2007 ISUZU KB P190 belt

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

6 – 16 TROUBLESHOOTING
14. Battery Charging and Noise Problem
Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? —
Repair or
replace the
brush and/or the slip ring. Go to Step 3
3 Inspect the stator coil on the generator.
Was there an open circuit or the scorching on the
stator coil? —

Replace the stator coil. Go to Step 4
4 Inspect the rotor coil on the generator.
Was there an open circuit or the scorching on the
rotor coil? —

Replace the rotor coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? —
Replace the
rectifier Go to Step 6
6 Inspect the IC regulator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved

14-2 Battery Overcharging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the terminal circuit.
Were the B and F terminals shorted? —
Repair the
short circuit. Go to Step 3
3 Check the regulating voltage.
Was the IC regulator voltage excessive? —
Replace the IC
regulator. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 29


Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water. Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C ( °F)
82 (180)
Oil Cooler Thermo Valve °C ( °F)
76.5 (170)
EGR Cooler Thermo Valve °C ( °F)
40 (104)

4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature °C ( °F)
95 (203)
Oil Cooler Thermo Valve °C ( °F)
90 (194)
EGR Cooler Thermo Valve °C ( °F)
55 (131)
Valve Lift at Fully Open position mm (in)
9.5 (0.37)
Oil Cooler Thermo Valve mm (in)
4.5 (0.18)
EGR Cooler Thermo Valve mm in)
3.5 (0.14)



Drive Belt Adjustment
Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and
adjust as necessary.
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
4 Oil pump pulley or idler pulley
5 Compressor pulley or idler pulley


030LX014
033RY00002

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ISUZU KB P190 2007

6A – 30 ENGINE MECHANICAL


Cooling Fan Pulley Drive Belt
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10 kg/22 lb)
force.
Cooling Fan Drive Belt Deflection mm (in)
New belt 4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley




A/C Compressor Drive Belt
Compressor belt tension is adjusted by moving the P/S
pumppulley.
Depress the drive belt mid-portion with a 98N (10 kg/22 Ib)
force.
A/C Compressor Drive Belt Deflection mm (in)
New belt 9 - 10 (0.35 - 0.39)
Reuse belt 12 - 13 (0.47 - 0.51)
1 Crankshaft damper pulley
2 P/S pump pulley
2 A/C Compressor pulley
033RY00003
033RY00004

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ISUZU KB P190 2007

6A – 120 ENGINE MECHANICAL









4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified torque.
Suction Pipe Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)





5. Generator and Adjusting Plate
1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.



3) Connect the vacuum pump rubber hose (4) to the
vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body

052R300001
7. Compressor Bracket 1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8×1.25
19 (1.9/14)
M10×1.25
40 (4.1/30)











066RY00002
032R300001
042RY00003

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 123




15. Starter Motor
Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N·m(kg·m/Ib ft)
85 (8.7/63)

16. Injection Pump
17. Injection Pump Cover (4JA1TC/4JH1TC only)


18. Engine Foot Install the engine foot to the cylinder body and tighten the
bracket bolts to the specified torque.
Engine Foot Bolt Torque N·m(kg·m/Ib ft)
Right Side M10
×1.25
40 (4.1/30)
M10×1.25
40 (4.1/30) Left Side
M14×1.50
127 (13/93)









4JA1L, 4JH1TC
022R300003

















4JA1TC
RTW 46ASH002601







RTW 36ASH001001
















19. Intake Manifold
1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts to the specified torque.
Intake Manifold Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)

Intake Manifold Flange Nut Torque N·m(kg·m/Ib ft)
24 (2.4/18)

4) Connect the PCV hose to the cylinder head cover.

5) Install the fan drive belt and adjust the belt tension referring SERVICING of this section



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ISUZU KB P190 2007

6B – 10 ENGINE COOLING

WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.




Removal
1. Radiator Upper Hose 1) Partially drain the engine coolant.
2) Remove the radiator upper hose.





031R300003
2. Water Outlet Pipe
1) Disconnect the turbocharger-cooling pipe from outlet pipe.
2) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud

5. Fan and Fan Clutch 1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.

030R300001 7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.

030R300002

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ISUZU KB P190 2007

ENGINE COOLING 6B – 11
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.
・ Cracks in the water pump body
・ Coolant leakage from the seal unit
・ Excessive radial play or abnormal noise in the fan center
when rotate by hand
・ Excessive thrust play in the fan center (Standard play: less
than 0.2mm)
・ Cracks or corrosion in the impeller





























Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
W ater Pump Bolt/Nut Torque N·m(kg·m/lb ft)
20 (2.0/14)

2. Fan Drive Belt and Pulley
1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt mid- portion to check the drive belt deflection.
Fan Drive Belt Deflection mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
030R300002


030R300001














3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque N·m(kg·m/lb in)
8(0.8/69)

4. Upper Fan Shroud

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ISUZU KB P190 2007