engine ISUZU KB P190 2007 Workshop Repair Manual

6C – 12 FUEL SYSTEM

Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Remove fuel tank assembly (9). Refer to “Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from fuel gauge unit.



140R100035
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.


Installation
1. Clean the seal surface of the fuel tank and the fuel gauge unit.
NOTE: If there is dust on the seal surface, it becomes cause o
f
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.


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ISUZU KB P190 2007

FUEL SYSTEM 6C – 15


140R100037
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.





140R100028
Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.






140R100036
Reuse of Quick–Connector
• Replace the port and connector if scratch, dent or crack is
found.
• Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms o
f
rust, dent, scratch.
• After cleaning the port, insert it straight into the connecto
r
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability). Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.





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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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FUEL SYSTEM 6C – 25
INJECTION NOZZLE (4JA1L)
DISASSEMBLY

RTW 76CMF000401

Disassembly Steps
1. Retaining nut 2. Nozzle & pin
3. Spacer & pin
4. Lift Piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring 9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
13. Nozzle holder body
14. Eye bolt



Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.

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ISUZU KB P190 2007

SECTION 6D
ENGINE ELECTRICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description ........................................................................................................ 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator ...................................................................................................................... ... 6D - 7
Removal and Installation ............................................................................................ 6D - 7
Disassembly ................................................................................................................ 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly ................................................................................................................. 6D - 18
Starter Motor .................................................................................................................. .. 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly ................................................................................................................ 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly ................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33
ENGINE ELECTRICAL 6D – 1

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6D – 2 ENGINE ELECTRICAL

MAIN DATA AND SPECIFICATIONS
Description
Item
60A 80A
Generator
Type
AC generator with IC regulator and vacuum pump
Hitachi LR160-503E Hitachi LR180-513B
Voltage V
Drive and rotation
Ground polarity 12
V-belt, clockwise viewed from the drive pulley Negative
Maximum output A 60 80
Engine speed ratio to 1 1.788
Maximum speed rpm 11,000
Weight with vacuum pump kg(lb) 5.8(12.8) 6.4(14.1)
Vacuum Pump
Delivery volume cm3/rev
Exhaust Characteristic

Maximum vacuum
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000 rpm

7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Starter Motor
Type
Solenoid controlled
Hitachi S13-555
12
2.3
8.76 300 Rated voltage V
Rated output kW
Load characteristics
Terminal voltage V
Load current A
Weight kg(Ib) 4.7 (10.4)


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ENGINE ELECTRICAL 6D – 3

GENERAL DESCRIPTION
GENERATOR STARTER MOTOR



066L300004 065L300002

The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.

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6D – 4 ENGINE ELECTRICAL

CHARGING CIRCUIT DIAGRAM





RTW46DSH005101


STARTING CIRCUIT DIAGRAM



RTW46DSH005501




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ENGINE ELECTRICAL 6D – 5
TORQUE SPECIFICATIONS
GENERATOR N
m (kg
m/Ib
ft)



RTW46DLF000201

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6D – 6 ENGINE ELECTRICAL
STARTER MOTOR N
m (kg
m/Ib
ft)



RTW46DLF000301


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