2007 ISUZU KB P190 air filter

6A-8 ENGINE MECHANICAL (4JK1/4JJ1)
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction
Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connect
Repair
Starter motor brushes stuck, worn,
or broken Replace brushes
Starter motor does not rotate
Starter motor internal damage Repair motor
Ring gear abrasion Replace ring gear Starter motor not meshed with
flywheel Magnetic switch (starter motor) not
properly adjusted Adjust
Dead or weak battery
Charge battery
Replace battery
Insufficient contact pressure
between starter motor brushes and
commutator Adjust pressure
Armature (starter motor) stuck Repair armature
Starter motor pinion meshed with
ring gear but does not rotate
Engine internal damage (Seizure) Repair engine

Engine turns over but does not start
Condition Possible Cause Correction
Air in fuel system Bleed air from fuel system
Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing
temperatures Drain existing fuel and replace with
appropriate fuel
Fuel is not delivered to fuel supply
pump
Clogged fuel filter Replace filter
Loose injection pipe connections Tighten connections
Loose or broken electrical
connectors Tighten and/or replace connectors
Bad rotational sensor
Replace sensor
Fuel is delivered to fuel supply
pump
Engine control system malfunction System diagnosis
Air in fuel system Bleed air from fuel system
Feed pump malfunction Repair pump
Loose or broken electrical
connectors Tighten and/or replace connectors
Clogged fuel filter
Replace filter
Insufficient or unstable fuel delivery
volume
Engine control system malfunction System diagnosis

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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

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

6C-8 FUEL SYSTEM (4JK1/4JJ1)
Trouble Shooting
Problems with starting
Condition Possible Cause Correction
Problems with starting Fuel tank is empty Fill the tank.
Air has entered the fuel system. Bleed the air.
Fuel line or fuel cooler is clogged or
damaged. Connection to the fuel line
is loose. Repair or replace the fuel line and
fuel cooler. Re-tighten the
connection.
Fuel filter element is clogged. Replace the cartridge.
Fault in the feed pump Replace the fuel supply pump.
Regulating valve is open. Replace
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Hunting during idling
Condition Possible Cause Correction
Hunting during idling Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel
system Repair or replace the fuel system.

Drops of water have entered the fuel
system. Replace the fuel.

Fuel filter element is clogged. Replace the fuel filter element
(cartridge).
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Insufficient horsepower
Condition Possible Cause Correction
Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel
system Repair or replace the fuel system.

W ater mixes in the fuel system Replace the fuel.
Fuel filter element is clogged. Replace the element or the
cartridge.
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Maximum engine speed is too low
Condition Possible Cause Correction
Maximum engine speed is too low Fuel line, fuel cooler is clogged or
damaged. Repair or replace the fuel line, fuel
cooler.
Defective engine control system Diagnose the engine control system.


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ISUZU KB P190 2007

6C-10 FUEL SYSTEM (4JK1/4JJ1)
Fuel System Check
Description
Conforms to a fuel leak. Engine acceleration raises fuel
pressure and which increases the leak.
Leak could be in the following pipes and locations.
• Between injectors and fuel rail.
• Between fuel rail and fuel supply pump.
• Between fuel supply pump and fuel filter.
• Between fuel filter and fuel tank.
• Between pressure limiter and fuel cooler.
• Between fuel cooler and fuel tank.
• Between injector over flow and leak off pipe.
Diagnostic Aids
Check the following items.
• Air in the fuel line
• Clogged fuel filter
• Fuel pipe malfunction (Crushing, breakage,
clogging, disconnection, etc.)
• Fuel cooler malfunction (Crushing, breakage,
clogging, disconnection, etc.)
• Fuel tank malfunction
• Injector malfunction
• Fuel supply pump malfunction
• Pressure limiter malfunction
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness.
Inspect the ECM harness and connector for imprope
r
mating, broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
ECU may set a DTC, if there is adequate air in fuel line.


