter set to measure current, adjust the loading device to apply a load of about 90% of the generator’s full output.
16 Using the multimeter set to measure voltage, check the generator output voltage against the specification.
Engine RPM............................................................ 1900
Load ......................................................................... 90 A
Output Voltage ........................................... 13.8 – 15.4 V
Full Load Output Test

Keep the time for this test to a minimum to
avoid undue heating and high engine speeds.
17 Increase the engine speed to the value outlined in the chart below .
18 Using the reading from the multimeter set to measure voltage, adjust the loading device to increase the load until the generator output voltage drops to 13.5 V. Full generator output, outlined in the chart below, is required.
19 Record the current reading displayed on the multimeter set to measure current.

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Charging System – V6 Page 6D1-1-13

20 Reduce the engine speed to idle.

On completion of the generator output test,
return the engine to idle and disconnect the
loading device from the battery terminals.
This prevents excessive battery discharge.
21 Stop the engine.
22 Disconnect the battery ground cable P-5 at the battery.
23 Remove the multimeters.
24 Reconnect the generator positive lead P-9.
25 Reconnect the battery ground cable P-5 to the battery.
Engine RPM............................................................ 1900
Load ................................................................ 5.0 – 10 A
Output Voltage ........................................... 13.8 – 15.4 V
Charging Circuit Voltage Drop Test
Prerequisites
Before testing the generator output, ensure that:
• all generator circuit connections are clean and tight,
• the generator is always connected to the battery during testing (to prevent damage to the diodes),
• the battery is fully charged, and
• the specific gravity does not vary more than 0.025 between cells. (It is recommended the average specific gravity
is 1.260 or higher). Refer to 6D1-3 Battery – V6.
Carry out a load test on the battery to determine its ability to supply and accept current. This is a good indicator of the
general condition of the battery. For details of battery testing, refer to 6D1-3 Battery – V6.
Inspect the drive belt and tensioner markings to determine if the drive belt is within operating limits. Replace the belt if it
is excessively worn or outside the operating range of the tensioner.
For further details, refer to 6A1 Engine Mechanical – V6.
Voltage Drop Test

Ensure the generator connections are clean
and tight.
1 Connect the positive lead of a multimeter set to measure voltage to the generator terminal P-9.
2 Connect the negative lead of the multimeter to the battery positive post.
3 Switch the headlamps on.
4 Start the engine.
5 Increase the engine speed to approximately 2500 r.p.m.
6 Record the voltage reading.
7 Reduce the engine speed to idle.

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Charging System – V6 Page 6D1-1-16


Reinstall
Reinstallation of the generator is the reverse of the removal procedure, noting the following:
1 Tighten all fasteners to the correct torque specification.
2 Reconnect the battery ground lead.
3 Start the engine.
4 Check the generator warning indicator operation.
5 Check the drive belt is correctly routed and aligned.
6 Check the generator output. Refer to 3.3 On-vehicle Testing.
7 Check the voltage regulator operation. Refer to 3.3 On-vehicle Testing.
8 Turn the ignition switch off.
Generator mounting bolts ........................... (1) 58.0 Nm
Generator mounting bolts ........................... (2) 58.0 Nm
Generator mounting bolts ........................... (4) 58.0 Nm
Battery harness to P-9 pin B nut
torque specification ...................................7.1 – 13.3 Nm

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Starting System – V6 Page 6D1-2–1

6D1-2
Starting System – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.1
WARNING, CAUTION and NOTES for correct workshop practices with regard to safety and/or property
damage.
1 General Information ............................................................................................................ ...................3
1.1 WARNING, CAUTION and NOTES .................................................................................................... ................... 3
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 3
WARNING defined ............................................................................................................................................. 3
CAUTION defined .............................................................................................................................................. 3
NOTE defined..................................................................................................................................................... 3
1.2 Components .......................................................................................................................................................... 4
Starting System Components ............................................................................................................................... 4
Starter Motor and Solenoid Switch Components................................................................................... ............. 4
Solenoid Switch.................................................................................................................................................. 4
Planetary Drive Train.......................................................................................................... ................................ 4
Armature ............................................................................................................................................................ 4
Brushes .............................................................................................................................................................. 4
1.3 System Operation .................................................................................................................................................. 5
Operation ...................................................................................................................... ..................................... 5
Sequence of Operation .......................................................................................................... ............................ 6
2 Diagnostics .............................................................................................................................................7
2.1 Diagnostic General Information............................................................................................................................ 7
Basic Diagnostic Tools Required ......................................................................................................................... 7
2.2 Tech 2 Data List ............................................................................................................... ...................................... 7
2.3 Diagnostic Systems Check ....................................................................................................... ............................ 7
2.4 Wiring Diagram ...................................................................................................................................................... 8
2.5 Starting System Inoperative / Malfunctioning ................................................................................... ................ 10
Circuit Description ............................................................................................................................................ 10
Diagnostic Table Notes ......................................................................................................... ........................... 10
Diagnostic Table............................................................................................................................................... 10
Diagnostic Table – Slow Cranking, Solenoid Clicks or Chatters.................................................................. ..... 14
3 Minor Service Operations ....................................................................................................................15
3.1 Safety Precautions............................................................................................................................................... 15
3.2 Maintenance ......................................................................................................................................................... 15
Regular Checks ................................................................................................................. ................................... 15
3.3 On-Vehicle Testing ............................................................................................................. ................................. 15
Engine Compartment Relay And Fuse Panel ........................................................................................ ........... 16
Bad Connection Test ........................................................................................................................................ 16
Starter Motor Ground Test ...................................................................................................... ......................... 17
Switching Circuit Test ....................................................................................................................................... 17
Cranking Voltage Test .......................................................................................................... ............................ 18
Current Draw Test ............................................................................................................................................ 18
4 Major Service Operations ....................................................................................................................19
4.1 Starter Motor ........................................................................................................................................................ 19
Remove ................................................................................................................................................................. 19

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Starting System – V6 Page 6D1-2–2

Reinstall ................................................................................................................................................................ 21
4.3 Starter Motor Bench Tests ...................................................................................................... ............................ 22
Preliminary Checks.............................................................................................................................................. 22
Pull-in Test............................................................................................................................................................ 22
Hold-in Test ................................................................................................................... ....................................... 23
Drive Assembly Return Test ..................................................................................................... .......................... 23
No Load Test ........................................................................................................................................................ 24
4.4 Starter Motor Disassemble and Reassemble ....................................................................................... ............. 25
Disassemble ......................................................................................................................................................... 25
Reassemble .......................................................................................................................................................... 26
4.5 Solenoid Switch Tests ......................................................................................................................................... 26
Test the Solenoid Switch .................................................................................................................................. 26
5 Specifications .......................................................................................................................................30
6 Torque Wrench Specifications................................................................................................... .........31
7 Special Tools ........................................................................................................................................32

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Starting System – V6 Page 6D1-2–3

1 General Information
All HFV6 engines are fitted with a Mitsubishi starter motor. This consists of a solenoid switch on a DC motor. The motor
has permanent magnet excitation, which has the advantage of low weight a with high output torque and is visually
identifiable by the absence of pole-shoe retaining screws.
The starter motor does not have field coil windings or pole shoes. These parts have been replaced by six permanent
magnets that are held in the pole housing by clips. The positive brushes are now part of the brush plate assembly.
The solenoid switch is the only component of the starter motor assembly that is serviced separately. If any other parts
require replacement, the starter motor must be replaced.
1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:

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