2007 ISUZU KB P190 fuel cap

FUEL SYSTEM (4JK1/4JJ1) 6C-11
Step Action Value(s) Yes No
6 Check the fuel tank.
If a problem is found, clean, repair, or replace
as necessary.
• Foreign material (Clogged suction port)
• Bent or cracked suction pipe
• Fuel tank distortion
• Fuel tank improper installation
• Fuel pump and sender malfunction
• Clogged fuel cap hole
• Water
Is the action complete? 

Go to Step 7 

7 Bleed the air from the fuel pipe again. Refer to
Fuel System Air Bleeding in this section.
Is the action complete? 

Verify repair 



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ISUZU KB P190 2007

6C-12 FUEL SYSTEM (4JK1/4JJ1)
Fuel Filter Assembly
Components






RTW 76CSF000101
Legend
1. Fuel Sedimenter Connector 2. Bolt
3. Harness Connector
4. Fuel Hose
5. Fuel Filter Assembly

Removal
1. Remove the fuel filler cap.
2. Remove the fuel sedimenter connector.
3. Disconnect the harness connector.
4. Remove the feed hose and the return hose from the fuel filter and plug it so that the fuel does not
flow out.
5. Remove the bolts for mounting the fuel filter.
6. Remove the fuel filter assembly.
Installation
1. Install the fuel filter assembly.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Connect the harness connector.
5. Install the fuel sedimenter connector.
6. Install the fuel filler cap.
7. Bleed out the air. • Refer to "Fuel System".





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ISUZU KB P190 2007

6C-30 FUEL SYSTEM (4JK1/4JJ1)
15. Align the timing marks at 3 locations as shown.




RTW 76ASH001301
Legend
1. TDC






RTW 56ASH006901
Legend
1.
Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap

16. Loosen the nut (1).




RTW 56CSH001601
17. Remove the timing chain tensioner.


RTW 56CSH003701
Legend
1. Timing Chain Tensioner.
2. Gasket
3. Nut



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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-35
9. Install the timing chain tensioner.
Tighten the nut to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/ 87 lb in)




RTW 56CSH001701
Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut


10. Unlock the tensioner hook.
• Press the place of the arrow in the figure.
• The hook is opened. The plunger pushes the
tension lever.




RTW 56ASH020401



11. Tighten the fuel supply pump shaft nut.
Tighten the nut (1) to the specified torque.
Tightening torque: 130 N ⋅
⋅⋅
⋅
m (13.3 kg ⋅
⋅⋅
⋅
m / 96 lb ft)





RTW 56CSH001601
12. Tighten the timing chain tension lever pivot bolt to
the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
13. Turn the crank pulley two rotations (720°CA).
14. Check mark (1) on intake camshaft and exhaust camshaft to mark of camshaft bearing cap.





RTW 56ASH006901


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-41
Removal
Note: W hen repairs to the fuel system have been
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission".
1. Disconnect the battery ground cable.
2. Slowly loosen the fuel filler cap.
Note: Be careful that fuel does not spout out because o
f
change of pressure in the fuel tank.
Note: Cover opening of the filler neck to prevent an
y
dust entering. 3. Jack up the vehicle.
4. Disconnect the quick connector (5) of the fuel tube at the fuel cooler way.
5. Remove fuel return hose (8) from the pipe.
6. Remove fixing bolt (7) of the bracket fuel coole
r
and remove bracket fuel cooler (6).
Note: Cover the opening of the pipe to prevent any dust
and fuel leakage.
Note: For remove fuel cooler, Remove bolts (10) of the
fuel cooler and remove fuel cooler.
7. Support underneath of the fuel tank with a lifter.
8. Remove the inner liner of the wheel house at rea
r
left side.
9. Remove fixing bolt of the filler neck from the body.
10. Disconnect the quick connector (5) of the fuel tube from the fuel pipe and the evapo tube from evapo
joint connector.
Note: Cover the quick connector to prevent any dust
entering and prevent fuel leakage.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
11. Remove fixing bolt (1) of the tank band and remove the tank band (2).
12. Disconnect the pump and sender connector on the fuel pump and remove the harness from the weld
clip on the fuel tank.
13. Lower the fuel tank (3).
Note: W hen lowering the fuel tank from the vehicle, do
not scratch the hoses and tubes by contact with othe
r
parts.

