sensor ISUZU KB P190 2007 Workshop Repair Manual

6A-42 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Drain the engine coolant.
2. Remove the engine cover.
3. Remove the intercooler. • Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




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4. Disconnect the vacuum hose from the
turbocharger actuator.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the front exhaust pipe.




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Legend
1. Gasket
2. Front Exhaust Pipe (4 ×2 High Ride Suspention,
4 ×4)
3. Gasket
4. Front Exhaust Pipe (4 ×2 Except High Ride
Suspention)

7. Remove the heat protector of the turbocharger.
• Remove the mud cover of front RH fender skirt
(4×4 only).
• Loosen the bolt of Turbocharger bracket.
8. Remove the catalyst converter.
9. Remove the turbocharger bracket.
10. Remove the oil feed and return pipe.
11. Remove the water feed and return pipe from the turbocharger.






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12. Remove the turbocharger from the exhaust
manifold.

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ISUZU KB P190 2007

6A-44 ENGINE MECHANICAL (4JK1/4JJ1)
3. Place a vernier caliper on the end of the control
rod of actuator. Release the vacuum pressure and
check the control rod moves. Measure the length
of the control rod moving.

Standard length mm (in)
12 (0.48)

Installation
1. Install the gasket and the turbocharger to the
exhaust manifold. Temporarily tighten nuts.
2. Install the oil feed and return pipe and temporaril
y
tighten.
3. Tighten the turbocharger nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Tighten the oil feed and return pipe bolts and nuts to the specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
5. Install the water feed and return pipe to the turbocharger.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
6. Install the heat protector to the turbocharger. Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
7. Install the turbocharger bracket.
8. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
9. Install the mud cover of front RH fender skirt (4 ×4
only).
10. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅
⋅⋅
⋅m (6.8 kg⋅
⋅⋅
⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N
⋅
⋅⋅
⋅
m (4.4 kg ⋅
⋅⋅
⋅
m / 32lb ft)
11. Install the intercooler. • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
12. Install the intake duct between the turbocharge
r
and the air cleaner.
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
13.Replenish the coolant.


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ISUZU KB P190 2007

6A-74 ENGINE MECHANICAL (4JK1/4JJ1)
8. Remove the A/C compressor adjust pulley.








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Legend
1. Bolt
2. Nut


9. Remove the battery.
10. Disconnect the A/C compressor connector and A/C compressor with hose.
11. Remove the A/C compressor bracket.





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Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor






12. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




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13. Remove the intake hose and duct (Standard
output).




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Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-75
14. Disconnect the fuel injector connector (2).
15. Remove the fuel leak off hose (1).







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Note:
Do not reuse the fuel leak off hose clips.
16. Disconnect each connector. • Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• W ater temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.


22. Loosen the nuts of catalyst converter and
turbocharger.



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Legend
1. Catalyst Converter
2. Turbocharger

23. Remove the exhaust front pipe.





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Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension, 4×4)
2. Exhaust Front Pipe (4×2 Except High Ride Suspension)




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-97
47. Install the A/C compressor adjust pulley.
Tighten the bolt and nut to the specified torque.
Tightening torque: bolt 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
Tightening torque: nut 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)






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Legend
1. Bolt
2. Nut


48. Install the A/C compressor and connector.
Tighten the bolt to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
49. Connect each connector. • Barometric Sensor
• EGR Valve
• Glow plug
• W ater temperature sensor
• Camshaft Position sensor
• Throttle Assembly

50. Install the turbocharger engine oil return pipe (1).
Tighten the bolt and nut to the specified torque.
Tightening torque: nut: 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
bolt: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)





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51. Install the turbocharger engine oil feed pipe (1).
Tighten the bolt to the specified torque.
Tightening torque: bolt 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m/17 lb ft)




RTW 56ASH010801


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-99
67.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
68. Install the intake hose.




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Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler

69. Install the engine head cover.
70. Replenish the coolant.



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-127
Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail" in the fuel system section.
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
8. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
9. Remove the timing gear train.
Refer to "Timing Gear Train".
10.Remove the oil pump.
Refer to "Oil Pump".
11. Remove the gear case assembly.
Refer to “Gear Case Assembly”.
12. Remove the crankshaft gear.









901R100008
13. Remove the crank case.
Refer to "Crank Case and Oil Pan".
14.Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the bearing cap. • Loosen the crankshaft bearing cap bolts in
numerical order a little at a time.







