2007 ISUZU KB P190 fuel pump

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW 36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure W arning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler W ater Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. W ater Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 45




4JA1L
RTW 46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the EGR valve assembly.





4JA1TC RTW 46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level gauge.


6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.




4JH1TC RTW 36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW 36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

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ISUZU KB P190 2007

6A – 46 ENGINE MECHANICAL
13. Injection Pump
Refer to section 6C-19 (Injection Pump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger 1) Disconnect the water hose between thermostat housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


027R100007
037RY00001

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ISUZU KB P190 2007

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW 36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. W ater Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler W ater Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure W arning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

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ISUZU KB P190 2007

6A – 122 ENGINE MECHANICAL

















RTW 46ASH001601































9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque N·m(kg·m/Ib ft)
39 (4.0/29)

10) Install the water feed pipe with the gaskets and tighten to the specified torque.
W ater Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)

11) Install the water return pipe with the gaskets and tighten to the specified torque.
W ater Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)

13) Install the hoses for the water feed and return.






















9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)

Do not install the catalytic converter, if drop down it.
10. Heat Protector Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque N·m(kg·m/Ib ft)
9 (0.9/6.5 Ib in)

033R300002











11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified torque.
Pulley Nut Torque N·m(kg·m/Ib ft)
8 (0.8/6)

12. Oil Cooler Water Pipe
13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch
027R100007

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ISUZU KB P190 2007

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10 ×1.25
37 (3.8/28)
2
3M8×1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position. Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)



















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

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ISUZU KB P190 2007

SECTION 6C
FUEL SYSTEM


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C - 2
General Description ...................................................................................................... 6C - 3
Fuel Flow.................................................................................................................... 6 C - 3
Fuel Filter and Water Separator ............................................................................... 6C - 4
Injection Pump........................................................................................................... 6C - 6
Injection Nozzle ......................................................................................................... 6C - 7
Fuel Tank...................................................................................................................... .. 6C - 8
Removal .................................................................................................................... 6 C - 9
Installation ................................................................................................................ 6C - 9
Fuel Gauge Unit ............................................................................................................. 6C - 11
Removal ..................................................................................................................... 6 C - 12
Installation ................................................................................................................. 6C - 12
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck .................................................................................................................... .. 6C - 16
Removal ..................................................................................................................... 6 C - 16
Installation ................................................................................................................. 6C - 16
Fuel Filler Cap................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6 C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal ..................................................................................................................... 6C - 18
Installation ................................................................................................................. 6 C - 21
Injection Nozzle (4JA1L) ............................................................................................... 6C - 25
Disassembly .............................................................................................................. 6C - 25
Reassembly ............................................................................................................... 6C - 26
Special tools .................................................................................................................. 6C - 37
FU
EL SY STEM 6C – 1

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ISUZU KB P190 2007

6C – 2 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS
Description Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor
VE type Bosch distributor VP44 type
Governor type
Mechanical variable
(Half speed oil pressure) Electrical controled
Timer type
Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
19.1 (195) 19.0 (194) 19.5 (199) Injection nozzle designed operating
pressure MPa (kg/cm2) 1st
2nd 25.0 (255)
33.5 (328) 33.8 (331)
Main fuel filter type Disposable cartridge paper element


Precautions
When working on the fuel system, there are several things
to keep in mind:
•
Any time the fuel system is being worked on,
disconnect the negative battery cable except fo
r
those tests where battery voltage is required.
•
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O” rings. Replace if required.
•
Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.

NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.


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ISUZU KB P190 2007