compression ratio ISUZU KB P190 2007 Workshop User Guide

6E-268 Engine Control System (4JH1)
Checks Action
Engine Mechanical Check Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Improper mechanical timing
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
Additional Checks •
Inspect the generator output voltage. Repair if less than 9 volts or more than 16
volts.
• Inspect the EGR system operating correctly.
• Inspect the engine overheat condition. Refer to the Engine Cooling section.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation (A/T only).


Hesitation, Sag, Stumble
Checks Action
DEFINITION:The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur
at any vehicle speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe
enough, the condition may cause the engine to stall.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect for a proper transmission shift pattern and down shift operation.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Inspect the scan tool Data List in this section.
• Inspect the engine control module (ECM) and fuel injection pump control unit (PCU)
grounds for being clean, tight, and in their proper locations.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
• Use the scan tool to compare the MAF Sensor parameter with the Desired MAF
parameter. Start the engine and warm up (allow engine coolant temperature to reach
at least 60°C [140°F]). The MAF Sensor parameter must follow the Desired MAF
parameter within 100 mg/strk. If not, inspect the air intake system, EGR system
components and contaminated, skewed or slow MAF sensor.
• Use the scan tool to observe the Accelerator Pedal Position Accelerator Pedal
Position. Accelerator Pedal Position parameter should change linearly from 0% to
100% according to the accelerator pedal operation.

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ISUZU KB P190 2007

6E-270 Engine Control System (4JH1)
Checks Action
Engine Mechanical Check Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Improper mechanical timing
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
Additional Checks •
Inspect the generator output voltage. Repair if less than 9 volts or more than 16
volts.
• Inspect the EGR system operating correctly.
• Inspect the A/C operation.
• Inspect the torque converter clutch (TCC) operation.


Fuel Knock/Combustion Noise
Checks Action
DEFINITION:A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with the throttle opening.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Ensure the vehicle has an actual problem.
• Inspect for smoke associated with the combustion noise.
• Inspect the fuel quality (cetane index).
• Inspect the scan tool Data List in this section.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
• Use the scan tool to compare the MAF Sensor parameter with the Desired MAF
parameter. Start the engine and warm up (allow engine coolant temperature to reach
at least 60°C [140°F]). The MAF Sensor parameter must follow the Desired MAF
parameter within 100 mg/strk. If not, inspect the air intake system, EGR system
components and contaminated, skewed or slow MAF sensor.
• Inspect the crankshaft position (CKP) sensor is tight and the flywheel circumference
is not damaged.
Fuel System Checks •
If excessive smoke is present, check for an injection nozzle(s).Remove each glow
plug from the cylinder head and inspect the tip of the glow plugs for wet by fuel. Use
the cylinder compression gauge. Proper compression is more than 2100 kPa (309
psi). If poor compression is observed, inspect the engine mechanical.
• Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.

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Engine Control System (4JH1) 6E-271
Checks Action
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks •
Inspect the EGR system operating correctly.
• Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.


Poor Fuel Economy
Checks Action
DEFINITION:Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected.
Also, the economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Are excessively heavy loads being carried?
• Is the acceleration too much, too often?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (A/T only).
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
• Suggest to the driver to read the Important Facts on Fuel Economy in the Owner
Manual.
• Inspect the odometer is correctly operated.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect the fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to the Cooling System
Section.
• Inspect the engine coolant level.
• Inspect the engine thermostat for always being open or for the wrong heat range.
• Inspect the engine cooling fan for always being ON.

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6E-272 Engine Control System (4JH1)
Checks Action
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction or leak in the intercooler.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
• Inspect for a restriction in the catalytic converter or exhaust pipes.
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).


Excessive Smoke (Black Smoke)
Checks Action
DEFINITION:Black smoke under load, idle or start up hot or cold.
Preliminary Check •
Ensure the vehicle has an actual problem.
• Inspect the engine control module (ECM) and fuel injection pump control unit (PCU)
grounds for being clean, tight, and in their proper locations.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Inspect the Service Bulletins for ECM software updates.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
• Use the scan tool to compare the MAF Sensor parameter with the Desired MAF
parameter. Start the engine and warm up (allow engine coolant temperature to reach
at least 60°C [140°F]). The MAF Sensor parameter must follow the Desired MAF
parameter within 100 mg/strk. If not, inspect the air intake system, EGR system
components and contaminated, skewed or slow MAF sensor.
• Use the scan tool to observe the Accelerator Pedal Position Accelerator Pedal
Position. Accelerator Pedal Position indicating angle parameter should change
linearly from 0% to 100% according to the accelerator pedal operation.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.

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ISUZU KB P190 2007

Engine Control System (4JH1) 6E-273
Checks Action
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction or leak in the intercooler.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or deposit in the intake throttle bore.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
• Inspect for a worn or damaged turbocharger turbine wheel, shaft or compressor
wheel. Refer to turbocharger inspection in the Engine Mechanical section.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to the Exhaust System
section.
• Inspect for a restriction in the catalytic converter or exhaust pipes.
Engine Mechanical Check Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Inspect for any excessive oil entering combustion chamber.
• Improper mechanical timing
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
Additional Checks •
Inspect the EGR system operating correctly.
• Inspect the excessive blow-by gasses.
• Inspect the scan tool Data List in this section.


