start ISUZU KB P190 2007 Workshop Repair Manual

ENGINE COOLING (4JK1/4JJ1) 6B-7
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“MIN" and “MAX" lines of the reserve tank when the
engine is cold. If low, check for leakage and add EC up
to the “MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.

1. Remove the radiator skid plate.
2. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.




RTW 56BSH000301
3. Remove the radiator cap.
WARNING:
To avoid the danger of being burned, do not
remove the cap while the engine and radiator are
still hot. Scalding fluid and steam can be blown out
under pressure.
4. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.

5. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change).
• Make sure that the engine is cool.
• Open radiator cap and pour coolant up to fille
r
neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and
reopen the radiator cap. If the water level is lower,
replenish.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor o
r
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.
• After tightening the 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.
• Check to see the thermostat has opened through
the needle position of the water thermometer,
conduct a 5–minute idling again and stop the
engine.
• W hen the engine has been cooled, check fille
r
neck for water level and replenish if required.
Should extreme shortage of coolant be found,
check the cooling system and reservoir tank hose
for leakage.
• Pour coolant into the reservoir tank up to “MAX"
line.

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-17
Fan Clutch with Cooling Fan
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage or any other abnormal conditions are
found through inspection.

Visually inspect for damage, leak (silicon grease) o
r
other abnormal conditions.
1. Inspection (on-vehicle) a) Turn the fan clutch by hand when in a lo
w
temperature condition before starting the
engine, and confirm that it can be turned
readily.
b) Start the engine to warm it up until the temperature at the fan clutch portion gets to
around 85°C (185°F). Then stop the engine and
confirm that the fan clutch can be turned with
considerable effort (clutch torque) when turned
by hand.
If the fan clutch rotates more readily, however, this indicates that the silicone grease is leaking
internally.
Replace the fan clutch with a new one.






RTW 56ASH025401

2. Inspection (in unit)
W arm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 85°C
when measured with the thermistor. Then confirm
that the fan clutch can be turned with considerable
effort (clutch torque).
If the fan clutch rotates more readily at this time, this indicates that the silicone grease is leaking
internally.
Replace the fan clutch with a new one.







033RY00011



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6C-2 FUEL SYSTEM (4JK1/4JJ1)
Fuel System
Service Precautions
Parts of the fuel system such as the internal part of the
fuel injector, and holes and clearances that form
passages for fuel are finished to a very high degree o
f
accuracy. They are therefore highly sensitive to foreign
matter and the entry of foreign matter could cause
damage to the fuel passage. Therefore, effective
measures should be taken to prevent the entry o
f
foreign matter.
If a water removal agent is used in the fuel then it will
absorb moisture in the light oil and may cause rust.
Therefore, do not use a water removal agent in the fuel
tank.
W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.
Discard gaskets and O-rings and replace them with ne
w
ones.

Work procedure
•
The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.

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ISUZU KB P190 2007

6C-6 FUEL SYSTEM (4JK1/4JJ1)
Fuel injector



RTW 76CMH000201
Legend
1. Terminal
2. Fuel Injector ID Code
3. Two Dimensional Barcode
4. Parts Number
5. Port for Mounting the Injection Pipe
6. O-ring

Fuel filter





RTW 76CSH001001
Legend
1. Element
2. Air Bleeding Plug
3. Switch; Clogging Monitoring
4. Sensor; W ater
5. Drain Plug

Functional check
Air bleeding
1. Ignition switch is turned to the ON position for 15 seconds.
2. Ignition switch is turned to the OFF position.
3. The above operation is repeated 5 times.
Note: If the air bleeding work is insufficient then it could
lead to faults in the engine. Therefore, the procedures
after starting the engine should always be implemented.

Water drain
A warning lamp will light up if water above the specified
volume collects in the sedimenter. In such cases, drain
out the water by performing the following operations:
1. Draining with fuel filter drain plug. a. Set a container at the tip of the plastic hose.
b. Loosen the air bleeding plug and the drain plug.
c. Discharge the water.
d. Tighten the drain plug after discharging the water.
e. Tighten the air bleeding plug to the specified torque.
Tightening torque: 3 N ⋅m(0.3 kg ⋅m/26 lb in)
f. Ignition switch is turned ON for 15 seconds check for fuel leakage.

