ISUZU KB P190 2007 Workshop Repair Manual

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)


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-21
Fuel Rail Assembly
Components



RTW 76CLF000301
Legend
1. Injection Pipe (#1 to #4)
2. Fuel Feed Pipe Assembly
3. Injection Pipe Clips
4. Fuel Rail
5. Fuel Rail Bracket
6. Fuel Leak Off Pipe and Hose


Parts of the fuel system such as the internal part of the
fuel injector, holes and clearances that form passages
for fuel are finished to a very high degree of 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 of foreign matter.


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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


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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


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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.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-25
6. Tighten the fuel leak off pipe and hose (1) using
the mounting eyebolt using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)




RTW 76CSH000401
7. Install the fuel hose (1).





RTW 76CSH000601

8. Install the fuel feed pipe (1) for supply pump and
tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m/33 lb ft)



RTW 76CSH000501
9. Install the starter motor. • Refer to removal procedure for engine
electricals in this manual.



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6C-26 FUEL SYSTEM (4JK1/4JJ1)
Torque Specifications






RTW 76CLF000401



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FUEL SYSTEM (4JK1/4JJ1) 6C-27
Fuel Supply Pump
Components



RTW 76CMF000201
Legend
1. Fuel Feed Pipe Assembly
2. Injection Pipe Sleeve Nut
3. Fuel Supply Pump
4. Bracket 5. Noise Cover
6. Timing Chain Cover Lower
7. Nut
8. Sprocket
9. Fuel Supply Pump Gear

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.








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6C-28 FUEL SYSTEM (4JK1/4JJ1)
Removal
1. Partially drain the engine coolant.
Refer to drain procedure for engine cooling in this manual.
2. Remove the radiator upper hose.





RTW 56FSH000101
3. Remove the fan guide.




RTW 46BSH000101
Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling Fan.




RTW 56ASH025401
5. Remove the A/C compressor drive belt.
6. Remove the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut

7. Remove the battery.


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FUEL SYSTEM (4JK1/4JJ1) 6C-29
8. Disconnect the A/C compressor.



RTW 56ASH024201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor

9. Remove the A/C compressor bracket.
10. Remove the fuel rail assembly.
Refer to “Fuel Rail Assembly”.
11. Remove the cylinder head cover.
Refer to “Cylinder Head Cover” in ENGINE MECHANICAL section.
12. Disconnect the camshaft position senso
r
connector (1).






RTW 56ESH003201

13. Remove the noise cover (1).





RTW 56CSH001401
14. Remove the timing chain cover assembly. Upper &
lower.



RTW 56CSH001501
Legend
1. Timing Chain Cover Upper
2. Timing Chain Cover Lower.


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ISUZU KB P190 2007