lock ISUZU KB P190 2007 Workshop Repair Manual

FUEL SYSTEM (4JK1/4JJ1) 6C-13
Fuel Filter Element
Removal
1. Detach the drain hose on the lower part of the fuel
filter or the drain plug, loosen the air bleed plug,
and drain the fuel from the fuel filter.
2. Detach the water-in-fuel switch harness.
3. Turn the element case counterclockwise to detach, and remove the filter element.
4. Replace the O-ring and confirm the snap-fit position, and fit a new filter element inside the
element case.
NOTE
It is strongly advisable to use the ISUZU/GM genuine
fuel filter for replacement.




RTW 76CSH000901
Legend
1. Element
2. O-ring
3. Sedimenter Sensor


Installation
1. Apply a light coat of new diesel oil to the O-ring
and gasket.
2. Turn the element case clockwise until it is completely seated against the upper cover. Then
check that the drain hose is in its correct position,
and then use a filter wrench and tighten to the
specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
3. Use a clip to fix the drain hose at the base of the fuel filter, and fit the water-in-fuel switch harness.





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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-42 FUEL SYSTEM (4JK1/4JJ1)
Fuel Gauge Unit
Fuel Gauge Unit and Associated Parts






RTW 56CLF001001
Legend 1. Fuel Tube/Quick Connector
2. Fuel Feed Port
3. Retainer Ring (Fuel Gauge Unit Lock)
4. Connector; Fuel Gauge Unit 5. Fuel Return Port
6. Fuel Gauge Unit and Sender Assembly
7. Seal; Fuel Gauge Unit
8. Fuel Tank Assembly


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FUEL SYSTEM (4JK1/4JJ1) 6C-43
Removal
Note: W hen repairs to the fuel system have been
completed, start the engine and check the fuel system
for loose connections or leakage. For the fuel system
diagnosis, see Section "Drivability and Emission".
1. Remove the fuel tank assembly (8). Refer to "Fuel Tank Removal" in this section.
2. Disconnect the quick connector (1) of the fuel tube from the fuel gauge unit.






140R100035
3. Remove the retainer ring (3) from the fuel tank
with the removal tool 5-8840-2602-0.
4. Slowly remove the fuel gauge unit (6) from the fuel tank as no bend float arm.
Note: Cover opening for the fuel gauge unit on the fuel
tank to prevent any dust entering.
5. Discard the fuel gauge unit seal (7) because it cannot be reused.

Installation
1. Clean the seal surface of the fuel tank and the fuel
gauge unit.
Note: If there is dust on the seal surface, it can cause a
fuel leak.
2. Install the new fuel gauge unit seal (7) to the opening of the fuel tank along the groove.
3. Slowly install the fuel gauge unit (6) into the fuel tank so there is no bend in the float arm.
4. Set the flange of the fuel gauge unit on the fuel gauge unit seal as mating convexity of the fuel
gauge unit and reentrant of the fuel tank.
5. Slowly lock the retainer ring (3) to the fuel tank with the remover tool 5-8840-2602-0.
6. Connect the quick connector (1) of the fuel tube to the gauge unit.
Note: Pull off the left checker of the fuel pipe.
Note: Refer to "Fuel Tube/Quick Connector Fittings" in
this section when performing any repairs.
7. Check for leak. Method of leak check.
1. Plug the end of the quick connector and breather hose (Pull off the breather hose from
fuel tank) and tighten fuel filler cap until at least
one click is heard.
2. Apply soapy water around the fuel gauge unit seal area.
3 Pressure air into the fuel tank from the end o
f
the breather pipe at 34.3 kPa (0.35 kg / cm2 / 5
psi) over 15 seconds.
4 Verify that no bubbles from around the fuel gauge unit seal area.
8. Install the fuel tank assembly (8).
Note: Refer to "Install the fuel tank" in this section.



Special Tool


ILLUSTRATION PART NO.
PART NAME

5-8840-2602-0
Remover: fuel pump retainer ring


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FUEL SYSTEM (4JK1/4JJ1) 6C-45
Note: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light
oil) and/or push and pull the connector until the pipe is
disconnected.







140R100037
Cover the connectors that were removed with a plastic
bag, to prevent dust or rain water from entering.




140R100028

Reuse of Quick-Connector
•
Replace the port and connector if a scratch, dent
or crack is found.
• Remove any dirt build up on the port when
installing the connector. Replace the connector, i
f
there is any rust, dents or scratches.
• After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling it
out at 49 N (5 kg / 11 lb) to make sure that it is not
drawn and is securely locked.




140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dust
from sticking to the pipe surface - which may decrease
sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system ma
y
affect the fuel injection system.
3. Check for fuel leakage from the connector.





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6D-8 ENGINE ELECTRICAL (4JK1/4JJ1)
Specifications
Battery power Volts 12
Generator output Amperes 90
Rotational direction (Viewed from pulley)  Clockwise
Rated speed 5,000
Maximum speed rpm
18,000


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6D-22 ENGINE ELECTRICAL (4JK1/4JJ1)



RTW 46DSH003901
Brush and Brush Holder
1. Use a vernier caliper to measure the brush length
(four brushes).
Replace the brushes as a set if one or more of the brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)



RTW 46DSH004001
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the othe
r
probe to the positive brush holder.
There should be no continuity.




RTW 46DSH004101
3. Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire yoke must be replaced.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.







