cooling ISUZU KB P190 2007 Workshop User Guide

HEATER AND AIR CONDITIONING 1-91
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Reduced or no air flow through
the condenser
•
Condenser clogged or dirty
• Radiator (condenser) fan
does not operate properly •
Clean
• Check cooling fan
operation
No bubbles in sight glass when
condenser is cooled by water
(Insufficient cooling)



•
Excessive refrigerant in
system




•
Check sight glass.
(See “Reading Sight
Glass”)
• Discharge and
recover refrigerant.
Recharge to specified
amount
Discharge
(High)
pressure
gauge
abnormally
high
After stopping air conditioning,
pressure drops approx. 196 kPa
(2.0kg/cm
2 / 28psi) quickly •
Air in system
•
Evacuate and charge
refrigerant system
Insufficient cooling and excessive
bubbles in the sight glass





•
Insufficient refrigerant in
system





•
Check sight glass.
(See “Reading Sight
Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount
Low pressure gauge indicates
vacuum •
Clogged or defective
expansion valve •
Replace the
expansion valve
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pres-
sure gauge indicates vacuum •
Restriction caused by debris
or moisture in receiver/drier

•
Check system for
restriction and
replace receiver/drier

Discharge
(High)
pressure
gauge
abnormally
low
After turning off air conditioning,
high and low pressure gauge
balanced quickly
•
Compressor seal defective
• Poor compression due to
defective compressor
gasket •
Replace or repair
compressor
Low pressure gauge is lowered
after condenser is cooled by
water
•
Excessive refrigerant in
system

•
Discharge and
recover refrigerant
Recharge to specified
amount
Low pressure hose temperature
around the compressor refrigerant
line connector is lower than
around evaporator

•
Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve
• Expansion valve opens too
long •
Replace the
expansion valve




After turning off air conditioning,
high and low pressure gauge is
balanced quickly •
Compressor gasket is
defective
•
Replace


Suction
(Low)
pressure
gauge
abnormally
high
Air conditioning turns off before
passenger compartment is
sufficiently
cool •
Electronic thermostat
defective
•
Check the electronic
thermostat and
replace as necessary


* For the charging and discharging operations in the table above, refer to “RECOVERY, RECYCLING,
EVACUATION AND CHARGING” in this section.

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1-92 HEATER AND AIR CONDITIONING
RESULT SYMPTOM TROUBLE CAUSE CORRECTION
Condenser is not hot and
excessive bubble in sight glass





•
Insufficient refrigerant






•
Check sight
glass.(See “Reading
Sight Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount
Frost on the expansion valve inlet
line •
Expansion valve clogged
•
Replace the
expansion valve
A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier •
Receiver/drier clogged


•
Replace the receiver/
drier


Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum

•
The temperature sensor of
the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant •
Replace the
expansion valve



Discharge temperature is low and
air flow from vents is restricted
•
Frozen evaporator core fins

•
Check electronic
thermostat and
replace as necessary
Suction
(Low)
pressure
abnormally
low

Low-pressure gauge reading is
low, or a vacuum reading may be
shown •
Clogged or blocked
refrigerant line
•
Replace refrigerant
line
No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)



•
Excessive refrigerant in
system




•
Check sight
glass.(See “Reading
Sight Glass”)
• Discharge and
recover refrigerant.
Recharge to specified
amount
Reduce air flow through con-
denser
•
Condenser clogged
• Radiator (condenser) fan
does not rotate properly •
Clean
• Check cooling fan
operation
Suction
(Low) and
Discharge
(High)
pressure
abnor-
mally
high

Suction (Low) pressure hose is
not cold •
Air in system • Evacuate and charge
refrigerant
Suction
(Low) and
Discharge
(High)
pres-sure
abnor-
mally
low Insufficient cooling and excessive
bubbles in the sight glass •
Insufficient refrigerant in
system
•
Check sight glass.
(See “Reading Sight
Glass”)
• Check for leaks
• Discharge and
recover refrigerant.
Recharge to specified
amount

