ECO mode ISUZU KB P190 2007 Workshop Manual Online

6C – 28 FUEL SYSTEM

Injection Nozzle Adjustment
First nozzle opening pressure adjustment
1.Clamp the nozzle holder in a vise.

2. Install the shim, first spring and spring seat in the nozzle holder.

3. Install the collar, second spring, shim, spring seat and pushrod in the nozzle holder.

4. Install the pins, lift piece and spacer in the nozzle holder.



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6C – 32 FUEL SYSTEM

8. Operate the nozzle tester and increase the in-line
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm2) so that
the nozzle’s needle valve moves through its full lift.
Record full lift ‘L’. (Read dial gauge)
Nozzle Full Lift mm (in)
0.25 ± 0.02 (0.0098 ± 0.00008)
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.

Pre-lift confirmation 1. W ith the needle valve at full lift, release the nozzle tester handle.

Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.


040R300008

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FUEL SYSTEM 6C – 33

2. Read the needle valve “pre-lift” point from the dial gauge indication (once the needle valve has
descended when the second spring has stopped
operating).
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
1 MPa (10 kg/cm
2).
Pre-lift mm
Pressure Mpa
(psi/ kg/cm
2) Lift mm (in)
4JA1T(L) 20.1 (2,858/205) 0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.

3. Confirm that pre-lift is as specified.
4. If pre-lift is not as specified, replace the pins, lift piece, spacer and nozzle assembly as a set with the service
kit.
Service kit
105017-2990 (Bosch AS)
897302-3070 (ISUZU)

Second nozzle opening pressure confirmation
1. After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
kg/cm
2) so that the nozzle’s needle valve moves
through its full lift.


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6C – 34 FUEL SYSTEM
2. Release the nozzle tester handle so that in-line
pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.



3. Then, read the pressure gauge indication (second
nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift + 0.05 mm).
Second Nozzle Opening Pressure
Pressure Mpa
(psi/ kg/cm
2) Lift mm (in)
4JA1T(L) 25.5-27.0
(3768-3911/260-275) 0.09 (0.0035)


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FUEL SYSTEM 6C – 35


Second nozzle opening pressure adjustment
If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
• Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
• Use a micrometer to measure shim thickness.
• Use some combination of 3 adjusting shims to
adjust the pressure.


• Second nozzle opening pressure adjusting shims
Part No. (ISUZU) Thickness
(mm) Part No.
(ISUZU) Thickness
(mm)
897116-0290 0.10 897116-0380 0.53
897116-0320 0.20 897116-0390 0.54
897116-0330 0.30 897116-0400 0.55
897116-0340 0.40 897116-0410 0.56
897116-0350 0.50 897116-0420 0.57
897116-0360 0.51 897116-0430 0.58
897116-0370 0.52 897116-0440 0.59


Final inspection
1. Remove the dial gauge, nut and dial gauge holder.

2. Remove the adjustment retaining nut and gasket.
3. Install the original retaining nut, confirm that the pins are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 7.0 kg·m (50.6 Ib·ft/69 N·m)


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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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6D – 8 ENGINE ELECTRICAL

033RY00009




















































Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys. 1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley


3. Adjust the fan belt tension
Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection mm (in)
New belt 4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)

4. Tighten the adjusting plate bolts to the specified torque.
Adjusting Plate Bolt N·m (kg·m/lb·ft)
19 (1.9/14)

5. Reconnect the battery cable to the battery.


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6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
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.























Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Disconnect the magnetic switch cable at the terminal bolts.
3. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
4. Remove the starter motor from the engine.

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.









Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N⋅m (kg ⋅m/lb ⋅ft)
85 (8.7/63)

3. Reconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
4. Reconnect the battery cable and the ground cable at the battery terminals.



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6D – 32 ENGINE ELECTRICAL


MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M ”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).





RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.




RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.




RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.




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6E-30 Engine Control System (4JH1)
Diagnostic Information And Prosedures
Engine Control System Check Sheet





ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name
Customer’s Name Model & Model Year
Driver’s Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading Km/miles

□ Engine Does
Not Run □
Engine does not crank
□No initial combustion
□ No complete combustion
□
Hard Start
□ Engine cranks slowly
□Other ( )
□
Abnormal idling speed
□High idling speed ( RPM)
□ Low idling speed ( RPM)
□
Rough idling □
Incorrect Idle
□ Other ( )
□
Hesitation, sag, stumble
□Surge, chuggles
□ Cut out, misses
□
Lack of power, sluggishness, sponginess □
Poor
Driveability □ Other ( )

□ Soon after starting
□After accelerator pedal depressed
Engine Stall
□ During A/C operation
□After accelerator pedal released
□ Shifting from N to D □

□ Other ( )
□
Black smoke
□White smoke
□ Poor fuel economy
□
Fuel knock, combustion noise
Problem Symptoms
□
Others
□ Other ( )
Dates problem occurred
□
Constant
□Intermittently ( times per day/month)
□ Once only Problem frequency
□ Other (
)
□ Fine
□Cloudy
□Rainy
□ Snow Weather
□ Various/Other (
)
□ Hot (approx. )
□Warm
□Cool
□ Cold (approx. )Outside
Temperature □ Any temperature
□
Highway
□Suburbs
□City area
□ Uphill Place
□ Downhill
□Rough road
□Other (
)
□ Over (approx. tons)
□No load
Load Condition
□ Other (approx. tons)

□ Cold
□Warming up
□After warming up
□ Any temperature Engine
Temperature □ Other ( )
□
Starting
□Just after starting ( Min.)
□ Idling
□
Racing
□Driving
□Constant speed
□ Acceleration
□
Deceleration
□A/C switch On/Off Engine Operation
□ Other ( )
Fuel Amount
□ Full
□Above 1/2
□Below 1/2
□ Near empty
Condition When Problem Occurs
Fuel
Bland
Condition of MIL
□Remains On
□Intermittently turns On
□ Does not turn On
Present Code
□Nothing
□P Code & Symptom Code
No. ( )Diagnostic Trouble
Code (DTC) or Flash
Code History Code □Nothing
□P Code & Symptom Code
No. ( )

Other Additional
Condition


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