ABS ISUZU KB P190 2007 Workshop Owners Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 717 of 6020
5C-18 BRAKES
BRAKE LINES (HOSES AND PIPES)
(MODEL WITH ABS)
N ⋅m (kgf ⋅m/lb ⋅ft)
This illustration is based on the RHD model
RTW 75CLF000301
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Page 724 of 6020
BRAKES 5C-25
Filling Master Cylinder Reservoir
CAUTION:
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used for petroleum based fluids or a containe
r
which is wet with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the hydraulic
brake system. Water mixed with brake fluid lowers the
fluid boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine
is cold.
Never allow the brake fluid to come in contact with the
painted surfaces.
The master cylinder reservoir must be kept properly filled
to ensure adequate reserve and to prevent air and
moisture from entering the hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and the engine, the reservoir must not be
overfilled. Thoroughly clean reservoir cap before removal
to avoid getting dirt into reservoir. Add fluid as required to
bring level to the “MAX” mark on the reservoir tank. Use
“DOT 3” Hydraulic Brake Fluid.
Leakage of Brake Fluid
W ith engine idling, set shift lever in the neutral position and
continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually, leakage
from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.
BLEEDING OF THE BRAKE HYDRAULIC
CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoi
r
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
The bleeding operation calls for co-operative action of 2
persons.
• Set the parking brake firmly while bleeding.
• Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.
Make sure exhaust is suitably ventilated.
• Bleed the hydraulic system with the fluid reservoir filled to
the specified level.
• Bleed the system starting with the rear wheel cylinde
r
farthest from the master cylinder.
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Page 827 of 6020
6A – 22 ENGINE MECHANICAL
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacturer Remarks
RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C Three Bond
Three Bond
W ater Base
ThreeBond 1141E
ThreeBond 1215 Three Bond
Three Bond
Solvent
ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402 Three Bond
Isuzu
Isuzu
Isuzu
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 262 Loctite
Loctite
Loctite Recommended for
transaxle repairs
* RTV : Room Temperature Vulcanizer
Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface. Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.
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Page 929 of 6020
6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10 ×1.25
37 (3.8/28)
2
3M8×1.25
18 (1.8/13) (Bolt ID:8)
040R300005
21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position. Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)
Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)
Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)
22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)
23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)
24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)
M8 19 (1.9/14)
M6 8 (0.8/6)
431RY00013
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ISUZU KB P190 2007
Page 987 of 6020
FUEL SYSTEM 6C – 23
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)
7. Injection Pipe Clip Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)
8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.
9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
10. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming pump.
2) Connect the fuel hoses to the injection pump.
12. Oil Level Gauge Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)
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Page 1016 of 6020
ENGINE ELECTRICAL 6D – 15
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.
Oil Seal Replacement
1. Push the old oil seal from the rear bracket outside holes.
2. Use the insertion tool to press the new oil seal into place. Follow the procedure shown in Figures A, B, C
and D.
Position the oil seal beneath the shaft and the
guide lip.
Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.
After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution
Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.
Take care not to damage the D surface.
Under no circumstances may the original oil seal
be reused.
The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.
RTW46DSF000101
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Page 1060 of 6020
6E-26 Engine Control System (4JH1)
Clutch Switch
LNW 46ESH000801
Connector No. C-77
Connector Color W hite
Test Adapter No. J-35616-42
Pin W ire Color Pin Function
1 BLU/RED Clutch Pedal Switch Ignition Voltage
2 YEL Clutch Pedal Switch Signal
Data Link Connector (DLC)
LNW 36ESH015801
Connector No. B-58
Connector Color Black
Test Adapter No. J-35616-2A
Pin W ire Color Pin Function
1
Not Used
2 GRN J1850 (Class 2)
3
Not Used
Connector No. B-58
Connector Color Black
Test Adapter No. J-35616-2A
Pin W ire Color Pin Function
4 BLK Ground
5 BLK Ground
6 BLU Diag Request Switch
7 YEL/BLU Keyword 2000
8
Not Used
9
Not Used
10
Not Used
11 YEL/BLK TCM Diagnostic
12 ORN/W HT ABS C/U Diagnostic
13 RED SRS Diagnostic
14
Not Used
15
Not Used
16 RED/YEL Power Supply
EGR Solenoid Valve
RTW 66ESH000601
Connector No. C-115
Connector Color Black
Test Adapter No. J-35616-4A
Pin W ire Color Pin Function
1 BLU/RED Solenoid Valve 12 Volts Feed
2 BLK/ORN Solenoid Valve Control
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Page 1068 of 6020
6E-34 Engine Control System (4JH1)
Step Action Value(s) Yes No
2 1. Turn ON the ignition, with the engine OFF.