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FUEL SYSTEM (4JK1/4JJ1) 6C-7
g. Check that the warning lamp in the meter is off.
2. Draining with drain plug in engine room. a. W ith the engine off, open the engine hood and loosen the drain plug (1) located on the left
hand side of the engine room. (3-4 turns)
b. Turn the starter switch to the “ON” position fo
r
10 seconds, and then turn the starter switch to
the “OFF” position for 10 seconds. Then, once
again turn the starter switch to the “ON”
position for 10 seconds.
c. Tighten the drain plug firmly.
d.
After starting the engine, check that there is no
fuel leakage from the drain plug. Also check
that the water separator indicator has turned
off.










RTW 76CSH001301
NOTE:
• If the water separator requires frequent draining,
have the fuel tank drained at your ISUZU/GM
Dealer.
• Be sure to stop the engine when draining the fuel
tank.
• Confirm that there are no combustible materials
under the drain hose, and use a receptacle to
catch the drained water.


Engine starting cautions
• Before starting the engine, turn the ignition switch
to the “ON” position. W ait 15 seconds. Return the
switch to the “LOCK” position. Repeat this
procedure 5 times.
• After starting the engine, allow it to idle for 10
minutes.

Fuel Pump Functional Check
1. Turn the starter switch to “ON” position.
2. Touch the under portion of the Fuel Tank by the hand as shown in the following figure within 12
seconds.





RTW 56CSH003501
Legend
1. Touch this area by the hand

3. Make sure a vibration by the Fuel Pump is
detected.
Fuel Pump stops within 12 seconds of turning the starter switch to the “ON” position.
W hen the check is repeated, return the starte
r
switch to the “LOCK” position for 10 – 15 seconds
and perform procedures 1 – 3.
WARNING: FUEL PUMP FUNCTIONAL CHECK
MUST BE CONDUCTED UNDER THE FOLLOWING
CONDITIONS TO AVOID INJURY.
•
••
•
APPLY THE PARKING BRAKE.
•
••
•
STOP THE ENGINE.


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6C-8 FUEL SYSTEM (4JK1/4JJ1)
Trouble Shooting
Problems with starting
Condition Possible Cause Correction
Problems with starting Fuel tank is empty Fill the tank.
Air has entered the fuel system. Bleed the air.
Fuel line or fuel cooler is clogged or
damaged. Connection to the fuel line
is loose. Repair or replace the fuel line and
fuel cooler. Re-tighten the
connection.
Fuel filter element is clogged. Replace the cartridge.
Fault in the feed pump Replace the fuel supply pump.
Regulating valve is open. Replace
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Hunting during idling
Condition Possible Cause Correction
Hunting during idling Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel
system Repair or replace the fuel system.

Drops of water have entered the fuel
system. Replace the fuel.

Fuel filter element is clogged. Replace the fuel filter element
(cartridge).
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Insufficient horsepower
Condition Possible Cause Correction
Insufficient horsepower Air has entered the fuel system. Bleed air from the fuel system.
Leakage or clogging of the fuel
system Repair or replace the fuel system.

W ater mixes in the fuel system Replace the fuel.
Fuel filter element is clogged. Replace the element or the
cartridge.
Sticking of the fuel injector Replace the fuel injector.
Defective engine control system Diagnose the engine control system.

Maximum engine speed is too low
Condition Possible Cause Correction
Maximum engine speed is too low Fuel line, fuel cooler is clogged or
damaged. Repair or replace the fuel line, fuel
cooler.
Defective engine control system Diagnose the engine control system.


