2007 ISUZU KB P190 Workshop Repair Manual

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Page 3521 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Diagnostics Page 6C1-2–243

B1S1 Lambda Value (Bank 1 Sensor 1) :1 (= Lambda) 1.000 1.003
B1S2 O2 Sensor (Bank 1 Sensor 2) mV 440 445
B1S2 Short Term Fuel Trim (Ba

Engine Management – V6 – Diagnostics Page 6C1-2–243

B1S1 Lambda Value (Bank 1 Sensor 1) :1 (= Lambda) 1.000 1.003
B1S2 O2 Sensor (Bank 1 Sensor 2) mV 440 445
B1S2 Short Term Fuel Trim (Bank 1 Sensor 2) % 99.2% 99.2%
B2S1 O2 Sensor (Bank 2 Sensor 1) mA 0.000 0.024
B2S1 Lambda Value (Bank 2 Sensor 1) :1 (= Lambda) 1.003 0.995
B2S2 O2 Sensor (Bank 2 Sensor 2) mV 440 475
B2S2 Short Term Fuel Trim (Bank 2 Sensor 2) % 99.2 99.2
Fuel System 1 Automatic Control Loop — — —
Fuel System 2 Automatic Control Loop — — —
Calculated Load % 100.0 18.8
Engine Coolant Temperature
°C 56 90
B1 Short Term Fuel Trim (Bank 1)
% 0.0 –0.8
B1 Long Term Fuel Trim (Bank 1) % 0.0 0.0
B2 Short Term Fuel Trim (Bank 2) % 0.0 0.8
B2 Long Term Fuel Trim (Bank 2) % 0.0 0.0
Engine Speed RPM 0 588
Vehicle Speed km/h 0 0
Ignition Timing Advance for Cylinder 1
°CA 0 13
Intake Air Temperature
°C 47 32
Mass Air Flow
g/s 0.00 2.75
Absolute TP (Throttle Position) % 14.5
OBD Requirements to which Vehicle is Designed EOBD — —
Distance W hile MIL is Activated km 0 0
8.6 Actuator Tests
Fuel Pump Relay Test
This test allows the Technician to turn the fuel pump on and off.
NOTE
To avoid the possibility of engine flooding and
subsequent catalytic converter damage, Tech 2
will deactivate the fuel pump relay after 2
seconds.
Precondition: Ignition ‘On’, engine ‘Off’.
Electronic Throttle Control Test
This selection from the Tech 2 Actuator Test menu, provides two parameters; the Calculated Throttle Position and the
Desired Throttle Position. As the Technician increases or decreases the throttle opening in 10% increments, each of the
two parameters should be the same.
Preconditions: Ignition ‘On’, engine ‘Off’, vehicle speed is 0 km/h, there are no vehicle speed DTCs set and the ECM is
not performing a throttle learn procedure.
A/C Relay Test
Allows the Technician to turn the air conditioning relay ‘On’ and ‘Off’.

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Page 3522 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Diagnostics Page 6C1-2–244

Precondition: Ignition ‘On’.
Cooling Fan (PWM)
Take care that no-one can access the engine
compartment during these tests!
This te

Page 3523 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Diagnostics Page 6C1-2–245

Starter Motor Relay Test
The engine will crank and start during the
starter relay test.
Allows the Technician to turn the starter relay