065RY00035


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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-11
Power Distribution (2)
RTW76EXF003701
C-108
5
WHT
3
WHT/
BLK
5
WHT
3
WHT/
BLK
3BLU
3BLK/RED
3
WHT/
BLK
3
BLK/
YEL 3
BLK/
WHT B-62
B-63
2
4
B-62
B-63 1
1
3
C-18
Rr
Def.
20A C-21
Door
lock
20A C-19
Meter
(+B)
10A C-15
Stop
lamp
15A C-22
Anti
theft
10A C-13
Audio
(+B)
15A
C-16
RR
Fog
10A C-17
Room
10A C-20
Power
window
30A Fuse/
relay box
(Cabin)
C-14
Meter
10A C-8
SRS
10AC-7
TCM
10A
or
15A C-9
Front
wiper
20A C-10
Back
up
15A C-6
Engine
10A
C-5
ABS/4WD
10AC-1
Starter
10AC-2
Trailer
10AC-3
ELEC IG
10A C-4
Turn
10AC-12
Cigar
lighter
&
ACC
Socket
20A C-11
Audio
10A
SBF9
IG2
60A Fuse/
relay
box
(Engine
room)
Starter relay
SBF5
IG1
40A
1
2
3 B-62 B1
B2
OFF
ACC
IG2ST
IG1 Ignition
switch

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6E-56 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Scan Tool Does Not Power Up
Circuit Description
The data link connector (DLC) is a standardized 16-
cavity connector. Connector design and location is
dictated by an industry wide standard, and is required
to provide the following:
• Scan tool power battery positive voltage at terminal 16.
• Scan tool power ground at terminal 4. • Common signal ground at terminal 5.
The scan tool will power up with the ignition OFF.
Some modules however, will not communicate unless
the ignition is ON.
Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls
Connector End Views or ECM Connector End Views
Circuit/ System Testing Scan Tool Does Not Power Up
Step Action Value(s)Yes No
1 Important
: Make sure the scan tool works properly
on another vehicle before using this chart.
1. Turn OFF the ignition.
2. Inspect the Meter (+B) (10A) fuse in the cabin fuse block.
Is the Meter (+B) (10A) fuse open? —
Go to Step 2 Go to Step 3
2 Replace the Meter (+B) (10A) fuse. If the fuse
continues to open, repair the short to ground on
one of the circuits that is fed by the Meter (+B)
(10A) fuse or replace the shorted attached
component.
Did you complete the repair? —
Go to Step 7
—
31. Check each circuit at the data link connector
(DLC) (B-58) for a backed out, spread or
missing terminal.
2. Repair the terminal as necessary.
Did you find and complete the repair? —
Go to Step 7 Go to Step 4
4 Connect a test lamp between the +B circuit (pin 16
of B-58) at the DLC and a known good ground.
Does the test lamp illuminate? —
Go to Step 6 Go to Step 5
5 Repair the open in the battery voltage circuit to the
DLC.
Did you complete the repair? —
Go to Step 7
—
61. Test each ground circuit at the DLC (pins 4
and 5 of B-58) for an open circuit or high
resistance.
2. Repair the circuit(s), clean or tighten ground as necessary.
Did you find and correct the condition? —
Go to Step 7 Go to Intermittent
Conditions
7 1. Connect the scan tool to the DLC.
2. Attempt to turn ON the scan tool.
Does the scan tool ON? —
System OK Go to Step 1

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6E-66 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
4Notice:
Make sure the in-tank fuel pump operation
before performing the following procedures. Refer
to In-tank Fuel Pump System Check in this section.
1. Turn OFF the ignition.
2. Disconnect the fuel hose from the fuel supply pump suction side. In order to measure the
discharged fuel amount, put the hose into a
bottle or a container with a scale. (The inlet of
a bottle or a container must be larger than the
diameter of hose.)
3. Turn ON the ignition for 20 seconds, with the engine OFF.
4. Turn OFF the ignition for 10 seconds.
5. Perform 3 and 4 three times. The accumulated fuel of three ignition cycles must be more than
300 cc. (Normal amount is more than 100 cc
per one ignition cycle.)
Notice: If there is a leak or a restriction on the
suction side, the fuel from the hose will not flow out
sufficiently that is most likely caused by fuel
leakage, clogged fuel filter, kinked or crushed fuel
hose or pipe. Also inside the fuel tank for any
foreign materials may be getting drawn into the fuel
line pickup.
6. Repair fuel system leaking or restrictions as necessary.
Did you find and correct the condition? —
Go to Step 12 Go to Step 5
5 1. Turn OFF the ignition.
2. Remove the Fuel Pump (10A) fuse from the engine room fuse block in order to disable in-
tank fuel pump.
3. Disconnect each fuel injector harness connector from all fuel injectors in order to
disable injection.
4. Remove the rubber fuel hose from the leak-off pipe. Then, remove the leak-off pipe assembly
from the engine that is jointed to the fuel
supply pump and the pressure limiter valve.
Use a pan to catch the fuel from the removed
fuel line.
5. Crank over the engine while observing the fuel leak from the pressure limiter valve.
Important: Safety glasses must be worm. Fuel
may splash if the pressure limiter valve is faulty.
Is there fuel leak from the pressure limiter valve? —
Go to Step 11 Go to Step 6
Step
Action Value(s)Yes No

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