2007 ISUZU KB P190 engine

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 – 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump
Step Action Value(s) Yes No
1 Check clogged, damaged the fuel piping or the
connector loosen.
Was any problem found? —

Repair replace problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved

Incase of the fuel is being delivered to the injection pump
Step Action Value(s) Yes No
1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 5 Bleed the air
3 Was the injection spray condition complete? —
Go to Step 4 Replace the
injection nozzle
4 Was the injection nozzle injection starting pressure OK? (See below)
Go to Step 5 Replace the
injection nozzle
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction found? (Include radiator cap) —
Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the fan
clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the fan
clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump assembly.
8 Was the restriction by the foreign materials in the cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. —
Clean or
replace the clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? —
Replace the
sealing cap or replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 2 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve and relation parts.
2 Was the PCV (Positive Crankcase Ventilation) valve working completely? —

Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

6 – 12 TROUBLESHOOTING
10. Abnormal Engine Noise
10–1 Engine knocking
Step Action Value(s) Yes No
1 Was the injection nozzle pressure or injection spray
pattern OK? —

Go to Step 2 Replace the
injection nozzle
2 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm Go to Step 3 Replace the
cylinder head gasket or
piston ring
3 Are any DTC stored? — Go to indicated
DTC Solved

10–2 Gas leakage noise
Step Action Value(s) Yes No
1 Was the exhaust pipe loose or broken? — Retighten or
replace the
exhaust pipe Go to Step 2
2 Was the exhaust manifold loose? —
Retighten or
replace the exhaust
manifold. Or replace the exhaust
manifold gasket Go to Step 3
3 Was the injection nozzle loose? — Retighten or
replace the
injection nozzle fixing bolt Go to Step 4
4 Was the cylinder head gasket broken? — Replace the
cylinder head gasket Go to Step 5
5 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the turbocharger? —

Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? —
Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged? — Replace the
damaged gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? —
Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? —
Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? —
Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? —
Repair or
replace the oil feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? —
Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/ 10W –30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? —
Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved


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6 – 18 TROUBLESHOOTING
14-5 Charging System Noise Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and
decreasing engine speed? —

Replace the bearing. Go to Step 3
3 Was there a growling sound and does this sound
stop when the connector was disconnected? —
Replace the
stator coil. Go to Step 4
4 Was intermittent sound heard when the generator
was running? —
Replace the
brush and/or slip ring. Go to Step 5
5 Was frictional sound heard when generator was
running? —
Clean the slip
ring or replace the brush. Go to Step 6
6 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

SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
4 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing ...................................................................................................................... .. 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6 A - 24
Lubricating System.................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 2 7
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ..................................................................... 6A - 32
General Description ...................................................................................................... 6A- 3 6
Removal and Installation .............................................................................................. 6A- 37 Removal ...................................................................................................................... 6 A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment ......................................................................................... 6A- 41
Engine Warm-Up .................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A - 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6 A- 43
External Parts ......................................................................................................... 6A- 43
E N GINE MECHA NICA L 6A – 1
Main Dat a and Specif ications ....................................................................................... 6A -
Torque Specif ications ................................................................................................... 6A -

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