2. Attempt to establish communication with the listed control modules. • Engine control module (ECM)
• Transmission control module (TCM) (A/T
only)
• Electronic hydraulic control unit (EHCU)
Does the scan tool communicate with all the listed
control modules?
Go to Step 3 Go to scan tool
Does Not
Communicate with Keyword 2000 Device
3 Attempt to start the engine. Does the engine start and idle?
Go to Step 4 Go to Engine
Cranks but Does Not Run
4 Select the DTC display function for the following control modules: • ECM
• TCM (A/T only)
• EHCU
Does the scan tool display any DTCs?
Go to Step 5 Go to Step 12
5 1. Turn OFF the ignition for 30 seconds. 2. Start the engine.
3. Monitor the DTC Information with the scan tool.
Did you complete the action?
Go to Step 6
6 Does the scan tool display ECM DTC P0602?
Go to Applicable
DTC Go to Step 7
7 Does the scan tool display ECM DTC P0251 (Symptom Code 9 or A), P0606 (Symptom Code A
or B) or P1605 (Symptom Code C, D or E)?
Go to Applicable
DTC Go to Step 8
8 Does the scan tool display ECM DTC P0560 (Symptom Code 1, 2 or A)?
Go to Applicable
DTC Go to Step 9
9 Does the scan tool display following ECM DTC
P0561 (Symptom Code A or B) or P1625 (Symptom
Code A or B)?
Go to Applicable
DTC Go to Step 10
10 Does the scan tool display following ECM DTC P1650 (Symptom Code A or B) or P1651 (Symptom
Code A or B)?
Go to Applicable
DTC Go to Step 11
11 Is there any other code in any controller that has not
been diagnosed?
Go to Applicable
DTC Go to Step 12
12 Is the customer’s concern with the automatic
transmission? Go to Diagnostic
System Check Transmission Control Go to Step 13
13 Is the customer’s concern with the ABS system?
Go to Diagnostic
System Check Brake Control Go to Step 14
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Page 1377 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-17
RTW 56ASH004401
Legend
1. Engine Hanger (Rear Side)
27.Hang wire on the engine hanger and hoist to lift up
the engine slightly.
28.Remove the engine mount.
• Remove the fastening bolts for the engine mount
on the engine side.
29.Remove the engine assembly.
• Hoist the engine slightly to provide space to
remove the catalytic converter.
Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N ⋅
⋅⋅
⋅
m (4.9kg ⋅
⋅⋅
⋅
m / 35 lb ft)
3. Remove the engine hanger.
4. Install the catalytic converter.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8kg ⋅
⋅⋅
⋅
m /20 lb ft)
5. Install the front exhaust pipe. Tightening torque: 67 N ⋅
⋅⋅
⋅
m (6.8kg ⋅
⋅⋅
⋅
m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4 ×4).
9. Install the harness of engine, battery and earth to the body side.
10.Install the power steering pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
14.Install the fan assembly. Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8kg ⋅
⋅⋅
⋅
m / 69 lb in)
15.Install the drive belt.
Refer to removal procedure for drive belt in this manual.
16.Install the fan guide.
17.Install the breather hose and lower hose of the radiator.
18.Install the engine harness clip (1).
RTW 76ASH001401
19.Install the radiator upper hose.
20.Install the intake hose (turbocharger -intercooler) (Standard output).
• Install the harness connector.
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ISUZU KB P190 2007
Page 1543 of 6020
6C-2 FUEL SYSTEM (4JK1/4JJ1)
Fuel System
Service Precautions
Parts of the fuel system such as the internal part of the
fuel injector, and holes and clearances that form
passages for fuel are finished to a very high degree o
f
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Therefore, effective
measures should be taken to prevent the entry o
f
foreign matter.
If a water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use a water removal agent in the fuel
tank.
W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with ne
w
ones.
Work procedure
•
The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.
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