lock ISUZU KB P190 2007 Workshop Repair Manual

5D-10 PARKING BRAKE SYSTEM
Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin and shoe clamp spring.
4. Remove return spring.
5. Remove shoe assembly with parking brake lever.
6. Remove shoe assembly with adjuster lever and spring.
7. Remove parking brake inner cable from parking brake lever.
8. Use offset box wrench (12 mm hex.) to compress locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.




RTW 55CSH000301

Legend
(1) Offset Box W rench (12 mm hex)
9. Remove nut to fix the cable on the leaf spring.
10. Take out parking brake rear cable from the back plate.
11. Remove parking brake cable bolt and nut.
12. Disconnect T-end from the equalizer of front cable.

Installation

NOTE: Be sure to use a new shoe clamp spring and a
new adjuster lever clip.
1. Apply grease (multipurpose type grease) to the connecting portion of the rear cable and equalizer.
(arrow mark).
2. Install parking brake outer cable in back plate and inner cable in parking brake lever.
3. Install return spring.
4. Install shoe clamp spring and tension pin.
5. Install shoe assembly with adjuster lever, shoe assembly with parking brake lever and spring. ----
snap action
6. Install nut and tighten it to the specified torque. Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
7. Connect T-end with equalizer through outer cable retainer.
8. Install parking brake cable nut and tighten it to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
9. Install parking brake cable bolt and tighten it to the specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13.
Adjust parking brake lever adjusting nut so that
parking brake lever goes through 6-9 notches
(Bucket Seat) or 8 −14 notches (Bench Seat), when
pulled with an operation force of 294 N (30 kg/
66 lb).
14. Check brake for no drag.


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? —
Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at 200rpm
Go to Step 11 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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ISUZU KB P190 2007

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.


RTW 36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element (Except wet type element)
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0200-0


RTW 36ASH000101



4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face.
7. Use the filter wrench to turn in the filter an additional 2/3 turns.
Filter W rench: 5-8840-0200-0
8. Check the engine oil level and replenish to the specified level if required.
130RY00003
6A-6

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ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
W ith oil filter
replacement W ithout oil
filter
replacement
4 × 2
4 × 4
(4JA1L/TC)6.2 (1.64/1.36) 5.2 ∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 2
(4JH1TC)
6.2 (1.64/1.36) 5.2
∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 4
(4JH1TC) 7.0 (1.85/1.54) 6.2 ∼ 5.2
(1.64 ∼ 1.37
/ 1.36 ∼ 1.14) 5.3
∼ 4.3
(1.72 ∼ 1.14
/ 1.17 ∼ 0.95)

9. Start the engine and check for oil leakage from the
main oil filter.



RTW 66ASH003201




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.




RTW 66ASH003301








2. Clean the fuel filter cartridge fitting faces. This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a filter wrench.
Filter W rench : 5-8840-0253-0 (J-22700)




6. Operate the priming pump until the air discharged completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.

041RY00009

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ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


014RY00015
8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end.

014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360 °.
14. Realign the crankshaft damper pulley TDC notched line with the timing pointer.
15. Adjust the clearances for the remaining valves as shown in the illustration.



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6A – 34 ENGINE MECHANICAL



RTW 46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8 °)
is aligned with the pointer.

Injection Timing : BTDC 8 ° ± 2 °

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket bolts.
11. Adjust the injection pump setting angle.
W hen large than standard value W hen smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.
12. Install the distributor head bolt.
Distributor head bolt torque N·m (kg·m /lb·ft)
29 (3.0/22)



ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant temperature reaches 70 - 80 °C (158 - 176 °F).


4. Disconnect the engine control cable from the control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 ± 25 rpm



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ENGINE MECHANICAL 6A – 35
Idling Speed Adjustment
1. Loosen the idling set screw lock nut c on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by turning the idling set bolt
d.
3. Lock the engine set nut
c with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of slack). If required, remove the slack from the cable.
Fast Idling Speed Inspection
1. Set tachometer to the engine.
2. Disconnect the vacuum hose
c from the fast idle
actuator
g on the injection pump.
3. Disconnect the other vacuum hose
d from the
vacuum switching valve
e and connect it to the fast
idle actuator
g.
The vacuum line will now be connected directly from
the vacuum pump
f to the fast idle actuator.
4. Check the engine fast idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Fast Idling Speed rpm
850 ± 25

Fast Idling Speed Adjustment
1. Loosen the fast idle actuator bracket bolts.

2. Adjust the fast idling speed by moving the actuator bracket, so that the clearance “S” can be 1 ~ 2 mm
(0.04 ~ 0.08 in.).
3. Tighten the bracket bolts.


