2007 ISUZU KB P190 check engine light

BRAKE CONTROL SYSTEM 5A-47
ABS Warning Lamp ON Steady

Step Action Value(s) Yes No
1 1. Check the ABS warning lamp lighting circuit for a
short.
2. If a problem found, repair as necessary. W as a problem found? - Go to Step 3 Go to Step 2
2 1. Check the ABS warning lamp lighting circuit at the
meter for a short. Refer to METER, W ARNING
LIGHT AND INDICATOR LIGHT in 8 section.
2. If a problem is found, repair or replace the meter. W as a problem found? - Go to Step 3 Go to Step 4
3 1. Connect all connectors.
2. Ignition “ON”, engine “OFF”.
3. W ait for about 10 seconds.
4. Observe the ABS warning lamp. Is the ABS warning lamp turned “OFF”? - Verify repair Go to Step 4
4 Replace EHCU.
Note: Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2W D or 4W D Model)
Is the action complete? - Verify repair -


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ISUZU KB P190 2007

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.


RTW 36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element (Except wet type element)
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0200-0


RTW 36ASH000101



4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face.
7. Use the filter wrench to turn in the filter an additional 2/3 turns.
Filter W rench: 5-8840-0200-0
8. Check the engine oil level and replenish to the specified level if required.
130RY00003
6A-6

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
W ith oil filter
replacement W ithout oil
filter
replacement
4 × 2
4 × 4
(4JA1L/TC)6.2 (1.64/1.36) 5.2 ∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 2
(4JH1TC)
6.2 (1.64/1.36) 5.2
∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 4
(4JH1TC) 7.0 (1.85/1.54) 6.2 ∼ 5.2
(1.64 ∼ 1.37
/ 1.36 ∼ 1.14) 5.3
∼ 4.3
(1.72 ∼ 1.14
/ 1.17 ∼ 0.95)

9. Start the engine and check for oil leakage from the
main oil filter.



RTW 66ASH003201




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.




RTW 66ASH003301








2. Clean the fuel filter cartridge fitting faces. This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a filter wrench.
Filter W rench : 5-8840-0253-0 (J-22700)




6. Operate the priming pump until the air discharged completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.

041RY00009

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ISUZU KB P190 2007

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several times and check for fuel leakage.
5. Check the water separator indicator light. It should be off.



Except EURO III model
RTW 46ASH002901




For EURO III model
RTW 46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is felt.
2. W ait 1 minute, and operate the priming pump until strong resistance is felt.
3. Once more wait, and operate the priming pump until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. W ait until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


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8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end.

014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360 °.
14. Realign the crankshaft damper pulley TDC notched line with the timing pointer.
15. Adjust the clearances for the remaining valves as shown in the illustration.



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 33
INJECTION TIMING ADJUSTMENT
(4JA1T(L) only)
1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.





2. Bring the piston in the No. 1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark.
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
RTW 46ASH000601


3. Disconnect the injection pipe from the injection pump
4. Remove one bolt from the distributor head.
5. Install the adapter set, togather with static timing gauge.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)
Adapter Set: Static Timing Gauge: 5-8840-2834-0
RTW 36ASH002101 6. Rotate the crankshaft to bring the piston in the No. 1
cylinder to a point 30 - 40 ° BTDC.
7. Set the timing gauge needle to zero.
8. Move the crankshaft pulley slightly in both directions to check that the gauge indication is stable.

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ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
6. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system. Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 69
3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm
oil port.




Rocker Arm Correction
Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.



CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner. Refer to "Cylinder Liner Replacement".
















3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.

Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)


Cylinder Body Height (H) (Reference) mm (in)
Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)
4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner. Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.


014RY00024
012R100001
012RY00009 014RY00023

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