Schematic Reference: Engine Controls Schematics
Step Action Value(s) Yes No
1 Check the fuel quantity. W as a problem found? 

Go to Step 2 Add fuel and
Go to Step 2
2 Check the fuel quality.
1. Discharge the fuel from fuel tank
2. Replenish the tank with specified fuel
3. Bleed the air from the fuel system
4. Start the engine
Could the engine be started? 

Go to Step 7 Go to Step 3
3 Bleed the air from fuel system. Refer to Fuel
System Air Bleeding in this section.
Is the action complete? 

Go to Step 4 

4 Check the main fuel filter for clogging.
Clean, repair, or replace as required.
Notice: Replacement of a fuel filter is checking
to a dealer.
Is the action complete? 

Go to Step 5 

5 Check the fuel line and fuel cooler for damage
and leakage.
Clean, repair, or replace as required.
• Crushed areas
• Breakage
• Cracks
• Loose connections
Is the action complete? 

Go to Step 6 


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ISUZU KB P190 2007

6C-12 FUEL SYSTEM (4JK1/4JJ1)
Fuel Filter Assembly
Components






RTW 76CSF000101
Legend
1. Fuel Sedimenter Connector 2. Bolt
3. Harness Connector
4. Fuel Hose
5. Fuel Filter Assembly

Removal
1. Remove the fuel filler cap.
2. Remove the fuel sedimenter connector.
3. Disconnect the harness connector.
4. Remove the feed hose and the return hose from the fuel filter and plug it so that the fuel does not
flow out.
5. Remove the bolts for mounting the fuel filter.
6. Remove the fuel filter assembly.
Installation
1. Install the fuel filter assembly.
2. Install the bolts for mounting the fuel filter.
3. Install the feed hose and the return hose.
4. Connect the harness connector.
5. Install the fuel sedimenter connector.
6. Install the fuel filler cap.
7. Bleed out the air. • Refer to "Fuel System".





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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-13
Fuel Filter Element
Removal
1. Detach the drain hose on the lower part of the fuel
filter or the drain plug, loosen the air bleed plug,
and drain the fuel from the fuel filter.
2. Detach the water-in-fuel switch harness.
3. Turn the element case counterclockwise to detach, and remove the filter element.
4. Replace the O-ring and confirm the snap-fit position, and fit a new filter element inside the
element case.
NOTE
It is strongly advisable to use the ISUZU/GM genuine
fuel filter for replacement.




RTW 76CSH000901
Legend
1. Element
2. O-ring
3. Sedimenter Sensor


Installation
1. Apply a light coat of new diesel oil to the O-ring
and gasket.
2. Turn the element case clockwise until it is completely seated against the upper cover. Then
check that the drain hose is in its correct position,
and then use a filter wrench and tighten to the
specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
3. Use a clip to fix the drain hose at the base of the fuel filter, and fit the water-in-fuel switch harness.





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ISUZU KB P190 2007

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-9
Schematic and Rounting Diagrams
Fuel System Routing Diagram
Legend1. Fuel rail
2. Fuel pressure limiter
3. Leak off pipe
4. Fuel injector
5. Fuel return pipe
6. Fuel cooler
7. Fuel tank
8. Fuel pump and sender assembly 9. Fuel filler cap
10. Vent valve 11. Fuel feed pipe
12. One-way valve
13. Fuel filter with sedimenter
14. Fuel pressure switch
15. Fuel supply pump

Vacuum Hose Routing Diagram
Legend
1. Swirl control solenoid valve
2. Actuator control vacuum hose
3. Swirl control actuator
4. Brake booster
5. Vacuum pipe
6. Vacuum pump 7. Actuator control vacuum hose
8. Air cleaner
9. Turbocharger nozzle control actuator
10. Solenoid valve ventilation hose 11. Turbocharger nozzle control solenoid valve

RTW76ESF000101
12 3
4
5
117
8
9
10
14
13
12
15
6
RTW76ESF000201
1 2
4
5
6
9
8
3
7
11
High output10

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ISUZU KB P190 2007