2007 ISUZU KB P190 sensor

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model) Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor.

14. Transmission member 1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing.
2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts.
16. Transmission coupling bolt 1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer) Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007
P1010025


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 39

18. Radiator 1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.
• TPS connector
• Oil pressure switch connector
• Thermo switch connector
• Injection pump connector
• Engine earth
• Thermometer unit connector
• TDC sensor
2) Remove the clips fixing engine harness.
P1010009

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 53
















20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.

Camshaft End Play mm (in)
Standard Limit
0.050 - 0.114
(0.002 - 0.0044) 0.20
(0.008)
















2. Remove the camshaft timing gear bolt from the
camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.


21. Camshaft Thrust Plate


22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.



23. Timing Gear Case

24. Cylinder Body Rear Plate



25. Piston Cooling Oil Jet The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.





014RT0001
901R100008
014RY00019
052RY00001

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ISUZU KB P190 2007

ENGINE COOLING 6B – 7
DIAGNOSIS
Engine Cooling Trouble
Symptom Possible Cause Action
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system
Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace



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ISUZU KB P190 2007

FUEL SYSTEM 6C – 19
7. Power Steering Pump Bracket

6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only) Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe 1) Disconnect the fuel hoses from the fuel filter or priming pump.
2) Disconnect the fuel hoses from the injection pump.
11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold 1) Remove the EGR valve from the intake manifold and EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)

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ISUZU KB P190 2007

6C – 24 FUEL SYSTEM







13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket

15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.

Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)

17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump (4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery



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ISUZU KB P190 2007

Engine Control System (4JH1) 6E-3
Rough, Unstable, or In co rr ect Idle And
Stallin g........................................................... .6E -260
Cut Out, Mi sses.............................................. .6E -262
Su rge s/Chuggle s............................................ .6E -263
La ck of Po wer, Sluggi shne ss, Spongine ss .... .6E -266
He sitation, Sag, Stu mble................................ .6E -268
Fuel Kno ck /Co mbu stion Noi se ....................... .6E -270
Poor F uel E cono my........................................ .6E -271
E xc ess ive S moke (B la ck S m oke) ................. .6E -272
E xc ess ive S moke (W hite S moke) ................. .6E -273
Repair In str u ctions ............................................ .6E -275
Engine Control Module (ECM) Replacement ..6E-275
Service Programming System (SPS)
Description .....................................................6E-276
Service Programming System (SPS)
(Remote Procedure) ......................................6E-277
Service Programming System (SPS)
(Pass-Thru Procedure) ..................................6E-278
Accelerator Pedal Position (APP) Sensor
Replacement ..................................................6E-279
Crankshaft Position Sensor (CKP) Sensor
Replacement ..................................................6E-279
EGR Solenoid Valve Replacement .................6E-280
Engine Coolant Temperature Coolant
(ECT) Sensor Replacement ...........................6E-280
Mass Air Flow (MAF) / Intake Air Temperature
Sensor Replacement......................................6E-280
Turbocharger Solenoid Valve Replacement
[High Altitude Spec] ........................................6E-281
Vacuum Pressure Sensor Replacement
[High Altitude Spec] ........................................6E-281
Vehicle Speed Sensor (VSS) Replacement ....6E-282
Description And Operation .................................6E-283 Engine Control Module (ECM) .......................6E-283
Engine Control Component Description ..........6E-284
Fuel Injection System Description ...................6E-288
Low Pressure Fuel Circuit Description ............6E-290
High Pressure Fuel Circuit Description ...........6E-291
Timing Control Device Description ..................6E-294
Exhaust Gas Recirculation (EGR) System
Description .....................................................6E-297
Turbocharger Description................................6E-298
Special Tools And Equipment ............................6E-299 Special Tools and Equipment .........................6E-299


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ISUZU KB P190 2007

6E-6 Engine Control System (4JH1)
High Altitude Spec





RTW 66EMF001101

Legend
1. Vacuum Pump
2. W hite Stripe Vacuum Hose
3. EGR Solenoid Valve
4. EGR Valve
5. W hite Stripe Vacuum Hose
6. Vacuum Regulating Valve
7. Port S
8. Port Z
9. Blue Stripe Vacuum Hose
10. Turbocharger Solenoid Valve
11. W hite Stripe Vacuum Hose
12. Yellow Stripe Vacuum Hose
13. Vacuum Pressure Sensor
14. Turbocharger




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ISUZU KB P190 2007