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ISUZU KB P190 2007

Section 6 Troubleshooting ....................................................................................... ..... 786
PAGE
Section 6A Engine Mechanical .................................................................................... 806
Section 6B Engine Cooling .......................................................................... ................ 945
Section 6C Fuel System .......................................................................... ..................... 96 5
Section 6D Engine Electrical ................................................................ ....................... 1002
Section 6E Engine Control System (4JH1) ....................................................... ......... 1034
Section 6F Exhaust System ....................................................... .............................. ... 1333
Section 6H Accelerator Control ....................................................... ..............................135 3
SECTION 6
ENGINE
TA BLE OF CONTENTS
ENGINE 6
4JA1/4JH1 MODELS

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TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction found? (Include radiator cap) —
Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the fan
clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the fan
clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump assembly.
8 Was the restriction by the foreign materials in the cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. —
Clean or
replace the clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? —
Replace the
sealing cap or replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 2 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve and relation parts.
2 Was the PCV (Positive Crankcase Ventilation) valve working completely? —

Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 13
10–3 Continuous noise
Step Action Value(s) Yes No
1 Was the fan belt tension OK? 9 – 13 mm
(0.35 – 0.51
in)
Go to Step 2 Adjust the fan
belt tension.
2 Was the cooling fan loose? — Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? — Repair or
replace the generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? — Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? — Readjust the
valve
clearance. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

10-4 Slapping noise
Step Action Value(s) Yes No
1 Was noise coming from the cylinder head cover? — Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valve
clearances Go to Step 3
3 Were the rocker arms damaged? — Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? — Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? — Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft.
Was the crankshaft bearing and/or crankshaft worn? —
Replace the
worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin.
Was the connecting rod bearing and/or crankpin
worn? —

Replace the worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or
piston pin.
Was the connecting rod small end bushing and/or
piston pin worn? —

Replace the worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner.
Was the piston and/or cylinder liner worn or
damaged? —
Replace the
worn or
damaged parts Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
4 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing ...................................................................................................................... .. 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6 A - 24
Lubricating System.................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 2 7
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ..................................................................... 6A - 32
General Description ...................................................................................................... 6A- 3 6
Removal and Installation .............................................................................................. 6A- 37 Removal ...................................................................................................................... 6 A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment ......................................................................................... 6A- 41
Engine Warm-Up .................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A - 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6 A- 43
External Parts ......................................................................................................... 6A- 43
E N GINE MECHA NICA L 6A – 1
Main Dat a and Specif ications ....................................................................................... 6A -
Torque Specif ications ................................................................................................... 6A -

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ENGINE MECHANICAL 6A – 5
Engine model
Item 4JA1T (L)
4JA1TC
Cooling system
W ater pump type Centrifugal
Thermostat type W ax pellet with jiggle valve
Air cleaner type Dry paper element Viscous paper element
Battery type/voltage × No. of units 80D26L × 1

95D31L × 1 (OPT)
Generator capacity V-A12 – 60
12 – 80
Starter motor output V-kW12 – 2.3
Turbocharger model
Turbine type
Compressor type *IHI RHF 4H
Mixed flow type
Backward & rake

*IHI: Ishikawajima-Harima Heavy Industries., Ltd.


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ENGINE MECHANICAL 6A – 7

Engine model
Item 4JH1TC
Cooling system
W ater pump type
Thermostat type
Air cleaner type

Battery type/voltage × No. of units



Generator capacity V-A
Starter motor output V-kW
Turbocharger model Turbine type
Compressor type
Centrifugal
W ax pellet with jiggle valve
Dry paper element (except for Euro3 spec) Viscous paper element (for Euro3 spec)
80D26L × 1
95D31L × 1 (OPT)
75D26R × 2 (OPT for EC, MT)
80D26R × 2 (OPT for EC, AT)
12 – 60/12 – 80 12 – 2.3
*IHI RHF5
Mixed flow type Radial-inflow
Backward & rake type Radial-outflow
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.

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6A – 12 ENGINE MECHANICAL
Cooling and Lubricating System
N·m (kg·m/lb·ft)





RTW 46AXF000701

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ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.



Engine coolant Filling up procedure
1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
7. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.
Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/W ater)
50 %


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