start ISUZU KB P190 2007 Workshop Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 1368 of 6020
6A-8 ENGINE MECHANICAL (4JK1/4JJ1)
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction
Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connect
Repair
Starter motor brushes stuck, worn,
or broken Replace brushes
Starter motor does not rotate
Starter motor internal damage Repair motor
Ring gear abrasion Replace ring gear Starter motor not meshed with
flywheel Magnetic switch (starter motor) not
properly adjusted Adjust
Dead or weak battery
Charge battery
Replace battery
Insufficient contact pressure
between starter motor brushes and
commutator Adjust pressure
Armature (starter motor) stuck Repair armature
Starter motor pinion meshed with
ring gear but does not rotate
Engine internal damage (Seizure) Repair engine
Engine turns over but does not start
Condition Possible Cause Correction
Air in fuel system Bleed air from fuel system
Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing
temperatures Drain existing fuel and replace with
appropriate fuel
Fuel is not delivered to fuel supply
pump
Clogged fuel filter Replace filter
Loose injection pipe connections Tighten connections
Loose or broken electrical
connectors Tighten and/or replace connectors
Bad rotational sensor
Replace sensor
Fuel is delivered to fuel supply
pump
Engine control system malfunction System diagnosis
Air in fuel system Bleed air from fuel system
Feed pump malfunction Repair pump
Loose or broken electrical
connectors Tighten and/or replace connectors
Clogged fuel filter
Replace filter
Insufficient or unstable fuel delivery
volume
Engine control system malfunction System diagnosis
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Page 1374 of 6020
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 β 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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ISUZU KB P190 2007
Page 1375 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-15
Engine Assembly
Removal
1. Disconnect the negative battery cable.
2. Remove the engine hood.
3. Drain the coolant.
4. Remove the starter motor.
5. Remove the transmission assembly.
Refer to removal procedure for βTRANSMISSIONβ in this manual.
6. Disconnect the ECM harness connector.
7. Remove the ECM.
8. Remove the air cleaner. β’ Disconnect the MAF sensor harness connector.
β’ Remove the intake pipe with the lid of ai
r
cleaner box.
β’ Remove the air cleaner box.
RTW 76ASH000401
Legend
1. ECM Harness Connector
2. ECM
3. Air Cleaner Box
4. MAF Sensor Harness Connector
9. Remove the intake hose (intercooler - intake
throttle) (Standard output).
10. Remove the intake hose (turbocharger - intercooler) (Standard output).
Remove the harness connector.
RTW 56ASH004001
Legend
1. Intake Hose (intercooler - intake throttle)
2. Intake Hose (turbocharger - intercooler)
11. Remove the intercooler (High output).
β’ Disconnect the BARO sensor harness
connector (2).
β’ Remove the two intake hoses.
β’ Remove the intercooler (1).
RTW 76ASH000501
12. Remove the radiator upper hose.
13. Remove the engine harness clip (1).
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Page 1378 of 6020
6A-18 ENGINE MECHANICAL (4JK1/4JJ1)
21.Install the intake hose (intercooler - intake throttle)
(Standard output).
RTW 56ASH004001
22.Install the intercooler (High output).
β’ Install the intercooler.
β’ Install the two intake hoses.
β’ Connect the BARO sensor harness connector.
23.Install the air cleaner.
β’ Install the intake pipe with the lid of air cleane
r
box.
β’ Install the air cleaner box.
β’ Connect the MAF sensor harness connector.
24.Install the ECM.
25.Connect the ECM harness connector.
26.Install the transmission assembly.
Refer to installation procedure fo
r
βTRANSMISSIONβ.
27.Install the starter motor.
Tightening torque: 94 N β
β
β
β
m (9.6kg β
β
β
β
m / 69 lb ft)
28.Replenish the coolant.
29.Install the engine hood.
Tightening torque: 10 N β
β
β
β
m (1.0kg β
β
β
β
m / 87 lb in)
30.Connect the negative battery cable.
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Page 1381 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-21
Removal
1. Remove the engine hood.
2. Remove the engine cover.
3. Set the hoist and the engine hanger of the special tool (special tool 5-8840-2823-0).
4. Remove the engine mount.
β’ Before removing the engine mount, hang the engine with a hoist.
β’ Remove the bolts of the engine mount.
β’ Hoist the engine assembly slightly to remove the engine mount.
RTW 56ASH004501
Installation
1. Install the engine mount and tighten up with the
specified torque.
Tightening torque: 52 N β
β
β
β
m (5.3 kg β
β
β
β
m / 38 lb ft)
2. Install the engine cover.
3. Install the engine hood. β’ Check if nothing is wrong with the engine
mount by starting the engine.
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Page 1472 of 6020
6A-112 ENGINE MECHANICAL (4JK1/4JJ1)
RTW 56ASH014201
3. Remove the driven plate.
β’ Remove the driven plate from the flywheel
along with the clutch aligner.