Excessive Smoke (White Smoke)
Checks Action
DIFINITION:W hite smoke under load, idle or start up hot or cold.
Preliminary Check •
Ensure the vehicle has an actual problem.
• Inspect the engine control module (ECM) and fuel injection pump control unit (PCU)
grounds for being clean, tight, and in their proper locations.
• Inspect the fuel quality (cetane index).
• Inspect the Service Bulletins for ECM software updates.
Sensor Check Inspect the engine control sensors for the following conditions. Refer to the scan tool
Data List in this section.
• Use the scan tool to compare the Engine Coolant Temperature (ECT) with the Intake
Air Temperature (IAT) and Fuel Temperature (FT) on a cold engine condition. If the
difference among temperature reading is more than 5°C (9°F) on a cold engine,
check for high resistance on the low reference circuit and signal circuit or for a
skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT sensor may
indicate a higher than normal intake air temperature if the ignition switch is being ON.
FT sensor is internal to the PCU and it is part of the fuel injection pump assembly.
• Inspect the crankshaft position (CKP) sensor is tight and the flywheel circumference
is not damaged.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to the Fuel System section.
• Inspect the fuel injection nozzle(s) for proper splay condition or operating pressure.
Notice: Only first stage of operating pressure can be checked.
• Inspect the timing device operating correctly. Observe the Actual Injection Timing
parameter with the scan tool while running the engine. The Actual Injection Timing
parameter must follow the Desired Injection Timing within 2°CA on each engine
speed. Engine idle > around 2000 RPM> around 3000 RPM. If not, inspect the fuel
system restriction, air in the fuel or fuel injection pump operation.

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ISUZU KB P190 2007

6E-274 Engine Control System (4JH1)
Checks Action
Air Intake System Checks Inspect the air intake system for the following conditions.
• Inspect the air cleaner and air intake ducts for a restriction, holes, or leaks.
• Inspect for a restriction or leak in the intercooler.
• Inspect for a restriction in the turbocharger inlet duct.
• Inspect for a restriction or leak in the intake manifold.
• Inspect for a restriction or damage at MAF sensor.
• Inspect for a worn or damaged turbocharger turbine wheel, shaft or compressor
wheel. Refer to turbocharger inspection in the Engine Mechanical section.
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to the Engine
Mechanical section.
• Inspect for poor cylinder compression. Proper compression is more than 2100 kPa
(309 psi).
• Inspect for incorrect basic engine parts such as camshaft, cylinder head, pistons,
etc.
• Improper mechanical timing
• Improper valve gap
• Broken or weak valve springs
• W orn camshaft lobes
• Inspect for any excessive fuel entering combustion chamber.
• Inspect for coolant entering the combustion chamber.
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to the Engine Electrical
section.
• Inspect the glow plug control (preheating) system operation.



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-9

Excessive black exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Carbon deposit at nozzle tip Clean fuel injector assembly
Sticking nozzle Replace fuel injector assembly
Bad fuel injector condition
Engine control system malfunction System diagnosis
Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to
damaged piston ring Replace piston ring
Damaged gasket
Replace gasket
Insufficient compression pressure
Piston scoring Replace piston
W ater in fuel Drain existing fuel and replace with
new fuel Fuel condition
Poor fuel quality Drain existing fuel and replace with
new fuel
Clogged intake pipes Clean or replace pipes Poor engine aspiration
Clogged air cleaner element Clean or replace element
Defective sensor Replace sensor Malfunction detected by engine
control system Engine control system malfunction System diagnosis
Intake throttle valve sticking Repair or replace valve
EGR valve sticking Repair or replace valve
EGR valve and/or intake throttle
valve malfunction
Engine control system malfunction System diagnosis
Damaged turbocharger blade Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Oil leakage from oil seal Replace turbocharger
Turbocharger malfunction
Broken actuator Replace turbocharger


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6A-10 ENGINE MECHANICAL (4JK1/4JJ1)
Excessive white exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Defective sensor Replace sensor
Control unit malfunction Replace unit
Malfunction detected by engine
control system
Engine control system malfunction System diagnosis
Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to
damaged piston ring Replace piston ring
Damaged gasket
Replace gasket
Insufficient compression pressure
Piston scoring Replace piston
Fuel condition W ater in fuel Drain existing fuel and replace with
new fuel
W orn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Excessive oil consumption
Clogged turbocharger oil return
pipe Repair pipe

Engine knocking
Condition Possible Cause Correction
Bad timing Engine control system malfunction System diagnosis
Defective sensor Replace sensor
Control unit malfunction Replace unit
Malfunction detected by engine
control system
Engine control system malfunction System diagnosis
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Clogged air cleaner element Clean or replace element
Clogged intake pipes Clean or replace pipes
Poor engine aspiration
Engine control system malfunction System diagnosis
Foreign material in cylinders Engine overhaul Engine break-down Scored pistons and/or bearings Replace pistons and/or bearings


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-13
Main Data and specifications
Item Engine model 4JK1 Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder
bore × strokes mm (in) 4-95.4 (3.76) × 87.4 (3.44) 4-95.4(3.76) × 104.9(4.13)
Displacement
cc (cu.in) 2499 (152) 2999 (183)
Compression ratio 18.3 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1 - 3 - 4 - 2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type W ater cooling type
Radiator type Corrugated fin (pressure type)
W ater pump type Centrifugal, belt drive type
Thermostat type W ax-type units
Thermostat valve-opening temperature °C ( °F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 - 90

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6A-14 ENGINE MECHANICAL (4JK1/4JJ1)

Item Engine model 4JK1 Engine model 4JJ1
Regulator type IC
Starting system Engage magnet type
Starter type Reduction type
Power output V-kW12 – 2.3
Preheat system type Glow plug
Glow plug standard voltage/electric current V-A 12 - 3.5


Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2822-0
Valve clearance
adjust nut wrench

5-8840-2675-0
Compression gauge

5-8840-2815-0
Compression gauge adapter





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