Accelerator Control Cable Adjustment
Refer to Sec. 6H-6 (Accelerator Control)



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6A – 68 ENGINE MECHANICAL






























ROCKER ARM SHAFT AND ROCKER ARM
Rocker Arm Shaft Run-Out
1. Place the rocker arm shaft on a V-block.
2. Use a dial indicator to measure the rocker arm shaft central portion run-out.
If the run-out is very slight, correct the rocker arm shaft
run-out with a bench press. The rocker arm must be at cold
condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.

Rocker Arm Shaft Run-Out mm (in)
Limit
0.3 (0.012)



















Rocker Arm Shaft Outside Diameter
Use a micrometer to measure the rocker arm fitting portion
outside diameter.
If the measured value is less than the specified limit, the rocker
arm shaft must be replaced.


Rocker Arm Shaft Outside Diameter mm (in)
Standard Limit
18.98–19.00 (0.747–0.748) 18.90 (0.744)
















Rocker Arm Shaft and Rocker Arm Clearance
1. Use either a vernier caliper or a dial indicator to measure
the rocker arm inside diameter.


Rocker Arm Inside Diameter mm (in)
Standard Limit
19.010–19.030 (0.748–0.749) 19.100 (0.752)









2. Measure the rocker arm shaft outside diameter.
If the measured value exceeds the specified limit, replace
either the rocker arm or the rocker arm shaft.


Rocker Arm Shaft and Rocker Arm Clearance mm (in)
Standard Limit
0.01–0.05
(0.0004–0.0020) 0.20 (0.008)
015LX009
014RY00024 015LX008

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6A – 72 ENGINE MECHANICAL


012RY00022
A mark was stamped on the upper side of the cylinder block
during production to indicate the correct liner.
The liner grade (i.e.1.2.3.4) is indicated in metal stamp.


Cylinder Liner Grade
4JA1T (L), 4JA1TC mm (in)
Liner
Outside Grade Cylinder Body
Bore Diameter Liner Outside
Diameter Liner Bore
Grade Service Liner Bore Measurement
AX 93.035-93.050 (3.6628-3.6634) 1 95.001-95.010
(3.7402-3.7405) 95.011-95.020
(3.7406-3.7409) CX 93.051-93.066 (3.6634-3.6640)
AX 93.035-93.050 (3.6628-3.6634) 2 95.011-95.020
(3.7406-3.7409) 95.021-95.030
(3.7410-3.7413) CX 93.051-93.066 (3.6634-3.6640)
AX 95.035-93.050 (3.6628-3.6634) 3 95.021-95.030
(3.7410-3.7413) 95.031-95.040
(3.7414-3.7417) CX 93.051-93.066 (3.6634-3.6640)
AX 93.035-93.050 (3.6628-3.6634) 4 95.031-95.040
(3.7414-3.7417) 95.041-95.050
(3.7418-3.7421) CX 93.051-93.066 (3.6634-3.6640)
4JH1TC mm (in)
Liner
Outside Grade Cylinder Body
Bore Diameter Liner Outside
Diameter Liner Bore
Grade Service Liner Bore Measurement
AX 95.435-95.450 (3.7573-3.7579) 1 97.001-97.010
(3.8189-3.8193) 97.011-97.020
(3.8193-3.8197) CX 95.451-95.466 (3.7579-3.7585)
AX 95.435-95.450 (3.7573-3.7579) 2 97.011-97.020
(3.8193-3.8197) 97.021-97.030
(3.8197-3.8200) CX 95.451-95.466 (3.7579-3.7585)
AX 95.435-95.450 (3.7573-3.7579) 3 97.021-97.030
(3.8197-3.8200) 97.031-97.040
(3.8200-3.8205) CX 95.451-95.466 (3.7579-3.7585)
AX 95.435-95.450 (3.7573-3.7579) 4 97.031-97.040
(3.8200-3.8205) 97.041-97.050
(3.8205-3.8209) CX 95.451-95.466 (3.7579-3.7585)

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ENGINE MECHANICAL 6A – 77


CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.














Camshaft Journal Diameter
Use a micrometer to measure each camshaft journal diameter
in two directions (1 and 2). If the measured value is less than
the specified limit, the camshaft must be replaced.

Camshaft Journal Diameter mm (in)
Standard Limit
49.945 - 49.975
(1.9663 - 1.9675) 49.60 (1.953)














Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.

Cam Height (H) mm (in)
Standard Limit
42.016 (1.6542) 41.65 (1.640)



















Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the
camshaft must be replaced.

Camshaft Run-Out mm (in)
Standard Limit
0.02 (0.0008) 0.10 (0.004)

014RY00032
014RY00033 014LX092

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