2007 ISUZU KB P190 ECO mode

ENGINE MECHANICAL (4JK1/4JJ1) 6A-17



RTW 56ASH004401
Legend
1. Engine Hanger (Rear Side)

27.Hang wire on the engine hanger and hoist to lift up
the engine slightly.
28.Remove the engine mount.
• Remove the fastening bolts for the engine mount
on the engine side.
29.Remove the engine assembly.
• Hoist the engine slightly to provide space to
remove the catalytic converter.
Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N ⋅
⋅⋅
⋅
m (4.9kg ⋅
⋅⋅
⋅
m / 35 lb ft)
3. Remove the engine hanger.
4. Install the catalytic converter.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8kg ⋅
⋅⋅
⋅
m /20 lb ft)
5. Install the front exhaust pipe. Tightening torque: 67 N ⋅
⋅⋅
⋅
m (6.8kg ⋅
⋅⋅
⋅
m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4 ×4).
9. Install the harness of engine, battery and earth to the body side.
10.Install the power steering pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
14.Install the fan assembly. Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8kg ⋅
⋅⋅
⋅
m / 69 lb in)
15.Install the drive belt.
Refer to removal procedure for drive belt in this manual.
16.Install the fan guide.
17.Install the breather hose and lower hose of the radiator.
18.Install the engine harness clip (1).

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19.Install the radiator upper hose.
20.Install the intake hose (turbocharger -intercooler) (Standard output).
• Install the harness connector.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-133






015LX115
4. Install the lower crankshaft bearing.
• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
• Apply the recommended liquid gasket or its
equivalent to the No. 5 crankshaft bearing cap
cylinder body fitting surfaces at the points
shown in the illustration.
Note:
Be sure that the bearing cap fitting surface is completel
y
free of oil before applying the liquid gasket. ThreeBond
1207B Do not allow the liquid gasket to obstruct the
cylinder thread holes and bearings.
ThreeBond 1207B is a fast-drying liquid gasket. Tighten
the bearing caps immediately after applying the gasket.







015LX127

5. Install the bearing cap.
• Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.








015LX128
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence
shown in the illustration.
Crankshaft Bearing Cap Torque N ⋅m (kg ⋅m / lb ft)
166 (16.9 / 122)
Check to see the crankshaft turns smoothly by
rotating it manually.
Note:
Confirm that the crankshaft turns smoothly.








015LX129
6. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-7
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“MIN" and “MAX" lines of the reserve tank when the
engine is cold. If low, check for leakage and add EC up
to the “MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.

1. Remove the radiator skid plate.
2. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.




RTW 56BSH000301
3. Remove the radiator cap.
WARNING:
To avoid the danger of being burned, do not
remove the cap while the engine and radiator are
still hot. Scalding fluid and steam can be blown out
under pressure.
4. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.

5. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change).
• Make sure that the engine is cool.
• Open radiator cap and pour coolant up to fille
r
neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and
reopen the radiator cap. If the water level is lower,
replenish.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor o
r
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.
• After tightening the 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.
• Check to see the thermostat has opened through
the needle position of the water thermometer,
conduct a 5–minute idling again and stop the
engine.
• W hen the engine has been cooled, check fille
r
neck for water level and replenish if required.
Should extreme shortage of coolant be found,
check the cooling system and reservoir tank hose
for leakage.
• Pour coolant into the reservoir tank up to “MAX"
line.

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ISUZU KB P190 2007

6C-6 FUEL SYSTEM (4JK1/4JJ1)
Fuel injector



RTW 76CMH000201
Legend
1. Terminal
2. Fuel Injector ID Code
3. Two Dimensional Barcode
4. Parts Number
5. Port for Mounting the Injection Pipe
6. O-ring

Fuel filter





RTW 76CSH001001
Legend
1. Element
2. Air Bleeding Plug
3. Switch; Clogging Monitoring
4. Sensor; W ater
5. Drain Plug

Functional check
Air bleeding
1. Ignition switch is turned to the ON position for 15 seconds.
2. Ignition switch is turned to the OFF position.
3. The above operation is repeated 5 times.
Note: If the air bleeding work is insufficient then it could
lead to faults in the engine. Therefore, the procedures
after starting the engine should always be implemented.

