2007 ISUZU KB P190 indicator

4C2-2 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2W D) and 4 wheel drive (4W D) electrically b
y
driver's pressing the 4W D switch (push button type) on
instrument panel.
This system controls below operations.
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft b
y
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4W D out signal to other Electronic Hydraulic Control Unit.

System Diagrams
RUW 34BLF000201


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ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-47
ABS Warning Lamp ON Steady

Step Action Value(s) Yes No
1 1. Check the ABS warning lamp lighting circuit for a
short.
2. If a problem found, repair as necessary. W as a problem found? - Go to Step 3 Go to Step 2
2 1. Check the ABS warning lamp lighting circuit at the
meter for a short. Refer to METER, W ARNING
LIGHT AND INDICATOR LIGHT in 8 section.
2. If a problem is found, repair or replace the meter. W as a problem found? - Go to Step 3 Go to Step 4
3 1. Connect all connectors.
2. Ignition “ON”, engine “OFF”.
3. W ait for about 10 seconds.
4. Observe the ABS warning lamp. Is the ABS warning lamp turned “OFF”? - Verify repair Go to Step 4
4 Replace EHCU.
Note: Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2W D or 4W D Model)
Is the action complete? - Verify repair -


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ISUZU KB P190 2007

5C-38 BRAKES


Installation Steps
1. Clip; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side o
f
the outer pad.

RUW 55CSH001701

3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.




RUW 55CSH000201
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)




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ISUZU KB P190 2007

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several times and check for fuel leakage.
5. Check the water separator indicator light. It should be off.



Except EURO III model
RTW 46ASH002901




For EURO III model
RTW 46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is felt.
2. W ait 1 minute, and operate the priming pump until strong resistance is felt.
3. Once more wait, and operate the priming pump until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. W ait until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

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ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
6. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system. Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 51

10. Timing Gear Case Cover The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.

11. Water Pump



12. Idle Gear B and shaft Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.



13. Idler Gear "A" 1. Measure the camshaft timing gear backlash and the crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the idler gear.

NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.



Timing Gear Backlash Measurement
1. Set a dial indicator to the timing gear to measured. Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.

Timing Gear Backlash mm (in)
Standard Limit
0.10 - 0.17 (0.0039 - 0.0067) 0.30 (0.012)
020L200006
020L200020
020RY00019
020RY00020

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ENGINE MECHANICAL 6A – 53
















20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.

Camshaft End Play mm (in)
Standard Limit
0.050 - 0.114
(0.002 - 0.0044) 0.20
(0.008)
















2. Remove the camshaft timing gear bolt from the
camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.


21. Camshaft Thrust Plate


22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.



23. Timing Gear Case

24. Cylinder Body Rear Plate



25. Piston Cooling Oil Jet The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.





014RT0001
901R100008
014RY00019
052RY00001

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6A – 62 ENGINE MECHANICAL





















Manifold Fitting Face Warpage
Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but less
than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.


Manifold Fitting Face Warpage mm (in)
Standard Limit Maximum Grinding
Allowance
0.05
(0.002) or less 0.20
(0.008) 0.40
(0.016)



















Exhaust Manifold Warpage
Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the manifold
must be replaced.


Exhaust Manifold Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)



























Valve Stem and Valve Guide Clearance
Measuring Method-I
1. With the valve stem inserted in the valve guide, set the dial indicator needle to "0".
2. Move the valve head from side to side. Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the valve
and the valve guide must be replaced as a set.


Valve Stem Clearance mm (in)
Standard Limit
Intake Valve 0.039 - 0.071
(0.0015 - 0.0028) 0.200
(0.008)
Exhaust Valve 0.064 - 0.096
(0.0025 - 0.0038) 0.250
(0.0098)
027RY00001
027RY00002
011RY00022

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ISUZU KB P190 2007