2007 ISUZU KB P190 fuel

SHEET METAL 2B-25


Important Operations - Removal
5. Fuel Filler Pipe and Evaporator Hose



7. Rear Body Assembly

Attach lifting wires to the rear body hooks and raise the rear
body.

Note:
In lifting up rear body, take care not to strike it against cab
body.



Important Operation – Installation
6. Bolt; Frame to Body

Torque N ⋅m(kgf ⋅m/lb ⋅ft)
54 (5.5 / 40)



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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 – 1




BASIC INSPECTION PROCEDURE....6– 2

1. HARD STARTING ............................6– 3

1-1.Starter Motor Inoperative ..........6– 3

1-2. Starter Motor Operates But
Engine Does Not Turn Over ...........6– 3

1-3. Engine Turns Over But Does
Not Start Engine ..............................6– 4

2. UNSTABLE IDLING .........................6– 5

3. INSUFFICIENT POWER ..................6– 6

4. EXCESSIVE FUEL
CONSUMPTION..................................6– 7

5. EXCESSIVE OIL CONSUMPTION ..6– 8

6. OVERHEATING ...............................6– 9

7. WHITE EXHAUST SMOKE..............6– 9

8. DARK EXHAUST SMOKE ...............6– 10

9. OIL PRESSURE DOES NOT RISE..6– 11

10. ABNORMAL ENGINE NOISE ........6– 12

10-1. Engine Knocking ....................6– 12

10-2. Gas Leakage Noise .................6– 12

10-3. Continuous Noise ...................6– 13

10-4. Slapping Noise ........................6– 13

10-5. Excessive Turbocharger
Noise ................................................6– 14
11. ROTATING PART WEAR OF
TURBOCHARGER.............................. 6– 14

12. OIL LEAKAGE FROM
TURBOCHRGER ................................ 6– 15

13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER........................ 6– 15

14. BATTERY CHARGING AND
NOISE PROBLEM .............................. 6– 16

14-1. Battery No Charging ............... 6– 16

14-2. Battery Overcharging ............. 6– 16

14-3. Battery Under Charging ......... 6– 17

14-4. Battery Unstable Charging
Current ............................................. 6– 17

14-5. Charging System Noise ......... 6– 18

15. STARTER MOTOR PROBLEM ..... 6– 19

15-1. Starter Motor Pinion Engages
to Ring Gear But Engine Does
Not Turn Over .................................. 6– 19

15-2. Incorrect Pinion And Ring
Gear Engagement ........................... 6– 19

15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off........................................ 6– 20

15-4. Excessive Commutator
Sparking .......................................... 6– 20


SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE PAGE

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ISUZU KB P190 2007

6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop. Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn ON ? Go to
section
6E “On Board Diagnostic
(OBD) System Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 3
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions. The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1 –1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch. Does the starter switch work? —

Go to Step 2 Repair or
replace the
starter switch
2 Check the starter relay. Does the starter relay work? —

Go to Step 3 Repair or
replace the
starter relay
3 Check the magnetic switch. Does the magnetic switch work? —

Go to Step 4 Repair or
replace the magnetic switch
4 Check the pinion gear condition on the starter motor. Was the condition normal? —

Go to Step 5 Replace the
pinion gear
5 Check the brush wear or brush spring weakness. Was the condition normal? —

Replace the
starter motor assembly Repair or
replace the
brush or brush spring

1-2 Starter motor operates but engine does not turn over
Step Action Value(s) Yes No
1 Check the engine internal seizure. Was the engine seized? —

Repair or
replace seized parts Check other
DTC by Tech 2 and go to
indicated DTC


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6 – 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump
Step Action Value(s) Yes No
1 Check clogged, damaged the fuel piping or the
connector loosen.
Was any problem found? —

Repair replace problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved

Incase of the fuel is being delivered to the injection pump
Step Action Value(s) Yes No
1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 5 Bleed the air
3 Was the injection spray condition complete? —
Go to Step 4 Replace the
injection nozzle
4 Was the injection nozzle injection starting pressure OK? (See below)
Go to Step 5 Replace the
injection nozzle
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? —
Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at 200rpm
Go to Step 11 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —

Go to Step 2 Clean or
replace the air cleaner
element.
2 Was the intake air leakage found from intake system? —
Repair or
replace the intake air system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —

Go to Step 4 Clean or
replace the fuel filter element.
4 Check the fuel injection pipes. Does the injection pipes have obstruction or any
damage? —
Repair or
replace the fuel injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —

Go to Step 7 Readjust the
injection nozzle pressure or replace the nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 8 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? —
Repair or
replace the exhaust system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? —
Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007