sensor ISUZU KB P190 2007 Workshop Repair Manual

6C-4 FUEL SYSTEM (4JK1/4JJ1)
Fuel rail assembly




RTW 76CLF000601
Legend 1. Fuel Pressure Limiter
2. Fuel Rail Pressure Sensor





BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-5
Fuel supply pump






RTW 56CLF000301
Legend 1. Fuel Temperature Sensor
2. Suction Control Valve
3. High Pressure Pipe
4. Camshaft Key
5. Camshaft Nut




BACK TO CHAPTER INDEX
TO MODEL INDEX
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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
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.





BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-19
Fuel Rail Pressure Sensor
Removal
1. Disconnect the fuel pressure sensor harness
connector (1).




LNW 76CSH001601
2. Remove the fuel pressure sensor (2).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.









RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter


Installation
1. Install the fuel pressure sensor.
Tightening torque: 98 N·m (10.0 kg·m/72 lb ft)
2. Connect the fuel pressure sensor connector.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6C-20 FUEL SYSTEM (4JK1/4JJ1)
Fuel Pressure Limiter
Removal
1. Remove the leak off pipe and hose (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.




RTW 76CSH000301
2. Remove the fuel pressure limiter.
Note: Cover the areas exposed during part removal to
prevent the entry of foreign material into the fuel
system.










RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter

Installation
1. Install the fuel pressure limiter.
Tightening torque: 172 N·m (17.5 kg·m/127 lb ft)
2. Install the fuel leak off pipe and hose using the mounting eyebolt using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6C-22 FUEL SYSTEM (4JK1/4JJ1)
Removal
1. Remove the starter motor.
• Refer to the removal procedure for engine
electricals in this manual.
2. Remove the fuel feed pipe (1) for supply pump.
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.



RTW 76CSH000501
3. Remove the fuel hose (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.





RTW 76CSH000601

4. Remove the leak off pipe and hose (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.




RTW 76CSH000301
5. Disconnect the fuel rail pressure sensor harness
connector (1).




LNW 76CSH001601


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-23
6. Disconnect the injection pipe sleeve nut (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.




RTW 76CSH000701
7. Disconnect the vacuum pipe and swirl control
solenoid valve from the fuel rail bracket.
8. Remove the fuel rail and fuel rail bracket.
Note: • Do not grasp the pressure sensor, during the
fuel rail removal procedure.
• Take care not to damage the connector unit o
f
the pressure sensor.





RTW 76CSH000801
Legend
1. Fuel Rail
2. Fuel Rail Bracket
3. Vacuum Pipe
4. Swirl Control Solenoid Valve


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6C-24 FUEL SYSTEM (4JK1/4JJ1)
Disassembly
1. Remove the fuel pressure limiter.
2. Remove the pressure sensor.









RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter

Reassembly
1. Install the fuel pressure limiter.
Tightening torque: 172 N ⋅
⋅⋅
⋅
m (17.5 kg ⋅
⋅⋅
⋅
m/127 lb ft)
2. Install the fuel pressure sensor. Tightening torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kg ⋅
⋅⋅
⋅
m/72 lb ft)

Installation
1. Tighten the fuel rail bracket and fuel rail using the
specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
2. Tighten the vacuum pipe to the fuel rail bracket using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)
3. Tighten the swirl control solenoid valve to the fuel rail bracket using the specified torque.
Tightening torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kg ⋅
⋅⋅
⋅
m/14 lb ft)
Note: • Do not grasp the pressure sensor, during the
fuel rail removal procedure.
• Take care not to damage the connector unit o
f
the pressure sensor.




RTW 76CSH000801
Legend
1. Fuel Rail
2. Fuel Rail Bracket
3. Vacuum Pipe
4. Swirl Control Solenoid Valve

4. Tighten the fuel pipe using the mounting sleeve
nut and the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
5. Connect the fuel rail pressure sensor harness connector.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6C-32 FUEL SYSTEM (4JK1/4JJ1)
22. Use a gear puller to remove the fuel supply pump
gear.





RTW 56CSH002901
23. Remove the supply pump (1) and supply pump
bracket (2).
• Disconnect the connector of supply pump.




RTW 58ESH002901
Legend
1. Fuel Temperature (FT) Sensor
2. Suction Control Valve (SCV)


Note:
• Do not hold the high pressure pipe, during the
supply pump removal procedure.
• Do not grasp the high pressure pipe, when
moving the supply pump from one location to
another.







RTW 56CSH002001

24. Remove the supply pump and O-ring.






RTW 56CSH002501
Legend
1. O-ring
2. Supply Pump
3. High Pressure Pipe



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007