Isuzu KB P190. Manual - part 201

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 

 

6 – 20  TROUBLESHOOTING 

15-3 Starter motor continues to run after the starter switch is turned off 

Step Action  Value(s) 

Yes 

No 

1 Was 

“

Visual/Physical Check" performed. 

 

—

 

Go to Step 2 

Go to 

visual/physical 

check 

2 

Inspect the magnetic switch contact point. 
Was the contact point seized? 

—

 Repair 

or 

replace the 

magnetic 

switch. Go 

to 

Step 3 

3 

Inspect the starter switch. 
Was the starter switch defective? 

—

 Replace 

the 

starter switch. 

Go to Step 4 

4 

Are any DTC stored? 

—

 Go 

to 

indicated 

DTC. Solved 

 

15-4 Excessive commutator sparking 

Step Action  Value(s) 

Yes 

No 

1 Was 

“

Visual/Physical Check" performed. 

 

—

 

Go to Step 2 

Go to 

visual/physical 

check 

2 

Inspect 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 

Was there the slag accumulation on the contact 
face? 

—

 Clean 

the 

contact face or 

replace the 

brush. Go 

to 

Step 4 

4 

Was the brush holder loose? 

—

 Repair 

the 

brush holder 

Go to Step 5 

5 

Inspect the commutator. 
Was there excessive wear or pitting? 

—

 Repair 

or 

replace the 

commutator. Go 

to 

Step 6 

6 

Was there loose the solder on the commutator? 

—

 Clean 

and 

repair Go 

to 

Step 7 

7 

Inspect the armature shaft. 
Was the run-out of armature shaft outside the 
standard value due to worn bearing ? 

—

 

Replace the 

bearing Go 

to 

Step 8 

8 

Are any DTC stored? 

—

 Go 

to 

indicated 

DTC. Solved 

 

 

 

 

 

 

 

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..................................................................................................................  6A -  24 

Lubricating System....................................................................................................  6A -  24 

Fuel System................................................................................................................  6A - 25 

Cooling System ..........................................................................................................  6A -  27 

Valve Clearance Adjustment.....................................................................................  6A -  31 

Compression Pressure Measurement .....................................................................  6A -  32 

General Description ......................................................................................................  6A-  36 

Removal and Installation ..............................................................................................  6A-  37 

Removal ...................................................................................................................... 6A- 37 

Installation ..................................................................................................................  6A- 40 

Coolant Replenishment .........................................................................................  6A-  41 

Engine Warm-Up ....................................................................................................  6A-  41 

Engine Repair Kit...........................................................................................................  6A- 42 

Engine Overhaul ............................................................................................................  6A- 43 

Removal ...................................................................................................................... 6A- 43 

External Parts .........................................................................................................  6A-  43 

ENGINE MECHANICAL   6A – 1 

Main Data and Specifications.......................................................................................  6A - 

Torque Specifications ...................................................................................................  6A - 

6A – 2  ENGINE MECHANICAL 

Disassembly ............................................................................................................... 6A-  47 

Internal Parts ..........................................................................................................  6A-  47 

Major Components .............................................................................................  6A-  47 

Minor Components .............................................................................................  6A-  56 

Rocker Arm Shaft and Rocker Arm ...............................................................  6A-  56 

Cylinder Head ..................................................................................................  6A-  57 

Piston and Connecting Rod ...........................................................................  6A-  59 

Inspection and Repair ...............................................................................................  6A-  61 

Cylinder Head .........................................................................................................  6A-  61 

Rocker Arm Shaft and Rocker Arm.......................................................................  6A-  68 

Cylinder Body .........................................................................................................  6A-  69 

Camshaft ................................................................................................................. 6A-  77 

Crankshaft and Bearing.........................................................................................  6A-  79 

Crankshaft Bearing Selection ...............................................................................  6A-  83 

Crankshaft Pilot Bearing .......................................................................................  6A-  85 

Flywheel and Ring Gear.........................................................................................  6A-  85 

Piston ...................................................................................................................... 6A- 86 

Cylinder Head Gasket Selection ...........................................................................  6A-  88 

Connecting Rod......................................................................................................  6A-  90 

Idler Gear Shaft and Idler Gear .............................................................................  6A-  91 

Timing Gear Case Cover........................................................................................  6A-  91 

Reassembly ................................................................................................................ 6A-  93 

Internal Parts ..........................................................................................................  6A-  93 

Minor Component ...............................................................................................  6A-  93 

Rocker Arm Shaft and Rocker Arm ...............................................................  6A-  93 

Cylinder Head ..................................................................................................  6A-  94 

Piston and Connecting Rod ...........................................................................  6A-  96 

Positive Crankcase Ventilation (PCV) Valve .................................................  6A-  99 

Major Component ...............................................................................................  6A- 101 

Installation ..................................................................................................................  6A- 118 

External Parts .........................................................................................................  6A- 118 

Lubrication System .......................................................................................................  6A- 126