Engine Management – V6 – Diagnostics Page 6C1-2–245

Starter Motor Relay Test
The engine will crank and start during the
starter relay test.
Allows the Technician to turn the starter relay ‘On’, thereby activating the starter motor and cranking the engine.
Preconditions: Apply park brake, firmly apply foot brake, ignition ‘On’, engine ‘Off’, transmission in Park or Neutral.
Fuel Injector Balance
This test allows the Technician to check the fuel flow through each injector when the engine is not running. The
sequence of events are:
1 Install a fuel pressure gauge to the fuel rail.
2 Select ‘Fuel Injector Balance Test’, from the ‘Actuator Test’ menu on Tech 2
3 Activate the fuel injector balance test with Tech 2. This action activates the fuel pump and stabilises the fuel delivery system fuel pressure. The fuel pump is then turned off.
4 Note the stabilised fuel rail pressure.
5 W hen the pump is turned ‘Off’, the injector is activated for a pre-determined time.
6 The fuel pressure drop is then noted from the fuel pressure gauge.
NOTE
For a detailed procedure and analysis of fuel
injector condition, refer to 5.3 Fuel Injector
Balance Test.
8.7 Programming
F0: ICU Link to ECM/PIM : Should the ECM, PIM or ICU be replaced, the modules must be security linked to
each other. If this linking procedure is not performed, the vehicle will not crank nor run. For additional
information relating to Tech 2 and the linking procedure, refer to 11A – Immobiliser.
NOTE
After an ECU reset, the ignition switch must be
turned Off for at least 10 seconds and then
turned On for at least one minute, before
attempting communication between Tech 2 and
the ECU.
Preconditions: TIS approval (TIS 2000 Security Access) must be obtained, the four digit security number
entered into Tech 2 and the theft deterrent system disarmed. Then the ignition must be turned ‘On’, using a
programmed remote coded key.
F1: Reset ECU : This function erases the security link between the Engine Control Module (ECM) and the
Powertrain Interface Modules (PIM). If this procedure is performed, the engine will not crank nor run. A ICU
Link to ECM/PIM procedure will need to be performed. For additional information relating to the ICU Link to
ECM/PIM procedure, refer to 11A – Immobiliser.

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Page 3524 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Diagnostics Page 6C1-2–246

NOTE
After an ECU reset, the ignition switch must be
turned Off for at least 10 seconds and then
turned On for at least one minute, bef

Page 3525 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Service Operations Page 6C1-3–1

6C1-3
Engine Management – V6 – Service Operations
ATTENTION
Before performing any service operation or other procedure describe

Engine Management – V6 – Service Operations Page 6C1-3–1

6C1-3
Engine Management – V6 – Service Operations
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.4 Warning
Caution and Notes for correct workshop practices with regard to safety and / or property damage.
1 General Information ............................................................................................................ ...................4
1.1 General Description ............................................................................................................ ................................... 4
1.2 Service Precautions and Requirements........................................................................................... .................... 4
Service Precautions............................................................................................................................................... 4
Service Requirements ........................................................................................................................................... 5
Basic Knowledge Required ....................................................................................................... ......................... 5
Basic Diagnostic Tools Required ......................................................................................................................... 6
1.3 Service Operations Not Covered In This Section................................................................................. ............... 6
Air-conditioning System........................................................................................................................................ 6
Electrical Components .......................................................................................................................................... 6
Fuel System ............................................................................................................................................................ 6
Transmission – Automatic ....................................................................................................... ............................. 7
Transmission – Manual ......................................................................................................................................... 7
1.4 Warning Caution and Notes .................................................................................................................................. 7
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 7
WARNING defined ............................................................................................................................................. 7
CAUTION defined .............................................................................................................................................. 7
NOTE defined..................................................................................................................................................... 7
2 General Service Operations ..................................................................................................... .............9
2.1 Accelerator Pedal Position Sensor .............................................................................................. ........................ 9
Remove ................................................................................................................................................................... 9
Reinstall .................................................................................................................................................................. 9
2.2 Air Cleaner Assembly ............................................................................................................................................ 9
Air Cleaner Upper Housing ...................................................................................................... ............................. 9
Remove .............................................................................................................................................................. 9
Reinstall ........................................................................................................................................................... 10
Air Cleaner Lower Housing Assembly ............................................................................................. .................. 10
Remove ............................................................................................................................................................ 10
Reinstall ........................................................................................................................................................... 11
2.3 Barometric Pressure Sensor..................................................................................................... .......................... 11
Remove ................................................................................................................................................................. 11
Reinstall ................................................................................................................................................................ 12
2.4 Camshaft Position Sensor ....................................................................................................... ........................... 12
Remove ................................................................................................................................................................. 12
Reinstall ................................................................................................................................................................ 13
2.5 Crankshaft Position Sensor ..................................................................................................... ........................... 13
Remove ................................................................................................................................................................. 13
Test ....................................................................................................................................................................... 15
Resistance Check ............................................................................................................... ............................. 15
Reinstall ................................................................................................................................................................ 15
2.6 Engine Coolant Temperature Sensor .............................................................................................. ................... 16
Remove ................................................................................................................................................................. 16
Test ....................................................................................................................................................................... 17
Resistance Check ............................................................................................................... ............................. 17
Reinstall ................................................................................................................................................................ 18
2.7 Engine Control Module.......................................................................................................... .............................. 18
Remove ................................................................................................................................................................. 19

