fuel pressure ISUZU KB P190 2007 Workshop Manual PDF

Engine Control System (4JH1) 6E-297
Exhaust Gas Recirculation (EGR) System Description





RTW 66ELF000101
Legend
1. EGR Cooler
2. Engine Coolant Outlet
3. Engine Coolant Inlet
4. EGR Valve


5. ECM
6. MAF & IAT Sensor
7. Intake Throttle Valve
The EGR system recirculates a part of exhaust gas
back into the intake manifold, which results in reducing
nitrogen oxide (NOx) emissions. The EGR control
system uses an electronic control system solenoid valve
and vacuum control EGR valve to ensure both
driveability and low emission. The engine control
module (ECM) controls the EGR flow amount based on
the engine speed, engine coolant temperature, intake
air temperature, barometric pressure and fuel injection
quantity. The ECM controls the EGR valve opening b
y
controlling the EGR solenoid valve drive duty. The mass
air flow (MAF) sensor monitors EGR gas flow amount.
An expected MAF amount should be detected while the
engine running.

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ISUZU KB P190 2007

6E-298 Engine Control System (4JH1)
Turbocharger Description






RTW 66EMF000501
Legend
1. Exhaust Gas
2. W astegate Valve
3. Turbine W heel
4. Compressor W heel
5. Air Cleaner


6. Vacuum Pressure Sensor
7. Engine Control Module (ECM)
8. Turbocharger Solenoid Valve
9. Vacuum Pump (ACG)
10. Change Air Cooler (Intercooler)
The turbocharger is used to increase the amount of ai
r
that enters the engine cylinders. This allows a
proportional increase of fuel to be injected into the
cylinders, resulting in increased power output, more
complete combustion of fuel, and increased cooling o
f
the cylinder heads, pistons, valves, and exhaust gas.
This cooling effect helps extend engine life.
Heat energy and pressures in the engine exhaust gas
are utilized to drive the turbine. Exhaust gas is directed
to the turbine housing. The turbine housing acts as a
nozzle to direct the shaft wheel assembly. Since the
compressor wheel is attached directly to the shaft, the
compressor wheel rotates at the same speed as the
turbine wheel. Clean air from the air cleaner is drawn
into the compressor housing and wheel. The air is
compressed and delivered through a crossover pipe to
the engine air intake manifold, then into the cylinders.
The amount of air pressure rise and air volume
delivered to the engine from the compressor outlet is
regulated by a wastegate valve in the exhaust housing.
The position of the wastegate valve is controlled by the
amount of pressure built up on the intake side of the
turbocharger. The diaphragm on the inside of the
wastegate is pressure sensitive, and controls the
position of the valve inside the turbocharger. The
position of the valve will increase or decrease the
amount of boost to the turbocharger.
The charge air cooler also helps the performance of the
diesel. Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressurized
air from the turbocharger then flows forward through the
charge air cooler located in the front of the radiator.
From the charge air cooler, the air flows back into the
intake manifold.
The charge air cooler is a heat exchanger that uses ai
r
flow to dissipate heat from the intake air. As the
turbocharger increases air pressure, the air temperature
increases. Lowering the intake air temperature
increases the engine efficiency and power by packing
more air molecules into the same space.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.

Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.

Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled
under every possible driving condition.

Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening o
r
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantit
y
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.


Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.

Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.

Functional inspection
Inspection/adjustment of valve clearance 1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead cente
r
(TDC).





RTW 76ASH001301
Legend
1. TDC



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6A-6 ENGINE MECHANICAL (4JK1/4JJ1)
• Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw o
f
the rocker arm. W hen the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.


Valve clearance mm (in)
Intake valve 0.15 (0.006)
Exhaust valve 0.15 (0.006)
Note:
Adjust while cold.
2. Adjustment of valve clearance • Loosen each adjusting screw of the rocker arm
completely.


RTW 56ASH003701
Legend
1. Screwdriver
2. Ring Spanner
3. Valve Clearance Adjust Nut W rench

Special tool
Valve clearance adjust nut wrench: 5-8840-2822-0
• Insert a 0.15 mm (0.006 in) thickness gauge
between the roller of the rocker arm and the
camshaft to tighten up the adjusting screw o
f
the rocker arm. W hen the movement of the
thickness gauge becomes tight, fasten the
adjusting screw nut of the rocker arm.






LHW 71BSH001201
Legend
1. Cam; Exhaust
2. Cam; Intake
3. Roller; Intake
4. Roller; Exhaust

Tightening torque:
Rocker arm adjustment screw nut 18 N ⋅
⋅⋅
⋅
m (1.8 kg ⋅
⋅⋅
⋅
m/ 13 lb ft)

Adjustment table

Cylinder No. 1 2 3 4
Valve
arrangement IN EX IN EX IN EX IN EX
No. 1 cylinder
Compression
TDC

No. 4 cylinder
Compression
TDC
× × × ×
• If the No.1 cylinder is the compression TDC, adjust
a valve clearance with
mark given on the table
and if the No. 4 cylinder is the compression TDC,
adjust that with × mark.
• Install the cylinder head cover.
Refer to "Cylinder Head Cover."
• Install the leak off hose.
• Install the fuel injector harness assembly.

Compression pressure inspection
• W arm up the engine.
• Disconnect the negative battery cable.

