2007 ISUZU KB P190 fuel

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several times and check for fuel leakage.
5. Check the water separator indicator light. It should be off.



Except EURO III model
RTW 46ASH002901




For EURO III model
RTW 46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is felt.
2. W ait 1 minute, and operate the priming pump until strong resistance is felt.
3. Once more wait, and operate the priming pump until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. W ait until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

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ISUZU KB P190 2007

6A – 36 ENGINE MECHANICAL
GENERAL DESCRIPTION









RTW 46AMF000401

The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.

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6A – 40 ENGINE MECHANICAL
140R300001
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).




RTW 46ASH000501
Remove the fuel hose from injection pump (EURO III
only).

27. Exhaust Pipe Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.

28. Engine Assembly
1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine compartment.






Installation
To reassemble, follow the removal steps in the reverse
order.


022R300002
F06R300008

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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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ENGINE MECHANICAL 6A – 45




4JA1L
RTW 46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the EGR valve assembly.





4JA1TC RTW 46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level gauge.


6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.




4JH1TC RTW 36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW 36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

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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

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW 36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. W ater Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler W ater Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure W arning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

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6A – 122 ENGINE MECHANICAL

















RTW 46ASH001601































9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque N·m(kg·m/Ib ft)
39 (4.0/29)

10) Install the water feed pipe with the gaskets and tighten to the specified torque.
W ater Return Pipe Torque N·m(kg·m/Ib ft)
39 (4.0/29)

11) Install the water return pipe with the gaskets and tighten to the specified torque.
W ater Return Torque N·m(kg·m/Ib ft)
39 (4.0/29)

12) Clamp the water feed pipe to the oil return pipe of the turbocharger.
Fixing Bolt (3) Torque N·m(kg·m/Ib ft)
8 (0.8/6)

13) Install the hoses for the water feed and return.






















9. Catalytic Converter
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque N·m(kg·m/Ib ft)
27 (2.7/20)

Do not install the catalytic converter, if drop down it.
10. Heat Protector Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque N·m(kg·m/Ib ft)
9 (0.9/6.5 Ib in)

033R300002











11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified torque.
Pulley Nut Torque N·m(kg·m/Ib ft)
8 (0.8/6)

12. Oil Cooler Water Pipe
13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch
027R100007

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