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Page 3526 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Service Operations Page 6C1-3–2

Reinstall ............................................................................................................................

Engine Management – V6 – Service Operations Page 6C1-3–2

Reinstall ................................................................................................................................................................ 20
ECM Reset ...................................................................................................................... ...................................... 20
2.8 Engine Control Module Bracket Assembly......................................................................................... ............... 21
Remove ................................................................................................................................................................. 21
Reinstall ................................................................................................................................................................ 21
2.9 Engine Oil Level and Temperature Sensor ........................................................................................ ................ 22
Remove ................................................................................................................................................................. 22
Test ....................................................................................................................................................................... 23
Engine Oil Level Sensor Check .................................................................................................. ...................... 23
Reinstall ................................................................................................................................................................ 23
2.10 Engine Oil Pressure Sensor..................................................................................................... ........................... 23
Remove ................................................................................................................................................................. 23
Reinstall ................................................................................................................................................................ 24
2.11 Evaporative Emission (EVAP) Canister Purge Valve Quick Connect Fittings ................................................ 24
Disconnect..................................................................................................................... ....................................... 24
Locking Lever Type ............................................................................................................. ............................. 25
Latch Type ....................................................................................................................................................... 25
Connect ............................................................................................................................................................ 25
2.12 Evaporative Emission Canister Purge Valve ...................................................................................... ............... 26
Remove ................................................................................................................................................................. 26
Test ....................................................................................................................................................................... 27
Resistance Check ............................................................................................................... ............................. 27
Functional Test................................................................................................................................................. 27
Reinstall ................................................................................................................................................................ 28
2.13 Fuel Rail Assembly ............................................................................................................. ................................. 28
Remove ................................................................................................................................................................. 28
Disassemble ......................................................................................................................................................... 30
Fuel Injector ..................................................................................................................................................... 30
Fuel Injector Wiring Harness Assembly.......................................................................................... .................. 32
Reinstall ................................................................................................................................................................ 33
2.14 Heated Oxygen Sensor........................................................................................................... ............................. 33
Service Precautions............................................................................................................................................. 33
Six Wire Sensor................................................................................................................................................ 34
Four Wire Sensor ............................................................................................................... .............................. 35
Test ....................................................................................................................................................................... 37
Heater Resistance Check – Six Wire HO2S........................................................................................ ............. 37
Heater Resistance Check – Four Wire HO2S ....................................................................................... ........... 37
2.15 Ignition Coil .......................................................................................................................................................... 38
Ignition Coils ................................................................................................................. ....................................... 38
Remove ............................................................................................................................................................ 38
Disassemble..................................................................................................................................................... 39
Reassemble ..................................................................................................................................................... 39
Test .................................................................................................................................................................. 39
Reinstall ........................................................................................................................................................... 40
2.16 Intake Air Duct Assembly....................................................................................................... ............................. 40
Remove ................................................................................................................................................................. 40
Reinstall ................................................................................................................................................................ 40
2.17 Intake Air Temperature Sensor .................................................................................................. ......................... 41
Test ....................................................................................................................................................................... 41
Resistance Check ............................................................................................................... ............................. 41
2.18 Knock Sensor, Bank 2 (LHS)..................................................................................................... .......................... 42
Remove ................................................................................................................................................................. 42
Reinstall ................................................................................................................................................................ 43
2.19 Knock Sensor, Bank 1 (RHS) ..................................................................................................... ......................... 43
Remove ................................................................................................................................................................. 43
Reinstall ................................................................................................................................................................ 44
2.20 Mass Air Flow Sensor........................................................................................................... ............................... 45
Handling Precautions .......................................................................................................................................... 45
Remove ................................................................................................................................................................. 45
Reinstall ................................................................................................................................................................ 46