Water drain
A warning lamp will light up if water above the specified
volume collects in the sedimenter. In such cases, drain
out the water by performing the following operations:
1. Draining with fuel filter drain plug. a. Set a container at the tip of the plastic hose.
b. Loosen the air bleeding plug and the drain plug.
c. Discharge the water.
d. Tighten the drain plug after discharging the water.
e. Tighten the air bleeding plug to the specified torque.
Tightening torque: 3 N ⋅m(0.3 kg ⋅m/26 lb in)
f. Ignition switch is turned ON for 15 seconds check for fuel leakage.

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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-7
g. Check that the warning lamp in the meter is off.
2. Draining with drain plug in engine room. a. W ith the engine off, open the engine hood and loosen the drain plug (1) located on the left
hand side of the engine room. (3-4 turns)
b. Turn the starter switch to the “ON” position fo
r
10 seconds, and then turn the starter switch to
the “OFF” position for 10 seconds. Then, once
again turn the starter switch to the “ON”
position for 10 seconds.
c. Tighten the drain plug firmly.
d.
After starting the engine, check that there is no
fuel leakage from the drain plug. Also check
that the water separator indicator has turned
off.










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NOTE:
• If the water separator requires frequent draining,
have the fuel tank drained at your ISUZU/GM
Dealer.
• Be sure to stop the engine when draining the fuel
tank.
• Confirm that there are no combustible materials
under the drain hose, and use a receptacle to
catch the drained water.


Engine starting cautions
• Before starting the engine, turn the ignition switch
to the “ON” position. W ait 15 seconds. Return the
switch to the “LOCK” position. Repeat this
procedure 5 times.
• After starting the engine, allow it to idle for 10
minutes.

Fuel Pump Functional Check
1. Turn the starter switch to “ON” position.
2. Touch the under portion of the Fuel Tank by the hand as shown in the following figure within 12
seconds.





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Legend
1. Touch this area by the hand

3. Make sure a vibration by the Fuel Pump is
detected.
Fuel Pump stops within 12 seconds of turning the starter switch to the “ON” position.
W hen the check is repeated, return the starte
r
switch to the “LOCK” position for 10 – 15 seconds
and perform procedures 1 – 3.
WARNING: FUEL PUMP FUNCTIONAL CHECK
MUST BE CONDUCTED UNDER THE FOLLOWING
CONDITIONS TO AVOID INJURY.
•
••
•
APPLY THE PARKING BRAKE.
•
••
•
STOP THE ENGINE.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-17
Record the Fuel Injector ID Code Data from
each injector housing
1. Remove each fuel injector harness connector.
2. Record all numbers of each cylinder on the harness connector housing. The correct order fo
r
the fuel injector ID codes of the following
illustration is as follows:
5F 05 00 FB 00 F7 08 F5 19 FF 04 49





RTW 76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector


Programming Fuel Injector ID Codes
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
4. In order to get programming approval, the on- screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the "Tech" 2 on the Diagnostic Tool Selection screen and click "Next".
f. Click "Close" on the Security Access Enabled screen.


g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Reinstall a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
8. Enter 24 figures of replaced fuel injector ID code.
9.
After complete the programming, turn OFF the
ignition for 30 seconds.
10.Start the engine and let idle.
11.Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.


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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

FUEL SYSTEM (4JK1/4JJ1) 6C-45
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.







140R100037
Cover the connectors that were removed with a plastic
bag, to prevent dust or rain water from entering.




140R100028

Reuse of Quick-Connector
•
Replace the port and connector if a scratch, dent
or crack is found.
• Remove any dirt build up on the port when
installing the connector. Replace the connector, i
f
there is any rust, dents or scratches.
• After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling it
out at 49 N (5 kg / 11 lb) to make sure that it is not
drawn and is securely locked.




140R100036
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 ma
y
affect the fuel injection system.
3. Check for fuel leakage from the connector.





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ISUZU KB P190 2007