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6A-8 ENGINE MECHANICAL (4JK1/4JJ1)
Trouble Shooting
Engine does not turn over
Condition Possible Cause Correction
Dead or weak battery Charge battery
Replace battery
Incomplete circuit Connect
Repair
Starter motor brushes stuck, worn,
or broken Replace brushes
Starter motor does not rotate
Starter motor internal damage Repair motor
Ring gear abrasion Replace ring gear Starter motor not meshed with
flywheel Magnetic switch (starter motor) not
properly adjusted Adjust
Dead or weak battery
Charge battery
Replace battery
Insufficient contact pressure
between starter motor brushes and
commutator Adjust pressure
Armature (starter motor) stuck Repair armature
Starter motor pinion meshed with
ring gear but does not rotate
Engine internal damage (Seizure) Repair engine

Engine turns over but does not start
Condition Possible Cause Correction
Air in fuel system Bleed air from fuel system
Air entering fuel pipe Replace pipe and bleed air from
fuel system
Empty fuel tank Replenish fuel
Clogged strainer (fuel suction) Clean or replace strainer
Clogged fuel pipe Clean or replace pipe
Feed pump malfunction Replace pump
Use of wrong fuel for prevailing
temperatures Drain existing fuel and replace with
appropriate fuel
Fuel is not delivered to fuel supply
pump
Clogged fuel filter Replace filter
Loose injection pipe connections Tighten connections
Loose or broken electrical
connectors Tighten and/or replace connectors
Bad rotational sensor
Replace sensor
Fuel is delivered to fuel supply
pump
Engine control system malfunction System diagnosis
Air in fuel system Bleed air from fuel system
Feed pump malfunction Repair pump
Loose or broken electrical
connectors Tighten and/or replace connectors
Clogged fuel filter
Replace filter
Insufficient or unstable fuel delivery
volume
Engine control system malfunction System diagnosis

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-9

Excessive black exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Carbon deposit at nozzle tip Clean fuel injector assembly
Sticking nozzle Replace fuel injector assembly
Bad fuel injector condition
Engine control system malfunction System diagnosis
Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to
damaged piston ring Replace piston ring
Damaged gasket
Replace gasket
Insufficient compression pressure
Piston scoring Replace piston
W ater in fuel Drain existing fuel and replace with
new fuel Fuel condition
Poor fuel quality Drain existing fuel and replace with
new fuel
Clogged intake pipes Clean or replace pipes Poor engine aspiration
Clogged air cleaner element Clean or replace element
Defective sensor Replace sensor Malfunction detected by engine
control system Engine control system malfunction System diagnosis
Intake throttle valve sticking Repair or replace valve
EGR valve sticking Repair or replace valve
EGR valve and/or intake throttle
valve malfunction
Engine control system malfunction System diagnosis
Damaged turbocharger blade Replace turbocharger
Rough turbocharger shaft rotation Replace turbocharger
Oil leakage from oil seal Replace turbocharger
Turbocharger malfunction
Broken actuator Replace turbocharger


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6A-10 ENGINE MECHANICAL (4JK1/4JJ1)
Excessive white exhaust smoke
Condition Possible Cause Correction
Bad injection timing Engine control system malfunction System diagnosis
Defective sensor Replace sensor
Control unit malfunction Replace unit
Malfunction detected by engine
control system
Engine control system malfunction System diagnosis
Excessive valve clearance Adjust clearance
Sticking valve stem (valve open) Repair or replace valve
Damaged valve spring Replace spring
Valve seat abrasion Repair valve seat
Compression leakage due to
damaged piston ring Replace piston ring
Damaged gasket
Replace gasket
Insufficient compression pressure
Piston scoring Replace piston
Fuel condition W ater in fuel Drain existing fuel and replace with
new fuel
W orn or damaged piston ring(s) Replace ring(s)
Defective valve stem oil seal Replace oil seal
Defective turbocharger oil seal Replace turbocharger
Excessive oil consumption
Clogged turbocharger oil return
pipe Repair pipe

Engine knocking
Condition Possible Cause Correction
Bad timing Engine control system malfunction System diagnosis
Defective sensor Replace sensor
Control unit malfunction Replace unit
Malfunction detected by engine
control system
Engine control system malfunction System diagnosis
Fuel condition Poor quality fuel Drain existing fuel and replace with
new fuel
Clogged air cleaner element Clean or replace element
Clogged intake pipes Clean or replace pipes
Poor engine aspiration
Engine control system malfunction System diagnosis
Foreign material in cylinders Engine overhaul Engine break-down Scored pistons and/or bearings Replace pistons and/or bearings


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-13
Main Data and specifications
Item Engine model 4JK1 Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder
bore × strokes mm (in) 4-95.4 (3.76) × 87.4 (3.44) 4-95.4(3.76) × 104.9(4.13)
Displacement
cc (cu.in) 2499 (152) 2999 (183)
Compression ratio 18.3 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1 - 3 - 4 - 2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type W ater cooling type
Radiator type Corrugated fin (pressure type)
W ater pump type Centrifugal, belt drive type
Thermostat type W ax-type units
Thermostat valve-opening temperature °C ( °F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 - 90

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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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FUEL SYSTEM (4JK1/4JJ1) 6C-3
Explanations on functions and operation
Fuel system diagram






RTW 76CMF000101
Legend
1. Fuel Rail
2. Fuel Pressure Limiter
3. Leak Off Pipe
4. Fuel Injector
5. Fuel Return Pipe
6. Fuel Cooler
7. Fuel Tank
8. Fuel Pump and Sender Assembly
9. Fuel Filler Cap
10. Check Valve
11. Fuel Feed Pipe
12. One W ay Valve 13. Fuel Filter W ith Sedimenter
14. Switch; Clogging Monitoring
15. Fuel Supply Pump


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