2007 ISUZU KB P190 oil

6B – 16 ENGINE COOLING

P1010064
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from the engine.





PTW 46BSH000101
5. Remove fan guide(1), clips(2) on both sides and the bottom
lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.




RTW 36BMH000101
7. Remove bracket(5).

8. Lift up and remove the radiator assembly with hose, taking
care not to damage the radiator core with a fan blade.


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ISUZU KB P190 2007

6B – 18 ENGINE COOLING




110RS005
• Check the rubber hoses for swelling.

Installation
1. Install radiator assembly (9) with hose, taking care not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the engine.




RTW 36BMH000101
6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.

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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

FUEL SYSTEM 6C – 15


140R100037
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.





140R100028
Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.






140R100036
Reuse of Quick–Connector
• Replace the port and connector if scratch, dent or crack is
found.
• Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms o
f
rust, dent, scratch.
• After cleaning the port, insert it straight into the connecto
r
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability). Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.





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FUEL SYSTEM 6C – 19
7. Power Steering Pump Bracket

6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only) Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe 1) Disconnect the fuel hoses from the fuel filter or priming pump.
2) Disconnect the fuel hoses from the injection pump.
11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold 1) Remove the EGR valve from the intake manifold and EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)

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FUEL SYSTEM 6C – 23




6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)






7. Injection Pipe Clip Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)

8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.






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








10. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming pump.
2) Connect the fuel hoses to the injection pump.








12. Oil Level Gauge Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)


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6C – 26 FUEL SYSTEM
REASSEMBLY

RTW 76CMF000501


Reassembly Steps
1. Nozzle holder body 2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment) 9. Spring seat
10. Lift Piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Eye bolt











Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.

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6C – 36 FUEL SYSTEM
4. Set the nozzle holder to the nozzle tester and check
first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. W hen replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.


040MV030.tif

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