torque ISUZU KB P190 2007 Workshop Repair Manual

6C-16 FUEL SYSTEM (4JK1/4JJ1)
3. Apply Engine oil to the threads and seating
surfaces of the clamp bolts.
4. Install the fuel injector clamps to the cylinder head.
5. Temporarily tighten the clamp bolts.
6.
Apply a thin coat of engine oil to the outer surface
of the fuel injector side sleeve nuts.
7. Install the fuel injector pipes to the position shown in the illustration.
8. Use a spanner to carefully tighten the sleeve nuts until the fuel injector pipes contact the fuel injecto
r
and fuel rail.
9. Tighten the fuel injector pipe clips to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)



RTW 76CMH000101
Legend
1. Fuel Injector
2. Pipe Clip


10. Tighten the injection pipes to the specified torque.
Tightening torque: 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)



RTW 76CSH000201
Legend
1. Clamp Bolt
2. Sleeve Nut

11. Tighten the fuel injector clamp bolts to the
specified torque.
Tightening torque: 26 N ⋅
⋅⋅
⋅
m (2.7 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
12. Tighten the engine oil level gauge guide tube. Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
13. Install the cylinder head cover.
Refer to the install procedure for the cylinder head cover in this manual.


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ISUZU KB P190 2007

6C-18 FUEL SYSTEM (4JK1/4JJ1)
Torque Specifications




RTW 76CLF000201

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FUEL SYSTEM (4JK1/4JJ1) 6C-19
Fuel Rail Pressure Sensor
Removal
1. Disconnect the fuel pressure sensor harness
connector (1).




LNW 76CSH001601
2. Remove the fuel pressure sensor (2).
Note: Cover the areas exposed during parts removal to
prevent the entry of foreign material into the fuel
system.









RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter


Installation
1. Install the fuel pressure sensor.
Tightening torque: 98 N·m (10.0 kg·m/72 lb ft)
2. Connect the fuel pressure sensor connector.



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6C-20 FUEL SYSTEM (4JK1/4JJ1)
Fuel Pressure Limiter
Removal
1. 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
2. Remove the fuel pressure limiter.
Note: Cover the areas exposed during part removal to
prevent the entry of foreign material into the fuel
system.










RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter

Installation
1. Install the fuel pressure limiter.
Tightening torque: 172 N·m (17.5 kg·m/127 lb ft)
2. Install the fuel leak off pipe and hose using the mounting eyebolt using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)


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6C-24 FUEL SYSTEM (4JK1/4JJ1)
Disassembly
1. Remove the fuel pressure limiter.
2. Remove the pressure sensor.









RTW 76CSH000101
Legend
1. Fuel Rail
2. Fuel Rail Pressure Sensor
3. Fuel Pressure Limiter

Reassembly
1. Install the fuel pressure limiter.
Tightening torque: 172 N ⋅
⋅⋅
⋅
m (17.5 kg ⋅
⋅⋅
⋅
m/127 lb ft)
2. Install the fuel pressure sensor. Tightening torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kg ⋅
⋅⋅
⋅
m/72 lb ft)

Installation
1. Tighten the fuel rail bracket and fuel rail using the
specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
2. Tighten the vacuum pipe to the fuel rail bracket using the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)
3. Tighten the swirl control solenoid valve to the fuel rail bracket using the specified torque.
Tightening torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kg ⋅
⋅⋅
⋅
m/14 lb ft)
Note: • Do not grasp the pressure sensor, during the
fuel rail removal procedure.
• Take care not to damage the connector unit o
f
the pressure sensor.




RTW 76CSH000801
Legend
1. Fuel Rail
2. Fuel Rail Bracket
3. Vacuum Pipe
4. Swirl Control Solenoid Valve

4. Tighten the fuel pipe using the mounting sleeve
nut and the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
5. Connect the fuel rail pressure sensor harness connector.


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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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6C-26 FUEL SYSTEM (4JK1/4JJ1)
Torque Specifications






RTW 76CLF000401



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FUEL SYSTEM (4JK1/4JJ1) 6C-33
Installation
1. Install the O-ring to the fuel supply pump.
2. Install the fuel supply pump.
Apply soapy water to the O-ring before attaching.
Note: Take care not to twist the O-ring. 3. Install the fuel supply pump bracket.
Temporarily tighten with the bolts and nuts (Gea
r
case side).
Temporarily tighten with the bolts (Cylinder bod
y
side).
Fully tighten the nuts and bolts (Gear case side).
Fully tighten the bolts (Cylinder body side).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m /18 lb ft)




RTW 56CSH002001
Legend
1. Fuel Supply Pump
2. Fuel Supply Pump Bracket


4. Confirm that the supply pump camshaft key is
turned to the right and is horizontal.







RTW 56CSH004301
5. Install the fuel supply pump gear to the pump
shaft.
a.
Align the fuel pump gear timing mark (1) with
the idle gear A paint marks (2).
b. Ensure that the pump gear is bitten with main gear (3) of the idle gear A. Depress the pump
gear when it is bitten with scissors gear (4) o
f
the idle gear A.





RTW 56CSH005101


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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-36 FUEL SYSTEM (4JK1/4JJ1)
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover" in ENGINE MECHANICAL section.
16. Apply liquid gasket (ThreeBond TB-1207C o
r
equivalent) to timing chain cover upper (1).
•
Attach cover within 5minutes after the
application of gasket.







RTW 56CSH002101
17. Install the timing chain cover upper (1).
Tighten the bolt to the specified torque. •
Apply Loctite #262 or equivalent to the bolt and
stud threads of cylinder head side (2).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)





RTW 76CSH001201

18. Apply liquid gasket (ThreeBond TB-1207C o
r
equivalent) to the timing chain cover lower (1).
•
Attach the cover within 5 minutes of applying
the liquid gasket.






RTW 56CSH002301
19. Install the timing chain cover lower.
Tighten the nuts and bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
20. Install the noise cover to the timing chain cove
r
lower.
Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
21. Connect the connectors. • Supply pump
• Camshaft position sensor
22. Install the fuel rail assembly. • Refer to the Install procedure for "Fuel rail
assembly" in this manual.
23. Install the A/C compressor bracket.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)


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ISUZU KB P190 2007