β’ Install the crankshaft stopper in the starte
r
installation part of the rear plate.
Note:
Make sure that the stopper is applied with the ring gea
r
and installed properly.
Special tool
Crankshaft stopper: 5-8840-0214-0
4. Remove the pilot bearing. β’ Remove the pilot bearing from the flywheel.
015RY00018
Special tool
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
5. Remove the flywheel.
β’ Gradually loosen the flywheel installation bolts
in the order shown in the drawing so that the
flywheel does not rotate.
β’
After loosening the bolts, remove the stopper
and remove the flywheel.
β’ In the case of A/T car, after loosening the
flywheel installation bolts, remove the washer,
flexible plate, flywheel and sleeve in this order.
015RY00001
6. Remove the ring gear.
β’ Put a bar on the ring gear and hit it with a
hammer to remove it.
LNW 21BSH012001
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Page 1474 of 6020
6A-114 ENGINE MECHANICAL (4JK1/4JJ1)
015RY00010
3. Install the flywheel.
β’ Install the flywheel of the crankshaft, tighten
them in the order shown in the illustration.
β’
Apply molybdenum disulfide on the screw part
and setting face of the bolt.
β’ Install the crankshaft stopper on the starte
r
installation part of the rear plate.
Tightening torque: 1st step = 59 N β
β
β
β
m (6.0 kg β
β
β
β
m / 43 lb ft)
2nd step = 60Β° - 90Β° (degrees)
Special tool
Crankshaft stopper: 5-8840-0214-0
015RY00001
4. Install the driven plate.
β’ Use a clutch aligner to install the driven plate
on the flywheel.
LNW 21BSH002601
Legend
1. Clutch Aligner
5. Install the clutch pressure plate.
β’ Install the pressure plate on the flywheel so that
the installation hole of the pressure plate
matches with the dowel pins of the flywheel.
β’ Tighten the pressure plate in the order shown
in the illustration.
Tightening torque: 18 N β
β
β
β
m (1.8 kg β
β
β
β
m / 13 lb ft)
RTW 56ASH023301
6. Install the transmission assembly.
Refer to removal procedure for βTRANSMISSIONβ.
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ISUZU KB P190 2007
Page 1500 of 6020
6A-140 ENGINE MECHANICAL (4JK1/4JJ1)
Lubrication System
Service Precautions
β’ During each disassembly, remove the old gasket
adhering to each part and mating part completel
y
using a scraper at the location, where the fluid
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton
and apply the specified new fluid gasket at each
location.
β’
Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
β’ Always, the start and end of the application should
be overlapped.
Explanations on functions and operation
The lubrication system uses the filter element combined
with a full flow bypass, water-cooled oil cooler, and oil
jet for piston cooling.
Lubricating system diagram
LNW 76ALF000201
1. Oil Pump Relief Valve Operating Pressure: 490 β 686 kPa (5.0 β 7.0 kg/cm2 / 71 β 100 psi)
2. Oil Cooler Relief Valve Opening Pressure: 176 β 216 kPa (1.8 β 2.2 kg/cm2 / 26 β 31 psi)
3. Oil Filter Relief Valve Opening Pressure: 80 β 120 kPa (0.8 β 1.2 kg/cm2 / 11 β 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 β 49.0 kPa (0.3 β 0.5 kg/cm2 / 4.3 β 7.1 psi)
5. Regulating Valve: 176 β 216 kPa (1.8 β 2.2 kg/cm2 / 26 β 31 psi)
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Page 1501 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-141
Functional Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil o
r
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.
RTW 56ASH015501
Legend
1. Oil Pressure Switch
5. W arm the engine.
6. Measure the oil pressure, to check whether it is more than 400 kPa (4 kg/cm
2 / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.
Engine oil
β’
Ensure the car is on level ground. Before starting
the engine or when 30 minutes or more have
elapsed after stopping the engine, check the
engine oil volume using the level gauge. The
volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lowe
r
limit. Also, check for contamination of the engine
oil.
RTW 56ASH015601
RTW 56ASH015701
Legend
1. Lower Limit
2. Upper Limit
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Page 1522 of 6020
6A-162 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the oil pressure SW .
2. Remove the nipple; oil gallery.
3. Remove the nipple; oil pressure warning SW and gasket.
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.
If there is no connectivity, replace with normal parts.
LNW 21HSH003301
Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the circuit between the meter and the oil pressure
switch, and repair the disconnected locations.
LNW 21HSH003401
Installation
1. Install the nipple; oil gallery, oil pressure warning
SW and gasket.
Tightening torque: 25 N β
β
β
β
m (2.5 kg β
β
β
β
m/18 lb ft)
2. Install the Nipple. Tightening torque: 15 N β
β
β
β
m (1.5 kg β
β
β
β
m/11 lb ft)
3. Install the oil pressure SW . Tightening torque: 15 N β
β
β
β
m (1.5 kg β
β
β
β
m/11 lb ft)
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