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Page 3527 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Service Operations Page 6C1-3–3

2.21 Schrader Valve – Fuel Pressure Gauge Connection Point..........................................................................

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

2.21 Schrader Valve – Fuel Pressure Gauge Connection Point............................................................................... 47
Remove ................................................................................................................................................................. 47
Reinstall ................................................................................................................................................................ 47
2.22 Spark Plugs .................................................................................................................... ...................................... 48
Service Precautions............................................................................................................ ................................. 48
Remove ................................................................................................................................................................. 48
Inspect .................................................................................................................................................................. 48
Spark Plug Inspection .......................................................................................................... ............................... 49
Poor Spark Plug Performance.................................................................................................... ...................... 49
Analysis of Spark Plug Condition ..................................................................................................................... 51
Reinstall ................................................................................................................................................................ 53
2.23 Throttle Body Assembly......................................................................................................... ............................. 53
Handling Precautions .......................................................................................................................................... 53
Remove ................................................................................................................................................................. 53
Inspect .................................................................................................................................................................. 55
Reinstall ................................................................................................................................................................ 55
3 Specifications ................................................................................................................. ......................57
4 Assembly Lubricants ............................................................................................................ ...............60
5 Torque Specifications ..........................................................................................................................61
6 Special Tools ........................................................................................................................................62

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Page 3528 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Management – V6 – Service Operations Page 6C1-3–4

1 General Information
1.1 General Description
This Section describes the correct service procedures to repair and test components of

Engine Management – V6 – Service Operations Page 6C1-3–4

1 General Information
1.1 General Description
This Section describes the correct service procedures to repair and test components of the V6 engine management
system. Emphasis is placed on the proper procedures and repair of components related to this specific system.
For component description, operation and location, refer to 6C1-1 Engine Management – V6 – General Information.
Engine cylinder identification follows the international
standard OBD II. This standard calls for the engine cylinder
bank number one to be identified by the location of cylinder
number one. Therefore the numbering for the V6 engine is:
• 1, 3, 5 – Right-hand side (Bank 1).
• 2, 4, 6 – Left-hand side (Bank 2).
The engine firing order is 1, 2, 3, 4, 5, 6.
Figure 6C1-3 – 1
1.2 Service Precautions and Requirements
Service Precautions

The following safety and precautionary
directions must be followed when servicing
the engine management system otherwise
personal injury and / or improper system
operation may occur:
• If working on a vehicle which has been subjected to an under bonnet thermal incident (fire), wear appropriate
protective clothing to prevent personal injury. Components that contain fluoro-elastomer may produce a corrosive
bi-product when subjected to extreme heat.
• Disconnection of the battery affects certain vehicle electronic systems. Refer to the battery disconnection
procedure in 6D1-3 Battery – V6 before disconnecting the battery.
• Disconnect the battery negative lead when performing the following procedures:
• disconnecting the engine control module (ECM) connectors, or
• charging the battery.
• Disconnect the battery negative lead and the ECM connectors before attempting any electric welding on the vehicle.
• Do not start the engine if the battery terminal is not properly secured to the battery.
• Do not disconnect or reconnect the following while the ignition is switched on or when the engine is running:
• any engine management system component wiring connector, or
• battery terminal leads.

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