Installation
1. Raise the fuel tank.
Note: W hen raising the fuel tank to the vehicle, do not
scratch the hoses and tubes by contact with other parts.
2. Connect the pump and sender connector to the fuel pump and install the harness to the weld clip
on the tank.
Note: The connector must be securely connected
against the stopper.
3. Install the tank band and fasten bolt.
Torque: 68 N ⋅
⋅⋅
⋅
m (6.9 kg ⋅
⋅⋅
⋅
m /50 lb ft)
Note: The anchor of the tank band must be securely
installed to the guide hole on the frame.
4. Connect the quick connector of the fuel tube to the fuel pipe and the evapo tube from evapo joint
connector.
Note: Pull off the left checker on the fuel pipe.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
5. Install the filler neck to the body with bolt.
Note: For install the fuel cooler to the bracket with bolt.
Torque: 6.5 N ⋅
⋅⋅
⋅
m (0.7 kg ⋅
⋅⋅
⋅
m /61 lb in)
6. Install the bracket to Frame with bolt. Torque: 48 N ⋅
⋅⋅
⋅
m (4.9 kg ⋅
⋅⋅
⋅
m /35 lb ft)
7. Install the fuel return hose at the fuel cooler way.
8. Install the quick connector at the fuel cooler way.
9. Install the inner liner of the wheel house at rear left side.
10. Remove lifter from the fuel tank.
11. Lower the vehicle.
12. Tighten the filler cap until at least three clicks.
13. Connect the battery ground cable.



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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-43
Removal
Note: W hen repairs to the fuel system have been
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission".
1. Remove the fuel tank assembly (8). Refer to "Fuel Tank Removal" in this section.
2. Disconnect the quick connector (1) of the fuel tube from the fuel gauge unit.






140R100035
3. Remove the retainer ring (3) from the fuel tank
with the removal tool 5-8840-2602-0.
4. Slowly remove the fuel gauge unit (6) from the fuel tank as no bend float arm.
Note: Cover opening for the fuel gauge unit on the fuel
tank to prevent any dust entering.
5. Discard the fuel gauge unit seal (7) because it cannot be reused.

Installation
1. Clean the seal surface of the fuel tank and the fuel
gauge unit.
Note: If there is dust on the seal surface, it can cause a
fuel leak.
2. Install the new fuel gauge unit seal (7) to the opening of the fuel tank along the groove.
3. Slowly install the fuel gauge unit (6) into the fuel tank so there is no bend in the float arm.
4. Set the flange of the fuel gauge unit on the fuel gauge unit seal as mating convexity of the fuel
gauge unit and reentrant of the fuel tank.
5. Slowly lock the retainer ring (3) to the fuel tank with the remover tool 5-8840-2602-0.
6. Connect the quick connector (1) of the fuel tube to the gauge unit.
Note: Pull off the left checker of the fuel pipe.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
7. Check for leak. Method of leak check.
1. Plug the end of the quick connector and breather hose (Pull off the breather hose from
fuel tank) and tighten fuel filler cap until at least
one click is heard.
2. Apply soapy water around the fuel gauge unit seal area.
3 Pressure air into the fuel tank from the end o
f
the breather pipe at 34.3 kPa (0.35 kg / cm2 / 5
psi) over 15 seconds.
4 Verify that no bubbles from around the fuel gauge unit seal area.
8. Install the fuel tank assembly (8).
Note: Refer to "Install the fuel tank" in this section.



Special Tool


ILLUSTRATION PART NO.
PART NAME

5-8840-2602-0
Remover: fuel pump retainer ring


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ISUZU KB P190 2007

6C-44 FUEL SYSTEM (4JK1/4JJ1)
Fuel Tube / Quick - Connector Fittings
Precautions
• Do not light a match or create a flame.
• Keep flames away from your work area to prevent
flammable materials from catching fire.
• Disconnect the battery ground cable to prevent
electrical shorts.
• Pre −treat the piping system or associated parts
from thermal damage or from spattering when
welding or similar heat −generating work.

Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electrolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.






140R100032
Legend
1. O-ring
2. Port
3. Connector
4. Plastic Tube


Removal
1. Open the fuel cap to relieve the fuel pressure in
the tank. Use compressed air to remove any dirt
on the fuel quick connect fittings prior to
disconnecting the fittings. W hen disconnecting the
fuel pipe, cover the area with a cloth to prevent
fuel from splashing as the fuel pipe may still have
some pressure in it.





140R100002
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connecto
r
with the other hand while pressing the square
release button of the connector, as illustrated.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-47
Fuel Filler Cap
General Description
A vacuum valve and pressure valve are built into the
fuel filler cap which adjusts the fuel pressure in the fuel
tank to prevent fuel tank damage.






RTW 46CSH000301
Legend
1. Seal Ring

Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective.
Note: A replacement fuel filler cap must be the same as
the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance ma
y
occur.



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ISUZU KB P190 2007