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16.Remove the lower crankshaft bearings.
17.Remove the crankshaft assembly.
18.Remove the thrust bearing.
19.Remove the upper crankshaft bearings.
Disassembly
1. Remove the crank angle sensor rotor (1). • Confirm that the pin (2) is not removed.




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6A-128 ENGINE MECHANICAL (4JK1/4JJ1)
Reassembly
1. Install the crank angle sensor rotor.
• Attach by making a rotor tooth’s running out
side into a front side.
•
Apply Loctite #262 or the equivalent to the bolt
threads (if a new bolt is used, Loctite
application is not required).
Tightening torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kg ⋅
⋅⋅
⋅
m / 104 lb in)



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Legend
1. Crank Angle Sensor Rotor
2. Pin

Inspection
1. Thrust clearance
• Measure the crankshaft end play at the cente
r
journal of the crankshaft.
• Do this before removing the crankshaft bearing
caps. If the measured value exceeds the
specified limit, the crankshaft thrust bearing
must be replaced.
Axial play of the crankshaft mm (in)
Standard 0.10 (0.004)
Limit 0.30 (0.012)
Note:
Measure the thrust clearance before dismounting.






015RY00002
2. Main bearing clearance
• Remove the crank case.
Set out disassembled main bearings in the order of the numbers.
• Remove the crankshaft. Remove the main
bearings.
• Clean the crankshaft journal and upper and
lower bearings.
• Check the bearings for damage or excessive
wear.

If you find damage or excessive wear, replace the bearings in pairs.

• Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it is horizontal.
Note:
Turn the crankshaft about 30 degrees to allow the
bearings to settle in.
• Place plastigage on the crankshaft journal as
shown.
• Place the lower bearings at original positions on
the bearing cap.

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ISUZU KB P190 2007

6B-6 ENGINE COOLING (4JK1/4JJ1)
Diagnosis
Engine Cooling Trouble
Condition Possible Cause Correction
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system
Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS

Fuel System ....................................................... 6C-2 Service Precautions ........................................ 6C-2
Trouble Shooting ............................................. 6C-8
Fuel System Check ......................................... 6C-10
Fuel Filter Assembly ........................................... 6C-12 Components .................................................... 6C-12
Removal .......................................................... 6C-12
Installation ....................................................... 6C-12
Fuel Filter Cartridge............................................ 6C-13 Removal .......................................................... 6C-13
Installation ....................................................... 6C-13
Fuel Injector........................................................ 6C-14 Components .................................................... 6C-14
Removal .......................................................... 6C-15
Installation ....................................................... 6C-15
Torque Specifications...................................... 6C-18
Fuel Rail Pressure Sensor ................................. 6C-19 Removal .......................................................... 6C-19
Installation ....................................................... 6C-19
Fuel Pressure Limiter ......................................... 6C-20 Removal .......................................................... 6C-20
Installation ....................................................... 6C-20
Fuel Rail Assembly............................................. 6C-21 Components .................................................... 6C-21
Removal .......................................................... 6C-22
Disassembly .................................................... 6C-24
Reassembly..................................................... 6C-24
Installation ....................................................... 6C-24
Torque Specifications...................................... 6C-26
Fuel Supply Pump .............................................. 6C-27 Components .................................................... 6C-27
Removal .......................................................... 6C-28
Installation ....................................................... 6C-33
Torque Specifications...................................... 6C-38
Fuel Sedimenter Switch ..................................... 6C-39 Inspection ........................................................ 6C-39
Fuel Tank and Fuel Cooler ................................. 6C-40 Fuel Tank and Associated Parts ..................... 6C-40
Removal .......................................................... 6C-41
Installation ....................................................... 6C-41

Fuel Gauge Unit ................................................. 6C-42 Fuel Gauge Unit and Associated Parts ........... 6C-42
Removal .......................................................... 6C-43
Installation ....................................................... 6C-43
Special Tool .................................................... 6C-43
Fuel Tube/Quick-Connector Fittings .................. 6C-44 Precautions ..................................................... 6C-44
Cautions During W ork ..................................... 6C-44
Removal .......................................................... 6C-44
Reuse of Quick-Connector.............................. 6C-45
Assembling Advice .......................................... 6C-45
Filler Neck .......................................................... 6C-46 Removal .......................................................... 6C-46
Installation ....................................................... 6C-46
Fuel Filler Cap .................................................... 6C-47 General Description ........................................ 6C-47
Inspection ........................................................ 6C-47

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