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6C-10 FUEL SYSTEM (4JK1/4JJ1)
Fuel System Check
Description
Conforms to a fuel leak. Engine acceleration raises fuel
pressure and which increases the leak.
Leak could be in the following pipes and locations.
• Between injectors and fuel rail.
• Between fuel rail and fuel supply pump.
• Between fuel supply pump and fuel filter.
• Between fuel filter and fuel tank.
• Between pressure limiter and fuel cooler.
• Between fuel cooler and fuel tank.
• Between injector over flow and leak off pipe.
Diagnostic Aids
Check the following items.
• Air in the fuel line
• Clogged fuel filter
• Fuel pipe malfunction (Crushing, breakage,
clogging, disconnection, etc.)
• Fuel cooler malfunction (Crushing, breakage,
clogging, disconnection, etc.)
• Fuel tank malfunction
• Injector malfunction
• Fuel supply pump malfunction
• Pressure limiter malfunction
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness.
Inspect the ECM harness and connector for imprope
r
mating, broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
ECU may set a DTC, if there is adequate air in fuel line.


Schematic Reference: Engine Controls Schematics
Step Action Value(s) Yes No
1 Check the fuel quantity. W as a problem found? 

Go to Step 2 Add fuel and
Go to Step 2
2 Check the fuel quality.
1. Discharge the fuel from fuel tank
2. Replenish the tank with specified fuel
3. Bleed the air from the fuel system
4. Start the engine
Could the engine be started? 

Go to Step 7 Go to Step 3
3 Bleed the air from fuel system. Refer to Fuel
System Air Bleeding in this section.
Is the action complete? 

Go to Step 4 

4 Check the main fuel filter for clogging.
Clean, repair, or replace as required.
Notice: Replacement of a fuel filter is checking
to a dealer.
Is the action complete? 

Go to Step 5 

5 Check the fuel line and fuel cooler for damage
and leakage.
Clean, repair, or replace as required.
• Crushed areas
• Breakage
• Cracks
• Loose connections
Is the action complete? 

Go to Step 6 


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-17
Record the Fuel Injector ID Code Data from
each injector housing
1. Remove each fuel injector harness connector.
2. Record all numbers of each cylinder on the harness connector housing. The correct order fo
r
the fuel injector ID codes of the following
illustration is as follows:
5F 05 00 FB 00 F7 08 F5 19 FF 04 49





RTW 76ESH002601
Legend
1. Fuel Injector ID Code
2. Fuel Injector


Programming Fuel Injector ID Codes
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
4. In order to get programming approval, the on- screen displays a message to user. Get
programming approval from the TIS 2000 using
the following procedure:
a. Connect a scan tool to the terminal that installed TIS 2000 with the latest software and
the hardware key is plugged into port.
b. Turn ON the scan tool and keep at title screen.
c. Launch the TIS application.
d. Select the Security Access at the main screen.
e. Highlight the "Tech" 2 on the Diagnostic Tool Selection screen and click "Next".
f. Click "Close" on the Security Access Enabled screen.


g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Reinstall a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle identification > 4JK1 or 4JJ1 > Programming >
Replace Injector.
8. Enter 24 figures of replaced fuel injector ID code.
9.
After complete the programming, turn OFF the
ignition for 30 seconds.
10.Start the engine and let idle.
11.Inspect for a proper engine running condition and for no DTC's. Refer to the Diagnostic System
Check - Engine Controls if needed.


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6C-22 FUEL SYSTEM (4JK1/4JJ1)
Removal
1. Remove the starter motor.
• Refer to the removal procedure for engine
electricals in this manual.
2. Remove the fuel feed pipe (1) for supply pump.
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.



RTW 76CSH000501
3. Remove the fuel hose (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.





RTW 76CSH000601

4. Remove the leak off pipe and hose (1).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.




RTW 76CSH000301
5. Disconnect the fuel rail pressure sensor harness
connector (1).




LNW 76CSH001601


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FUEL SYSTEM (4JK1/4JJ1) 6C-25
6. Tighten the fuel leak off pipe and hose (1) using
the mounting eyebolt using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)




RTW 76CSH000401
7. Install the fuel hose (1).





RTW 76CSH000601

8. Install the fuel feed pipe (1) for supply pump and
tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m/33 lb ft)



RTW 76CSH000501
9. Install the starter motor. • Refer to removal procedure for engine
electricals in this manual.



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