vacuum ISUZU KB P190 2007 Workshop Owner's Guide

6C – 18 FUEL SYSTEM
INJECTION PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.



Removal
1. Battery
Remove the battery from the battery tray.

Battery
Battery tray

P1010011
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly


P1010003
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.


5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the intake throttle.
6. Fan


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ISUZU KB P190 2007

6C – 24 FUEL SYSTEM







13. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket

15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.

Euro under Euro I Euro II Euro III
4JA1L without with with Not used
4JA1TC Not used Not used Not used With cooler
(EGR cooler)
4JH1TC without with with With
(EGR cooler)

17. Accelerator Control Cable
1) Connect the accelerator cable to the injection pump (4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery



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ISUZU KB P190 2007

6D – 2 ENGINE ELECTRICAL

MAIN DATA AND SPECIFICATIONS
Description
Item
60A 80A
Generator
Type
AC generator with IC regulator and vacuum pump
Hitachi LR160-503E Hitachi LR180-513B
Voltage V
Drive and rotation
Ground polarity 12
V-belt, clockwise viewed from the drive pulley Negative
Maximum output A 60 80
Engine speed ratio to 1 1.788
Maximum speed rpm 11,000
Weight with vacuum pump kg(lb) 5.8(12.8) 6.4(14.1)
Vacuum Pump
Delivery volume cm3/rev
Exhaust Characteristic

Maximum vacuum
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000 rpm

7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Starter Motor
Type
Solenoid controlled
Hitachi S13-555
12
2.3
8.76 300 Rated voltage V
Rated output kW
Load characteristics
Terminal voltage V
Load current A
Weight kg(Ib) 4.7 (10.4)


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 7
GENERATOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.


P1010002



























































Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.


Generator
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the bracket.



Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.



Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque N
m (kg
m/Ib
ft)
40 (4.1/30)




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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 9

DISASSEMBLY



RTW46DLF000401
Disassembly Step
1.
Vacuum pump
2.
O-ring
3.
Through bolt
4.
B Terminal nut
5.
Rear cover
6.
Pulley
7.
Rotor assembly
8.
Front cover assembly
9.
Rear rotor bearing
10.
Rectifier assembly
11.
Stator assembly
12.
Rotor assembly


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ISUZU KB P190 2007

6D – 10 ENGINE ELECTRICAL




RTW46DSH000101
Important Operations
1. Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover





RTW46DSH000201
3. Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
 The front cover oil seal must be replaced with a new
one when the front cover is removed.
 Take care not to damage the stator core with the
screwdriver tips.




RTW46DSH000601




RTW46DSH002101
4. Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.


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ISUZU KB P190 2007

6D – 16 ENGINE ELECTRICAL



RTW46DSH000901

















Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump housing.
2. Remove the vacuum pump rotor and the vanes from the housing.


Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.



Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.


Rotor
1. Inspect the rotor for excessive wear, abrasion, and scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash. Replace the rotor if backlash is present.














RTW46DSH005201
Check Value
1. Carefully force the valve from the
“B ” side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the “A ” side.
Air Pressure kPa (kg/cm
2/psi)
98 - 490 (1-5/14 – 71)

Check for air leakage from the check valve.
If there is air leakage, the valve must be replaced.

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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 17


RTW46DSH001801
Vacuum Pump Reassembly
1. Install the vanes to the rotor slits.
The rounded side of the vanes must be facing the
rotor housing.


RTW46DSH001901
2. Install the rotor with the concave side facing the center
plate.



RTW46DSH002001
3. Install the center plate to the rotor housing.
Be sure to use a new O-ring.


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ISUZU KB P190 2007

6D – 18 ENGINE ELECTRICAL
REASSEMBLY



RTW46DLF000501


Reassembly Step
1.
Front cover
2.
Rear rotor bearing
3.
Rotor Assembly
4.
Pulley
5.
Rectifier Assembly
6.
Stator Assembly
7.
Rear cover
8.
B Terminal nuts
9.
Through bolt
10.
O-ring
11.
Vacuum pump


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 21




RTW06DSH000201











9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the front cover and the rear cover.
2. Install the through bolts and tighten them to the specified torque.
Through Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
3.1 ∼ 3.9 (0.32 ∼ 0.41 / 2.6 ∼ 3.5)


11. Vaccum Pump To install the generator -

1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the 3 generator fixing points.
3. Twist the fixing points down and to the left to align them with the middle of the center plate and the rotor.




RTW46DSH006101
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.



RTW46DSH002401
Install the vacuum pump housing.
Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.



RTW46DSH002501












Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque N ⋅m (kg ⋅m/lb ⋅ft)
5.9 ∼ 6.9 (0.6 ∼ 0.7 / 5.2 ∼ 6.1)




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ISUZU KB P190 2007