2007 ISUZU KB P190 belt

6C – 18 FUEL SYSTEM
INJECTION PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.



Removal
1. Battery
Remove the battery from the battery tray.

Battery
Battery tray

P1010011
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly


P1010003
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.


5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the intake throttle.
6. Fan


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ISUZU KB P190 2007

6C – 24 FUEL SYSTEM







13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket

15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.

Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)

17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump (4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery



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ISUZU KB P190 2007

6D – 2 ENGINE ELECTRICAL

MAIN DATA AND SPECIFICATIONS
Description
Item
60A 80A
Generator
Type
AC generator with IC regulator and vacuum pump
Hitachi LR160-503E Hitachi LR180-513B
Voltage V
Drive and rotation
Ground polarity 12
V-belt, clockwise viewed from the drive pulley Negative
Maximum output A 60 80
Engine speed ratio to 1 1.788
Maximum speed rpm 11,000
Weight with vacuum pump kg(lb) 5.8(12.8) 6.4(14.1)
Vacuum Pump
Delivery volume cm3/rev
Exhaust Characteristic

Maximum vacuum
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000 rpm

7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Starter Motor
Type
Solenoid controlled
Hitachi S13-555
12
2.3
8.76 300 Rated voltage V
Rated output kW
Load characteristics
Terminal voltage V
Load current A
Weight kg(Ib) 4.7 (10.4)


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 7
GENERATOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.


P1010002



























































Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.


Generator
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the bracket.



Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.



Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque N
m (kg
m/Ib
ft)
40 (4.1/30)




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ISUZU KB P190 2007

6D – 8 ENGINE ELECTRICAL

033RY00009




















































Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys. 1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley


3. Adjust the fan belt tension
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection mm (in)
New belt 4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)

4. Tighten the adjusting plate bolts to the specified torque.
Adjusting Plate Bolt N·m (kg·m/lb·ft)
19 (1.9/14)

5. Reconnect the battery cable to the battery.


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ISUZU KB P190 2007

Engine Control System (4JH1) 6E-205
Step Action Value(s) Yes No
5 1. Test the engine cooling system for the following
condition. Refer to diagnosis of the engine
cooling system section for testing. • Engine coolant level
• Engine coolant leakage
• Cooling fan belt slippage
• Cooling fan clutch working
• Thermostat working
• W ater pump working
• Radiator clogging
2. Repair or replace as necessary.
Did you find and correct the condition? 

Go to Step 6 Go to Diagnostic
Aids
6 1. Reconnect all previously disconnected harness connector(s).
2. Clear the DTCs with the scan tool.
3. Turn OFF the ignition for 30 seconds.
4. Start the engine and wait until engine is fully warms upped.
5. Observe the ECT parameter with the scan tool.
Is the ECT parameter more than the specified
value? 100°C (212°F)
Go to Step 4 Go to Step 7
7 Observe the DTC Information with the scan tool. Are there any DTCs that you have not diagnosed?  Go to Diagnostic
Trouble Code (DTC) List System OK


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ISUZU KB P190 2007

Engine Control System (4JH1) 6E-271
Checks Action
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks •
Inspect the EGR system operating correctly.
• Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.


Poor Fuel Economy
Checks Action
DEFINITION:Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Are excessively heavy loads being carried?
• Is the acceleration too much, too often?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (A/T only).
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
• Suggest to the driver to read the Important Facts on Fuel Economy in the Owner
Manual.
• Inspect the odometer is correctly operated.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect the fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to the Cooling System
Section.
• Inspect the engine coolant level.
• Inspect the engine thermostat for always being open or for the wrong heat range.
• Inspect the engine cooling fan for always being ON.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-11
Abnormal engine rotation
Condition Possible Cause Correction
Defective control unit Replace unit Engine speed cannot be increased
Engine control system malfunction System diagnosis
Defective control unit Replace unit
Engine control system malfunction System diagnosis
Clogged fuel filter element Replace element
Defective fuel injector(s) Replace fuel injector assembly
W ater in fuel Drain existing fuel and replace with
new fuel
Engine speed unstable
Air in fuel system Bleed air from fuel system
Damaged turbocharger fan Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Turbocharger malfunction
Broken actuator Replace turbocharger

Abnormal battery charging
Condition Possible Cause Correction
Open or shorted wiring and/or
connectors Repair or replace wiring and/or
connectors
Defective generator Repair or replace generator
No charging
Defective battery Replace battery
Open or shorted wiring and/or
connectors Repair or replace wiring and/or
connectors
Defective generator Repair or replace generator
Loose generator drive belt Adjust belt tension or replace belt
Insufficient charging
Defective battery Replace battery
Shorted wiring Repair or replace wiring
Defective generator Repair or replace generator
Excessive charging
Defective battery Replace battery


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ISUZU KB P190 2007