2007 ISUZU KB P190 cooling

1-46 HEATER AND AIR CONDITIONING
Important Operations - Installation

7. Bolt; Compressor to Bracket
N⋅m (kgf ⋅m/lb ⋅ft)
Torque 44 (4.5/33)



6. Refrigerant Line
N⋅m (kgf ⋅m/lb ⋅in)
Torque 11 ∼19 (1.1/95 ∼1.9/168)



5. Drive Belt
Refer to SECTION 6A “COOLING SYSTEM”.



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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-89
AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE POSSIBLE CAUSE CORRECTION
1. Magnetic clutch does not run
•
Refer to “MAGNETIC CLUTCH”
troubleshooting in this section
2. Compressor is not rotating properly
• Drive belt loosened or broken •
Adjust the drive belt to the specified
tension or replace the drive belt
• Magnetic clutch face is not clean and
slips •
Clean the magnetic clutch face or replace

• Incorrect clearance between magnetic
drive plate and pulley •
Adjust the clearance (Refer to
“COMPRESSOR OVERHAUL”)
• Compressor oil leaks from shaft seal or
shell •
Replace the compressor

• Compressor seized • Replace the compressor
3. Insufficient or excessive charge of
refrigerant •
Discharge and recover refrigerant.
Recharge to specified amount.
4. Leaks in the refrigerant system


•
Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
5. Condenser clogged or insufficient radiation

•
Clean the condenser or replace as
necessary
• Check radiator or condenser fan function
6. Temperature control link unit of the heater
unit defective •
Repair the link unit
7. Unsteady operation due to foreign
substance in expansion valve •
Replace the expansion valve

No cooling or
insufficient
cooling
8. Poor operation of electronic thermostat
•
Check electronic thermostat and replace
as necessary
1. Evaporator clogged or frosted
•
Check evaporator core and replace or
clean the core
2. Air leaking from cooling unit or air duct
•
Check evaporator and duct connection,
then repair as necessary
Insufficient
velocity
of cooling air
3. Blower motor does not rotate properly
• Refer to “FAN CONTROL KNOB (FAN
SW ITCH)” troubleshooting in this section

* For the execution of the charging and discharging operation in the table above, refer to the “RECOVERY,
RECYCLING, EVACUATING AND CHARGING” in this section.



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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-91
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Reduced or no air flow through
the condenser
•
Condenser clogged or dirty
• Radiator (condenser) fan
does not operate properly •
Clean
• Check cooling fan
operation
No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)



•
Excessive refrigerant in
system




•
Check sight glass.
(See “Reading Sight
Glass”)
• Discharge and
recover refrigerant.
Recharge to specified
amount
Discharge
(High)
pressure
gauge
abnormally
high
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28psi) quickly •
Air in system
•
Evacuate and charge
refrigerant system
Insufficient cooling and excessive
bubbles in the sight glass





•
Insufficient refrigerant in
system





•
Check sight glass.
(See “Reading Sight
Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount
Low pressure gauge indicates
vacuum •
Clogged or defective
expansion valve •
Replace the
expansion valve
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum •
Restriction caused by debris
or moisture in receiver/drier

•
Check system for
restriction and
replace receiver/drier

Discharge
(High)
pressure
gauge
abnormally
low
After turning off air conditioning,
high and low pressure gauge
balanced quickly
•
Compressor seal defective
• Poor compression due to
defective compressor
gasket •
Replace or repair
compressor
Low pressure gauge is lowered
after condenser is cooled by
water
•
Excessive refrigerant in
system

•
Discharge and
recover refrigerant
Recharge to specified
amount
Low pressure hose temperature
around the compressor refrigerant
line connector is lower than
around evaporator

•
Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve
• Expansion valve opens too
long •
Replace the
expansion valve




After turning off air conditioning,
high and low pressure gauge is
balanced quickly •
Compressor gasket is
defective
•
Replace


Suction
(Low)
pressure
gauge
abnormally
high
Air conditioning turns off before
passenger compartment is
sufficiently
cool •
Electronic thermostat
defective
•
Check the electronic
thermostat and
replace as necessary


* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.

