ISUZU KB P190 2007 Workshop Repair Manual

6C-30 FUEL SYSTEM (4JK1/4JJ1)
15. Align the timing marks at 3 locations as shown.




RTW 76ASH001301
Legend
1. TDC






RTW 56ASH006901
Legend
1.
Align mark on intake camshaft and exhaust
camshaft to mark of bearing cap

16. Loosen the nut (1).




RTW 56CSH001601
17. Remove the timing chain tensioner.


RTW 56CSH003701
Legend
1. Timing Chain Tensioner.
2. Gasket
3. Nut



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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-31
18. Remove the timing chain tension lever pivot.
19. Remove the nut and sprocket.







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Legend
1. Tension Lever Pivot
2. Sprocket
3. Nut


20. Timing chain in moved upwards.




RTW 56CSH003301

21. Paint the alignment mark.
Between idle gear A and supply pump gear.




RTW 56AMH000401


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6C-32 FUEL SYSTEM (4JK1/4JJ1)
22. Use a gear puller to remove the fuel supply pump
gear.





RTW 56CSH002901
23. Remove the supply pump (1) and supply pump
bracket (2).
• Disconnect the connector of supply pump.




RTW 58ESH002901
Legend
1. Fuel Temperature (FT) Sensor
2. Suction Control Valve (SCV)


Note:
• Do not hold the high pressure pipe, during the
supply pump removal procedure.
• Do not grasp the high pressure pipe, when
moving the supply pump from one location to
another.







RTW 56CSH002001

24. Remove the supply pump and O-ring.






RTW 56CSH002501
Legend
1. O-ring
2. Supply Pump
3. High Pressure Pipe



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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-33
Installation
1. Install the O-ring to the fuel supply pump.
2. Install the fuel supply pump.
Apply soapy water to the O-ring before attaching.
Note: Take care not to twist the O-ring. 3. Install the fuel supply pump bracket.
Temporarily tighten with the bolts and nuts (Gea
r
case side).
Temporarily tighten with the bolts (Cylinder bod
y
side).
Fully tighten the nuts and bolts (Gear case side).
Fully tighten the bolts (Cylinder body side).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m /18 lb ft)




RTW 56CSH002001
Legend
1. Fuel Supply Pump
2. Fuel Supply Pump Bracket


4. Confirm that the supply pump camshaft key is
turned to the right and is horizontal.







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5. Install the fuel supply pump gear to the pump
shaft.
a.
Align the fuel pump gear timing mark (1) with
the idle gear A paint marks (2).
b. Ensure that the pump gear is bitten with main gear (3) of the idle gear A. Depress the pump
gear when it is bitten with scissors gear (4) o
f
the idle gear A.





RTW 56CSH005101


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6C-34 FUEL SYSTEM (4JK1/4JJ1)
6. Install the timing chain to the each sprocket and
install the fuel supply pump sprocket to the pump
shaft.
a.
Align the camshaft sprocket timing mark (1)
with the dark plate timing chain link (2).
b.
Align the fuel supply pump sprocket timing
mark (3) with the yellow plate timing chain link
(4).
c. Install the fuel supply pump sprocket to the fuel pump shaft by aligning the dowel pin that is
attached to the gear.
d. Hand-tighten the fuel supply pump shaft nut.





RTW 56CSH005001

7. Install the timing chain tension lever pivot. Hand-
tighten the pivot bolt.
• Confirm the tension lever moves smoothly.






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8. Attach the hook of the timing chain tensioner.
• Hold the latch (3) depressed. Insert the plunge
r
(2). Attach the hook (5) to the pin (1) to hold the
plunger in place.




RTW 56CSH004401


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-35
9. Install the timing chain tensioner.
Tighten the nut to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/ 87 lb in)




RTW 56CSH001701
Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut


10. Unlock the tensioner hook.
• Press the place of the arrow in the figure.
• The hook is opened. The plunger pushes the
tension lever.




RTW 56ASH020401



11. Tighten the fuel supply pump shaft nut.
Tighten the nut (1) to the specified torque.
Tightening torque: 130 N ⋅
⋅⋅
⋅
m (13.3 kg ⋅
⋅⋅
⋅
m / 96 lb ft)





RTW 56CSH001601
12. Tighten the timing chain tension lever pivot bolt to
the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
13. Turn the crank pulley two rotations (720°CA).
14. Check mark (1) on intake camshaft and exhaust camshaft to mark of camshaft bearing cap.





RTW 56ASH006901


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6C-36 FUEL SYSTEM (4JK1/4JJ1)
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover" in ENGINE MECHANICAL section.
16. Apply liquid gasket (ThreeBond TB-1207C o
r
equivalent) to timing chain cover upper (1).
•
Attach cover within 5minutes after the
application of gasket.







RTW 56CSH002101
17. Install the timing chain cover upper (1).
Tighten the bolt to the specified torque. •
Apply Loctite #262 or equivalent to the bolt and
stud threads of cylinder head side (2).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)





RTW 76CSH001201

18. Apply liquid gasket (ThreeBond TB-1207C o
r
equivalent) to the timing chain cover lower (1).
•
Attach the cover within 5 minutes of applying
the liquid gasket.






RTW 56CSH002301
19. Install the timing chain cover lower.
Tighten the nuts and bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
20. Install the noise cover to the timing chain cove
r
lower.
Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
21. Connect the connectors. • Supply pump
• Camshaft position sensor
22. Install the fuel rail assembly. • Refer to the Install procedure for "Fuel rail
assembly" in this manual.
23. Install the A/C compressor bracket.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)


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FUEL SYSTEM (4JK1/4JJ1) 6C-37
24. Install the A/C compressor.




RTW 56ASH004201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor

Tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
25. Install the battery.
26. Install the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut


Tighten the nut and bolt to the specified torque.
Bolt Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
Nut Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
27. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure fo
r
Heating and air conditioning in this manual.
28. Install the cooling fan.
29. Install the fan guide.
30. Install the radiator upper hose.
31. Replenish the engine coolant.

Fuel Supply Pump Relearn Procedure
The ECM goes through a fuel supply pump learn
procedure to fine tune the current supplied to the fuel
rail pressure (FRP) regulator. This learning process in
only performed when the engine is idling.
1. Install the scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Supply Pump Learn Reset with the scan tool.
4. Observe the Supply Pump Status parameter with the scan tool. Confirm the scan tool indicates Not
Learn.
5. Start the engine and let idle until engine coolant temperature (ECT) reads 149°F (65°C) or highe
r
while observing Supply Pump Status parameter
with the scant tool. The scan tool changes status
Not Learn > Learning > Learned.
6. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.


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6C-38 FUEL SYSTEM (4JK1/4JJ1)
Torque Specifications



RTW 56CLF001501


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FUEL SYSTEM (4JK1/4JJ1) 6C-39
Fuel Sedimenter Switch
Inspection
1. Check that there is continuity between the switch
connector terminals when the float in the fuel
sedimenter is above the water drain line.
2. Turn on the ignition switch, remove the fuel sedimenter connector, and connect the terminals
of the connectors on the harness side. Confirm
that the sedimenter warning lamp lights up.
If abnormalities are detected during the check, replace
the switch parts and carry out repairs in case o
f
defective connection between circuits or short circuits.




RTW 76CSH001101
Legend
1. Sensor
2. Connector on The Vehicle Side
3. Harness
4. Drain Valve




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