Page 923 of 6020
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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ISUZU KB P190 2007
Page 925 of 6020
6A – 120 ENGINE MECHANICAL
4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified torque.
Suction Pipe Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)
5. Generator and Adjusting Plate
1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.
3) Connect the vacuum pump rubber hose (4) to the
vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body
052R300001
7. Compressor Bracket 1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
M8×1.25
19 (1.9/14)
M10×1.25
40 (4.1/30)
066RY00002
032R300001
042RY00003
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Page 930 of 6020
ENGINE MECHANICAL 6A – 125
25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque N·m(kg·m/Ib ft)
31 (3.1/23)
Connector the vacuum hose.
025R100008
RTW 36ASH000301
26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)
EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)
RTW 48ASH001801
26-2. EGR Cooler (EURO III model only)
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)
EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct N·m(kg·m/Ib ft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
RTW 36ASH000201
28. Clutch Assembly or Flex Plate
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Page 961 of 6020
ENGINE COOLING 6B – 17
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 93.3
∼
∼∼
∼122.7 (13.5
∼
∼∼
∼17.8)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.
110RS006
Valve opening vacuum kPa (psi) 1.96 ∼
∼∼
∼ 4.91 (0.28 ∼
∼∼
∼ 0.71)
Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
• Leakage from the radiator
• Leakage from the coolant pump
• Leakage from the water hoses
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Page 970 of 6020
6C – 6 FUEL SYSTEM
INJECTION PUMP
RTW 46CLF000201
4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engine’s vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.
4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
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Page 981 of 6020
FUEL SYSTEM 6C – 17
FUEL FILLER CAP
RTW 46CSH000301
Legend
1. Seal Ring
General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.
Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective
CAUTION: A replacement fuel filler cap must be the same
as the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.
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Page 982 of 6020
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
Page 988 of 6020
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