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ISUZU KB P190 2007

1-92 HEATER AND AIR CONDITIONING
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Condenser is not hot and
excessive bubble in sight glass





•
Insufficient refrigerant






•
Check sight
glass.(See “Reading
Sight Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount
Frost on the expansion valve inlet
line •
Expansion valve clogged
•
Replace the
expansion valve
A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier •
Receiver/drier clogged


•
Replace the receiver/
drier


Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum

•
The temperature sensor of
the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant •
Replace the
expansion valve



Discharge temperature is low and
air flow from vents is restricted
•
Frozen evaporator core fins

•
Check electronic
thermostat and
replace as necessary
Suction
(Low)
pressure
abnormally
low

Low-pressure gauge reading is
low, or a vacuum reading may be
shown •
Clogged or blocked
refrigerant line
•
Replace refrigerant
line
No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)



•
Excessive refrigerant in
system




•
Check sight
glass.(See “Reading
Sight Glass”)
• Discharge and
recover refrigerant.
Recharge to specified
amount
Reduce air flow through con-
denser
•
Condenser clogged
• Radiator (condenser) fan
does not rotate properly •
Clean
• Check cooling fan
operation
Suction
(Low) and
Discharge
(High)
pressure
abnor-
mally
high

Suction (Low) pressure hose is
not cold •
Air in system • Evacuate and charge
refrigerant
Suction
(Low) and
Discharge
(High)
pres-sure
abnor-
mally
low Insufficient cooling and excessive
bubbles in the sight glass •
Insufficient refrigerant in
system
•
Check sight glass.
(See “Reading Sight
Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount

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ISUZU KB P190 2007

Section 6 Troubleshooting ....................................................................................... ..... 786
PAGE
Section 6A Engine Mechanical .................................................................................... 806
Section 6B Engine Cooling .......................................................................... ................ 945
Section 6C Fuel System .......................................................................... ..................... 96 5
Section 6D Engine Electrical ................................................................ ....................... 1002
Section 6E Engine Control System (4JH1) ....................................................... ......... 1034
Section 6F Exhaust System ....................................................... .............................. ... 1333
Section 6H Accelerator Control ....................................................... ..............................135 3
SECTION 6
ENGINE
TA BLE OF CONTENTS
ENGINE 6
4JA1/4JH1 MODELS

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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction found? (Include radiator cap) —
Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the fan
clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the fan
clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump assembly.
8 Was the restriction by the foreign materials in the cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. —
Clean or
replace the clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? —
Replace the
sealing cap or replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 2 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve and relation parts.
2 Was the PCV (Positive Crankcase Ventilation) valve working completely? —

Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 13
10–3 Continuous noise
Step Action Value(s) Yes No
1 Was the fan belt tension OK? 9 – 13 mm
(0.35 – 0.51
in)
Go to Step 2 Adjust the fan
belt tension.
2 Was the cooling fan loose? — Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? — Repair or
replace the generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? — Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? — Readjust the
valve
clearance. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

10-4 Slapping noise
Step Action Value(s) Yes No
1 Was noise coming from the cylinder head cover? — Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valve
clearances Go to Step 3
3 Were the rocker arms damaged? — Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? — Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? — Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft.
Was the crankshaft bearing and/or crankshaft worn? —
Replace the
worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin.
Was the connecting rod bearing and/or crankpin
worn? —

Replace the worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or
piston pin.
Was the connecting rod small end bushing and/or
piston pin worn? —

Replace the worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner.
Was the piston and/or cylinder liner worn or
damaged? —
Replace the
worn or
damaged parts Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

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 .................................................................................................................. 6 A - 24
Lubricating System.................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 2 7
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ..................................................................... 6A - 32
General Description ...................................................................................................... 6A- 3 6
Removal and Installation .............................................................................................. 6A- 37 Removal ...................................................................................................................... 6 A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment ......................................................................................... 6A- 41
Engine Warm-Up .................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A - 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6 A- 43
External Parts ......................................................................................................... 6A- 43
E N GINE MECHA NICA L 6A – 1
Main Dat a and Specif ications ....................................................................................... 6A -
Torque Specif ications ................................................................................................... 6A -

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