ISUZU KB P190 2007 Workshop Repair Manual

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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FUEL SYSTEM (4JK1/4JJ1) 6C-11
Step Action Value(s) Yes No
6 Check the fuel tank.
If a problem is found, clean, repair, or replace
as necessary.
• Foreign material (Clogged suction port)
• Bent or cracked suction pipe
• Fuel tank distortion
• Fuel tank improper installation
• Fuel pump and sender malfunction
• Clogged fuel cap hole
• Water
Is the action complete? 

Go to Step 7 

7 Bleed the air from the fuel pipe again. Refer to
Fuel System Air Bleeding in this section.
Is the action complete? 

Verify repair 



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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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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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6C-14 FUEL SYSTEM (4JK1/4JJ1)
Fuel Injector
Components





RTW 76CLF000101
Legend 1. Cylinder Head Cover
2. Fuel Injector Clamp
3. Fuel Injector Clamp Bolt
4. Fuel Injector
5. Fuel Injection Pipe
6. Fuel Injection Pipe Clip


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FUEL SYSTEM (4JK1/4JJ1) 6C-15
The fuel system consists of many tiny holes and spaces
that allow the movement of fuel from one place to
another. These holes and spaces are milled to
extremely high precision. This is especially true of the
fuel injector.
The fuel injector is very sensitive to foreign material.
Foreign material will result in fuel system breakdown.
Exercise great care not to allow the entry of foreign
material into the fuel system or fuel injector during the
removal and installation procedure.
Note: To avoid electric shock;
Set the switch to the 'OFF' position and disconnect the
negative battery cable before checking or repairing the
fuel injector, wiring or/and connectors.
Removal
1. Remove the cylinder head cover.
Refer to the removal procedure for the cylinde
r
head cover in this manual.
Remove the attachment bolt of the engine oil gauge
guide tube.
2. Loosen the fuel injector clamp fixing bolts and
remove the fuel injector.
If the fuel injector is difficult to remove, use the remover. Use a screwdriver to force the fuel
injector clamp off the fuel injector.
Note: Do not remove the fuel injector sleeve.
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.
3. Mark each fuel injector with the number of the cylinder from which it was removed. Store the fuel
injector in a safe place. Position the fuel injector so
that the nozzle is protected.

Note: Do not tamper with the electromagnetic portion of
the fuel injector. Reduced electromagnetic function will
result in injector failure.
Note: After replacement of the fuel injector, perform the
following procedure.
• All fuel injectors are replaced:
Remove the fuel injector ID code label on the cylinder head cover.
• Any fuel injector(s) is replaced:
Black out the replaced cylinder of the fuel injecto
r
ID code on the fuel injector ID code label with a
marking pen or equivalent.
Installation
1. Install the new gasket and O-ring to each fuel
injector.
Note: Do not reuse the clips (3).





RTW 66CSH000101
Legend
1. Fuel Injector
2. Leak Off Pipe
3. Clip
4. O-ring
5. Gasket

2. Install the fuel injector clamps. Refer to the
illustration.





RTW 56CSH000601
Legend
1. Fuel Injector
2. Bolt
3. Fuel Injector Clamp



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6C-16 FUEL SYSTEM (4JK1/4JJ1)
3. Apply Engine oil to the threads and seating
surfaces of the clamp bolts.
4. Install the fuel injector clamps to the cylinder head.
5. Temporarily tighten the clamp bolts.
6.
Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
7. Install the fuel injector pipes to the position shown in the illustration.
8. Use a spanner to carefully tighten the sleeve nuts until the fuel injector pipes contact the fuel injecto
r
and fuel rail.
9. Tighten the fuel injector pipe clips to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)



RTW 76CMH000101
Legend
1. Fuel Injector
2. Pipe Clip


10. Tighten the injection pipes to the specified torque.
Tightening torque: 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)



RTW 76CSH000201
Legend
1. Clamp Bolt
2. Sleeve Nut

11. Tighten the fuel injector clamp bolts to the
specified torque.
Tightening torque: 26 N ⋅
⋅⋅
⋅
m (2.7 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
12. Tighten the engine oil level gauge guide tube. Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
13. Install the cylinder head cover.
Refer to the install procedure for the cylinder head cover in this manual.


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FUEL SYSTEM (4JK1/4JJ1) 6C-17
Record the Fuel Injector ID Code Data from
each injector housing
1. Remove each fuel injector harness connector.
2. Record all numbers of each cylinder on the harness connector housing. The correct order fo
r
the fuel injector ID codes of the following
illustration is as follows:
5F 05 00 FB 00 F7 08 F5 19 FF 04 49





RTW 76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector


Programming Fuel Injector ID Codes
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
4. In order to get programming approval, the on- screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the "Tech" 2 on the Diagnostic Tool Selection screen and click "Next".
f. Click "Close" on the Security Access Enabled screen.


g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Reinstall a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
8. Enter 24 figures of replaced fuel injector ID code.
9.
After complete the programming, turn OFF the
ignition for 30 seconds.
10.Start the engine and let idle.
11.Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.


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6C-18 FUEL SYSTEM (4JK1/4JJ1)
Torque Specifications




RTW 76CLF000201

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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.



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