ISUZU KB P190 2007 Workshop Repair Manual

FUEL SYSTEM 6C – 17
FUEL FILLER CAP


RTW 46CSH000301
Legend
1. Seal Ring


General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.


Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective

CAUTION: A replacement fuel filler cap must be the same
as the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.







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ISUZU KB P190 2007

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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FUEL SYSTEM 6C – 19
7. Power Steering Pump Bracket

6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only) Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe 1) Disconnect the fuel hoses from the fuel filter or priming pump.
2) Disconnect the fuel hoses from the injection pump.
11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold 1) Remove the EGR valve from the intake manifold and EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)

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ISUZU KB P190 2007

6C – 20 FUEL SYSTEM


020L200017



RTW 46CSH000201
18. Timing Check Hole Cover
1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.



6C-7
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear “B” fixing hole to prevent the scissors gear from
turning.


29. Injection Pump Bracket
20. Injection Pump



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FUEL SYSTEM 6C – 21



RTW 46CSH000201
Installation
1. Injection Pump
1) Install the injection pump gear (W hen gear is removed).
Injection Pump Gear Nut N⋅m (kg ⋅m/lb ft)
64 (6.5 / 47)
2) Bring the piston in the No.1 cylinder to TDC on the
compression stroke by turning the crankshaft until the
crankshaft pulley TDC line aligned with the timing
mark.



020L200017






3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 × 30) from the idle gear “B”.


6C-7




6) Tighten the injection pump fixing bolts to the specified
torque.
Injection Pump Bolts Torque N·m (kg·m/lb ft)
19 (1.9 / 14)


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6C – 22 FUEL SYSTEM



4JA1T (L)
RTW 46CSH000101






4JA1TC/4JH1TC
RTW 36AMH000101


















2. Injection Pump Bracket
1) Install the injection pump bracket (6) and the bracket bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque N·m(kg·m / lb ft)
(8) 19 (1.9 / 14)

(7) 40 (4.1 / 30)









3. Timing Check Hole Cover
Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque N·m(kg·m / lb ft)
8 (0.8 / 69)















4. Injection Pump Cover (4JA1TC/4JH1TC only)
5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque N·m(kg·m / lb ft)
19 (1.9 / 14)

Intake Manifold Nuts Torque N·m(kg·m / lb ft)
24 (2.4 / 17)

2) Install the EGR valve to the intake manifold and EGR pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque N ⋅m (kg ⋅m/lb ft)
Nuts 24 (2.4/17)
Bolts 27 (2.8/20)

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FUEL SYSTEM 6C – 23




6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque N·m(kg·m / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC) N·m(kg·m / lb ft)
40 (4.1 / 30)






7. Injection Pipe Clip Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque N·m(kg·m / lb in)
8 (0.8 / 69)

8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.






9. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque N·m(kg·m / lb ft)
21 (2.1 / 15)








10. Fuel Filter Assembly (Except EURO III model) Install the fuel filter assembly to bracket and tighten bolts
to the specified torque.
Fuel Filter Assembly Bolts
Torque N·m(kg·m / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming pump.
2) Connect the fuel hoses to the injection pump.








12. Oil Level Gauge Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque N·m(kg·m / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)


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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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FUEL SYSTEM 6C – 25
INJECTION NOZZLE (4JA1L)
DISASSEMBLY

RTW 76CMF000401

Disassembly Steps
1. Retaining nut 2. Nozzle & pin
3. Spacer & pin
4. Lift Piece
5. Spring seat
6. Push rod
7. Shim (Second nozzle opening pressure adjustment)
8. Second spring 9. Collar
10. Spring seat
11. First spring
12. Shim (First nozzle opening pressure adjustment)
13. Nozzle holder body
14. Eye bolt



Important Operations
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.

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6C – 26 FUEL SYSTEM
REASSEMBLY

RTW 76CMF000501


Reassembly Steps
1. Nozzle holder body 2. Shim (First opening pressure adjustment)
3. First spring
4. Spring seat
5. Collar
6. Second spring
7. Push rod
8. Shim (Second opening pressure adjustment) 9. Spring seat
10. Lift Piece
11. Spacer & pin
12. Nozzle & pin
13. Retaining nut
14. Eye bolt











Important Operations
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.

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