check oil ISUZU KB P190 2007 Workshop Manual PDF

TROUBLESHOOTING 6 – 17
14-3 Battery Under Charging
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there intermittent contact between the brush
and the slip ring? —
Repair or
replace the
brush holder assembly. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there a short circuit in the rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit on the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the rectifier on the generator.
Was the rectifier defective? —
Replace the
rectifier Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Was the electrical load excessive? — Replace more
higher capacity generator. Go to Step 8
8 Are any DTC stored? — Go to indicated
DTC. Solved

14-4 Battery Unstable Charging Current
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the brush contact condition on the generator.
Was there poor contact between the brush and the
slip ring? —
Repair or
replace the
brush and/or the slip ring. Go to Step 3
3 Inspect the rotor coil on the generator.
Was there the short circuit or an open circuit in the
rotor coil? —
Repair or
replace the rotor coil. Go to Step 4
4 Inspect the stator coil on the generator.
Was there an open circuit or the short circuit in the
stator coil? —
Repair or
replace the stator coil. Go to Step 5
5 Inspect the connection between the rectifier and
stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ? —

Repair the loose
connection. Go to Step 6
6 Inspect the IC regulator on the generator.
Was the IC regulator defective? —
Replace the IC
regulator. Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

6 – 18 TROUBLESHOOTING
14-5 Charging System Noise Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Was there intermittent noise or continuous noise and
that could be identified clearly by increasing and
decreasing engine speed? —

Replace the bearing. Go to Step 3
3 Was there a growling sound and does this sound
stop when the connector was disconnected? —
Replace the
stator coil. Go to Step 4
4 Was intermittent sound heard when the generator
was running? —
Replace the
brush and/or slip ring. Go to Step 5
5 Was frictional sound heard when generator was
running? —
Clean the slip
ring or replace the brush. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 19
15. Starter Motor Problem
Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Check the contact condition between the brush and
the commutator.
Was the brush and the commutator contact
intermittent? —
Replace the
brush or repair the
commutator. Go to Step 3
3 Were the brush and the commutator contact faces
dirty?
—

Clean contact face Go to Step 4
4 Was the pinion clutch slipped? — Replace the
pinion clutch Go to Step 5
5 Inspect the armature field coil.
Was there an open circuit or a short circuit in the
armature field coil? —
Repair or
replace the
armature field coil. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC. Solved

15-2 Incorrect pinion and ring gear engagement
Step Action Value(s) Yes No
1 Was “Visual/Physical Check" performed.
—

Go to Step 2 Go to
visual/physical check
2 Inspect the pinion and the ring gear teeth.
Were the pinion and/or the ring gear teeth worn or
broken? —

Replace the wron parts. Go to Step 3
3 Inspect the pinion gear return movement.
Was the pinion gear return movement incorrect? —
Adjust or
replace the movement parts. Go to Step 4
4 Are any DTC stored? — Go to indicated
DTC. Solved


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ISUZU KB P190 2007

6A – 24 ENGINE MECHANICAL

SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.


RTW 36ASH000401
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.


AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.

Dust Fouled Element (Except wet type element)
Rotate the element with your hand while applying
compressed air to the inside of the element. This will blow
the dust free.
Compressed air pressure kPa (kg/cm
2 /psi)
392 – 490 (4 – 5/57 – 71)


LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0200-0


RTW 36ASH000101



4. Clean the oil cooler fitting face. This will allow the new oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted against the sealing face.
7. Use the filter wrench to turn in the filter an additional 2/3 turns.
Filter W rench: 5-8840-0200-0
8. Check the engine oil level and replenish to the specified level if required.
130RY00003
6A-6

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
W ith oil filter
replacement W ithout oil
filter
replacement
4 × 2
4 × 4
(4JA1L/TC)6.2 (1.64/1.36) 5.2 ∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 2
(4JH1TC)
6.2 (1.64/1.36) 5.2
∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 4
(4JH1TC) 7.0 (1.85/1.54) 6.2 ∼ 5.2
(1.64 ∼ 1.37
/ 1.36 ∼ 1.14) 5.3
∼ 4.3
(1.72 ∼ 1.14
/ 1.17 ∼ 0.95)

9. Start the engine and check for oil leakage from the
main oil filter.



RTW 66ASH003201




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.




RTW 66ASH003301








2. Clean the fuel filter cartridge fitting faces. This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a filter wrench.
Filter W rench : 5-8840-0253-0 (J-22700)




6. Operate the priming pump until the air discharged completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.

041RY00009

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 27
111R300001


COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the “MIN” line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the “MAX” line.



Engine coolant Filling up procedure
1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
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.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to “MAX” line
4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten 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.
6. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
7. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.
Engine Coolant Total Capacity Lit (U.S / UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/W ater)
50 %


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ENGINE MECHANICAL 6A – 29


Thermostat Operating Test
1. Completely submerge the thermostat in water.
2. Heat the water. Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C ( °F)
82 (180)
Oil Cooler Thermo Valve °C ( °F)
76.5 (170)
EGR Cooler Thermo Valve °C ( °F)
40 (104)

4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature °C ( °F)
95 (203)
Oil Cooler Thermo Valve °C ( °F)
90 (194)
EGR Cooler Thermo Valve °C ( °F)
55 (131)
Valve Lift at Fully Open position mm (in)
9.5 (0.37)
Oil Cooler Thermo Valve mm (in)
4.5 (0.18)
EGR Cooler Thermo Valve mm in)
3.5 (0.14)



Drive Belt Adjustment
Check drive belts for wear or damage, and replace with
new ones as necessary. Check belts for tension, and
adjust as necessary.
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
4 Oil pump pulley or idler pulley
5 Compressor pulley or idler pulley


030LX014
033RY00002

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
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.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten 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.
5. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
6. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system. Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 69
3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm
oil port.




Rocker Arm Correction
Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.



CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner. Refer to "Cylinder Liner Replacement".
















3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.

Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)


Cylinder Body Height (H) (Reference) mm (in)
Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)
4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner. Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.


014RY00024
012R100001
012RY00009 014RY00023

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ENGINE MECHANICAL 6A – 73






Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and bore surfaces.

NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2) from the top of the cylinder body.










4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).

NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
6. Use the bench press to apply a seating force of 4,900 N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder liner projection.
Refer to "Cylinder Liner Projection Inspection".

012RY00017
012RY00018

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