2007 ISUZU KB P190 Electrical

6D – 28 ENGINE ELECTRICAL
BRUSH AND BRUSH HOLDER
1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)


RTW46DSH004001













RTW46DSH004101
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.





3. Inspect the brushes for excessive wear. If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.

OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise. It should turn smoothly.
3. Try to rotate the pinion in the opposite direction. The pinion should lock.
065RY00035


RTW46DSH004401
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 29
REASSEMBLY



RTW46DLF000601


Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring



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ISUZU KB P190 2007

6D – 30 ENGINE ELECTRICAL


RTW46DSH005601
Important Operations
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic switch as illustrated.
2. Insert the shift lever into the plunger hole of the magnetic switch.




RTW46DSH005701











7. Gear Case
3,8. Dust Cover 1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.

Dust Cover Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
8 (0.8/5.4)



10. Pinion Assembly
Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041



RTW46DSH004501
21. Brush Holders
1. Install the brushes into the brush holder with raising the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of the yoke and the brush holder.



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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 31






24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
8.1 (0.83/6.00)

065RY00044


RTW46DSH002601






25. Lead Wire
Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque N ⋅m (kg ⋅m/lb ⋅ft)
8.6 (0.88/6.40)







RTW46DSH005801












Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)



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ISUZU KB P190 2007

6D – 32 ENGINE ELECTRICAL


MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M ”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).





RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.




RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.




RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.




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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 33
PRE-HEATING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.

VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.



825R300046




Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94 − 114

GLOW PLUG


LNW21KSH001401
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9

EGR SYSTEM 4JA1T (L)
Refer to 6F-9. (EGR system diagram)

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ISUZU KB P190 2007

6E-32 Engine Control System (4JH1)
Breaker Box
Breaker Box Connection Type A





RTW 66ESH003601
Legend
1. Engine Control Module (ECM)
2. Harness Adapter
3. ECM - Harness Connector
4. Breaker Box
5. ECM is disconnected

Breaker Box Connection Type B




RTW 66ESH003701
Legend
1. Engine Control Module (ECM)
2. Harness Adapter
3. ECM - Harness Connector
4. Breaker Box
5. ECM is connected

Although probe to the engine control module (ECM)
harness connector is possible by Test Adapter,
Breaker Box Connection Type A is suitable usage to
prevent misprobe and damage of female terminals
when test open circuit or short to ground between the
ECM and electrical components, since the terminals
where the harness connector of the ECM is thin have
gathered.
The ECM and other connectors have water proof
terminal that is not allowed to back probe. Breaker
Box Connection Type B is suitable usage to test short
to voltage circuit or signal check between the ECM
and electrical components.


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ISUZU KB P190 2007

6E-54 Engine Control System (4JH1)
DTC
(Symptom Code) Flash
Code MIL
Status DTC Name on
scan tool Condition for
Running the DTC Condition for
Setting the DTC Possible Cause
P0243
(8) 64 ON Turbocharger
W aste gate
Solenoid Boost
Solenoid Circuit
High Voltage •
The ignition switch
is ON. •
The ECM detects
that the high
voltage condition on
the turbocharger
solenoid valve
control circuit for
longer than 3
seconds when the
solenoid valve is
commanded ON.
•
Turbocharger solenoid valve
control circuit is short to battery
or ignition voltage circuit.
• Faulty turbocharger solenoid
valve.
• Faulty ECM.

P0251 (6) 53 ON Injection Pump
Fuel Metering
Control •
The fuel injection
pump CMP sensor
signal is generated.
• The CAN
communication
between the ECM
and PCU is normal.
•
The PCU detects
that the fuel
injection solenoid
valve is operated
when the desired
fuel injection
quantity is
commanded 0
mg/strk.
•
Faulty fuel injection pump.
• Faulty PCU.


P0251 (7) 53 ON Injection Pump
Fuel Metering
Control •
The fuel injection
pump CMP sensor
signal is generated.
• The CKP sensor
signal is generated.
• The engine speed
is higher than 500
RPM.
•
The PCU detects
that the doubled
fuel injection pump
speed is lower than
engine speed by
690 RPM for longer
than 0.2 seconds.
•
Faulty CKP sensor signal.
• Faulty fuel injection pump CMP
sensor signal.
• Electrical interference.
• Magnetic interference.
• Faulty PCU.

P0251 (9) 53 ON Injection Pump
Fuel Metering
Control •
The ignition switch
is ON. •
The PCU detects
internal fuel
injection pump
control maps are
not programmed
during self-test.
•
Faulty PCU.


P0251 (A) 53 ON Injection Pump
Fuel Metering
Control •
The ignition switch
is ON. •
The PCU detects
internal EEPROM
or A/D converter is
failed during self-
test.
•
Faulty PCU.


P0251 (B) 53 ON Injection Pump
Fuel Metering
Control •
The ignition switch
is ON. •
The PCU detects
that the fuel
injection solenoid
valve drive circuit is
failed during self-
test.
•
Faulty fuel injection pump.
• Faulty PCU.


P0251 (D) 53 ON Injection Pump
Fuel Metering
Control •
The ignition switch
is ON. •
The PCU detects
that the fuel
injection solenoid
valve drive circuit
voltage level is
abnormal during
self-test.
•
Faulty fuel injection pump.
• Faulty PCU.



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ISUZU KB P190 2007