2007 ISUZU KB P190 charging

ENGINE MECHANICAL (4JK1/4JJ1) 6A-7
• Remove the all glow plugs.

Note:
W hen the harness connector is removed, ECM judges
that it broke down and DTC is recorded. Upon
completion of measurement, never fail to clear the
memory of the ECM.
(For how to clear the memory of the ECM, refer to
“ENGINE CONTROL SYSTEM” Section)
• Connect the negative battery cable.
• Turn on the starter to emit foreign matter within the
cylinders.
• Install an adapter and a gauge of a compression
gauge of the special tool.




RTW 56ASH003801
Compression gauge: 5-8840-2675-0
Gauge adapter: 5-8840-2815-0
• Turn on the starter to inspect compression
pressure.

Compression pressure MPa(psi)/200rpm
Standard 2.84 − 3.24 (412 − 469)
Limit 1.96 (284)
Differences among
the cylinders 294 kPa (43)
•
Measure each cylinder one by one.

Note:
To keep engine speed at 200 rpm or more, use full
y
charged batteries.
• Remove a compression gauge of the special tool.
• Disconnect the negative battery cable.
• Install the glow plugs.
• Connect the negative battery cable.

A list of defective phenomena
• Engine does not turn over.
• Engine turns over but does not start.
• Excessive black exhaust smoke.
• Excessive white exhaust smoke.
• Engine knocking.
• Abnormal engine rotation.
• Abnormal battery charging.
• Turbocharger trouble shooting.


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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

ENGINE MECHANICAL (4JK1/4JJ1) 6A-13
Main Data and specifications
Item Engine model 4JK1 Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder
bore × strokes mm (in) 4-95.4 (3.76) × 87.4 (3.44) 4-95.4(3.76) × 104.9(4.13)
Displacement
cc (cu.in) 2499 (152) 2999 (183)
Compression ratio 18.3 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1 - 3 - 4 - 2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type W ater cooling type
Radiator type Corrugated fin (pressure type)
W ater pump type Centrifugal, belt drive type
Thermostat type W ax-type units
Thermostat valve-opening temperature °C ( °F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 - 90

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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

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS

Charging System ................................................ 6D-2
Servicing Cautions .......................................... 6D-2
Important Generator Components and
Function.......................................................... 6D-2
Troubleshooting .............................................. 6D-5
Diagnosis......................................................... 6D-7
Specifications .................................................. 6D-8
Unit Se rv ic ing (4 JJ 1) ....................................... .... ..6D -9
Disassembly .................................................... 6D-10
Inspection and Repair ..................................... 6D-11 Rotor Assembly ........................................... 6D-11
Stator Coil .................................................... 6D-12
Brushes ....................................................... 6D-12
Rectifier ....................................................... 6D-13
Regulator Assembly..................................... 6D-13
Measuring Procedure .................................. 6D-13
Reassembly..................................................... 6D-14
Final Assembly ................................................ 6D-14
Starter Motor ...................................................... 6D-15 Starting Circuit Diagram .................................. 6D-15
Removal and Installation ................................. 6D-15 Important Operations – Removal................. 6D-15
Important Operations – Installation.............. 6D-15
Disassembly .................................................... 6D-16 Disassembly Steps ...................................... 6D-16
Important Operations ................................... 6D-17
Inspection and Repair ..................................... 6D-20 Armature ...................................................... 6D-20
Yoke............................................................. 6D-21
Brush and Brush Holder .............................. 6D-22
Overrunning Clutch...................................... 6D-22
Bearing ........................................................ 6D-23
Reassembly..................................................... 6D-24 Reassembly Steps ....................................... 6D-24
Important Operations ................................... 6D-25
Inspection After Assembly ........................... 6D-26
Magnetic Switch .............................................. 6D-27
Torque Specifications...................................... 6D-28

Pre-Heating System ........................................... 6D-29 Inspection and Repair ..................................... 6D-29 Visual Check................................................ 6D-29
Glow Relay .................................................. 6D-29
Glow Plug .................................................... 6D-29


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ISUZU KB P190 2007

6D-2 ENGINE ELECTRICAL (4JK1/4JJ1)
Charging System
Servicing Cautions
• Battery polarity is important. If the battery cables
are reversed, the generator diodes will be
destroyed.
• Do not remove the battery cables or the charging
circuit wiring when the engine is running.
• Confirm that the terminal wires are connected to
the proper terminals by checking the terminal
numbers (the number on the terminal wire and the
terminal must be the same).
• Disconnect the battery negative cable (-) before
inspecting the generator.
• Do not open or close the battery relay switch when
the engine is running.
• Disconnect the battery negative cable (-) when
using external equipment (Quick-Charge) to
charge the battery.
• W hen steam cleaning or washing the engine, do
not allow steam or water to come in direct contact
with the battery and other electrical system
components.
• Be sure to read the item on belt tension
adjustment before beginning the procedure.
Important Generator Components
and Function
• The generator used on 4JK1 engine cannot be
disassembled.
• The generator uses a built-in solid-state IC voltage
regulator. The regulator and other important
components together with their connections are
shown in the illustration.
• The voltage regulator is installed to the rear cove
r
assembly of the generator together with the brush
holder and the rectifier. The generator requires no
additional voltage regulation.
• 9 diodes are connected to the stator coil to convert
AC to DC. The DC voltage is delivered to the
generator output terminal.


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ISUZU KB P190 2007

6D-4 ENGINE ELECTRICAL (4JK1/4JJ1)
Charging System (4JK1)







RTW 56DMF000601
Charging System (4JJ1)


RTW 56DMF000101

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ISUZU KB P190 2007

ENGINE ELECTRICAL (4JK1/4JJ1) 6D-5
Troubleshooting
Symptoms
• No charging
• Inadequate charging
• Excessive charging
• Unstable charging current
• Abnormal generator noise



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ISUZU KB P190 2007