2007 ISUZU KB P190 vacuum

BRAKES 5C-65
RTW 75CSH002801
6. Clevis; Yoke
Assemble such that the distance from the rear of the vacuum
booster assembly to the center of the clevis yoke hole is within
the range of the reference values.
Distance mm (in)
RHD 147.9 - 148.9 (5.823 - 5.862)
L LHD 160.7 - 161.7 (6.327 - 6.366)
Upon assembling the clevis yoke, tighten the nut to the
specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
15 - 25 (1.5 - 2.5 / 11 - 18)



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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 – 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

ENGINE MECHANICAL 6A – 35
Idling Speed Adjustment
1. Loosen the idling set screw lock nut c on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by turning the idling set bolt
d.
3. Lock the engine set nut
c with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of slack). If required, remove the slack from the cable.
Fast Idling Speed Inspection
1. Set tachometer to the engine.
2. Disconnect the vacuum hose
c from the fast idle
actuator
g on the injection pump.
3. Disconnect the other vacuum hose
d from the
vacuum switching valve
e and connect it to the fast
idle actuator
g.
The vacuum line will now be connected directly from
the vacuum pump
f to the fast idle actuator.
4. Check the engine fast idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Fast Idling Speed rpm
850 ± 25

Fast Idling Speed Adjustment
1. Loosen the fast idle actuator bracket bolts.

2. Adjust the fast idling speed by moving the actuator bracket, so that the clearance “S” can be 1 ~ 2 mm
(0.04 ~ 0.08 in.).
3. Tighten the bracket bolts.


Accelerator Control Cable Adjustment
Refer to Sec. 6H-6 (Accelerator Control)



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 39

18. Radiator 1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.
• TPS connector
• Oil pressure switch connector
• Thermo switch connector
• Injection pump connector
• Engine earth
• Thermometer unit connector
• TDC sensor
2) Remove the clips fixing engine harness.
P1010009

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ISUZU KB P190 2007

6A – 42 ENGINE MECHANICAL

ENGINE REPAIR KIT




RTW 36ALF000601

Removal Steps
1. Cylinder head gasket
2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket
11. Vacuum pump gasket
12. W ater pump O-ring
13. W ater outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal

NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.

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ISUZU KB P190 2007

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

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