2007 ISUZU KB P190 torque

Charging System – V6 Page 6D1-1-17

4.2 Generator Mounting Bracket
Remove
1 Remove the idler pulley bolt (7) then the idler pulley (6), Refer to 4.1 Generator.
2 Remove the bolts (1, 2, 3 ,4); five places attaching the generator mounting bracket (5) to the engine block.
3 Remove the generator mounting bracket from the vehicle.


Figure 6D1-1 6
Reinstall
Reinstallation of the generator mounting bracket and generator is the reverse of the removal procedure, noting the
following:
1 Tighten all fasteners to the correct torque specification.
2 Reinstall the generator, refer to 4.1 Generator.
Generator mounting bracket bolts ... (1) 40.0 – 60.0 Nm
Generator mounting bracket bolts ... (2) 100.0 Nm
Generator mounting bracket bolts ... (3) 40.0 – 60.0 Nm
Generator mounting bracket bolts ... (4) 40.0 – 60.0 Nm
Idler pulley bolt................................. (7) 58.0 Nm

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ISUZU KB P190 2007

Charging System – V6 Page 6D1-1-20

7 Torque Wrench Specifications
..................................................................................................................... Nm
Generator Mounting Bolts (1, 2, 4) ..............................................................58.0
Generator Mounting Bracket Bolts (1, 3, 4) ......................................40.0 – 60.0
Generator Mounting Bracket Bolts (2) ...........................................................0.0
Battery Harness to G8 – X1 pin A Nut................................................5.0 – 12.0


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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–4

• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.
1.2 Components
Starting System Components
The main components of the starting system are:
• battery,
• wiring,
• ignition switch,
• theft deterrent engine crank inhibitor (a function of the theft deterrent system),
• park / neutral and back-up switch (on vehicles with 4 speed automatic transmission),
• engine control module (ECM),
• start relay,
• solenoid switch, and
• starter motor.
Starter Motor and Solenoid Switch Components
Solenoid Switch
The solenoid switch is used to activate the DC motor and has two windings; the pull-in winding and the hold-in winding.
The pull-in winding has heavier wire and is grounded through the DC motor winding and brushes. The hold-in winding is
grounded through the solenoid casing.
Planetary Drive Train
The planetary drive train consists of an internally toothed ring gear and three planetary gear wheels, which rotate on
sleeve bearings on the planetary drive shaft. The ring gear is keyed into the drive-end housing and is made from
high-grade polyamide with mineral additives.
W hen the starter motor operates, the armature turns the planetary gears inside the fixed planetary ring gear. This drives
the planetary shaft at a reduced speed ratio which turns the drive assembly. A fork lever in the drive-end housing forces
the drive assembly forward to engage with the flexplate / flywheel ring gear on the engine and transmit cranking torque.
An internal clutch allows the drive assembly pinion gear to rotate freely when the engine starts. This prevents the
armature from being driven at excessive speed by the engine.
Armature
The armature shaft is supported at each end by oil absorbent, sintered metal bushes; one in the commutator end shield
and one in the planetary drive shaft. The front end of the armature has a gear profile. This meshes with the three
planetary gear wheels. These in turn, mesh with the internal teeth of the ring gear.
Brushes
A brush plate supports four commutator brushes. This plate is fixed to the commutator end shield with two retaining
screws. Two negative brushes are grounded to the pole housing. The two positive brushes are insulated from the pole
housing and connected to the solenoid switch M terminal, refer to Figure 6D1-2 – 1.

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Starting System – V6 Page 6D1-2–6

Sequence of Operation
1 W hen the ignition switch is turned to the START position, a signal is also sent to the ECM to request the engine to
crank.
• For automatic vehicles the transmission must be in either park (P) or neutral (N) for the ECM to allow
cranking to commence.
• The ECM will only allow cranking if the battery voltage is above the minimum battery voltage threshold value,
refer to 6C1-1 Engine Management – V6 – General Information for further information.
2 The ECM operates the start relay which provides power to the pull-in winding of the start solenoid.
3 Current flow to the pull-in winding develops powerful magnetism which pulls in the solenoid switch plunger.
4 The plunger closes the switch contacts connecting battery voltage to the DC motor and pivots the fork lever to engage the drive assembly to the flexplate / flywheel ring gear. Closing the solenoid switch contacts deactivates the
pull-in winding, the hold-in winding remains active.
5 W ith the solenoid switch contacts closed, current flows from the battery through the DC motor, which rotates the armature at high speed and provides cranking torque.







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Starting System – V6 Page 6D1-2–21

10 Unclip the oil level sensor harness from the heat shield
(1).
11 Remove the heat shield attaching screw (2).
12 Remove the lower starter motor attaching bolt (3).
13 Remove the heat shield.
14 Remove the upper starter motor retaining bolt (3).
15 Remove the starter motor from the engine block and lower the starter motor as far as possible to gain
access to the wiring harness connections.


Figure 6D1-2 – 12
16 Remove the wiring harness connector P – 3 (1) from the solenoid switch (2).
17 Remove the flange nut (3) and battery connector P – 4 (4) from the solenoid switch.
18 Remove the starter motor from the vehicle.

Figure 6D1-2 – 13
Reinstall
Reinstallation of the starter motor is the reverse of the removal procedure noting the following:
1 Tighten all fasteners to the correct torque specification.
Solenoid switch connector P – 4 nut (B+)
torque specification ............................................10.0 Nm
Starter motor heat shield lower bolts
torque specification ............................................23.0 Nm
Starter motor heat shield upper screw
torque specification .....................................3.0 – 5.0 Nm
Starter motor mounting bolt
torque specification ............................................45.0 Nm
Knock sensor bolt
torque specification ............................................23.0 Nm
2 Check the starter motor operates correctly.


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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–26

Reassemble
1 Reassemble the solenoid in the reverse order of the disassembly procedure noting the following points.

Dry all parts thoroughly before assembly,
taking care not to breathe in any vapours.
2 Lightly coat the solenoid switch plunger with 10% molybdenum disulphide grease.

Excess grease can enter the contact chamber
of the solenoid switch and cause contact
problems. Do not use too much grease.
3 Hook the plunger over the fork lever.
4 Insert the return spring into the plunger.
5 Slide solenoid switch over the plunger.
6 Align the solenoid switch with drive-end housing ensuring the solenoid switch terminal P – 4 faces away from the pole housing.
7 Install and tighten the solenoid switch mounting screws.
Solenoid switch mounting screw
torque specification .....................................4.1 – 7.6 Nm
8 W ith the starter motor reassembled, perform a No Load Test, refer to 4.3 Starter Motor Bench Tests.
9 If the starter motor fails the No Load Test specification, replace the starter motor.
4.5 Solenoid Switch Tests
Test the Solenoid Switch
1 Inspect the solenoid switch for any external damage.
2 Replace the solenoid switch if it displays significant damage.
3 Install the return spring and plunger into the solenoid switch.
4 Check the movement of the plunger, as follows: a Depress the plunger fully.
b Release the plunger.
c If the plunger sticks or binds in the switch bore, clean or replace the solenoid switch
assembly as required.
Figure 6D1-2 – 22

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