fuel pressure ISUZU KB P190 2007 Workshop Repair Manual

TROUBLESHOOTING 6 – 1




BASIC INSPECTION PROCEDURE....6– 2

1. HARD STARTING ............................6– 3

1-1.Starter Motor Inoperative ..........6– 3

1-2. Starter Motor Operates But
Engine Does Not Turn Over ...........6– 3

1-3. Engine Turns Over But Does
Not Start Engine ..............................6– 4

2. UNSTABLE IDLING .........................6– 5

3. INSUFFICIENT POWER ..................6– 6

4. EXCESSIVE FUEL
CONSUMPTION..................................6– 7

5. EXCESSIVE OIL CONSUMPTION ..6– 8

6. OVERHEATING ...............................6– 9

7. WHITE EXHAUST SMOKE..............6– 9

8. DARK EXHAUST SMOKE ...............6– 10

9. OIL PRESSURE DOES NOT RISE..6– 11

10. ABNORMAL ENGINE NOISE ........6– 12

10-1. Engine Knocking ....................6– 12

10-2. Gas Leakage Noise .................6– 12

10-3. Continuous Noise ...................6– 13

10-4. Slapping Noise ........................6– 13

10-5. Excessive Turbocharger
Noise ................................................6– 14
11. ROTATING PART WEAR OF
TURBOCHARGER.............................. 6– 14

12. OIL LEAKAGE FROM
TURBOCHRGER ................................ 6– 15

13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER........................ 6– 15

14. BATTERY CHARGING AND
NOISE PROBLEM .............................. 6– 16

14-1. Battery No Charging ............... 6– 16

14-2. Battery Overcharging ............. 6– 16

14-3. Battery Under Charging ......... 6– 17

14-4. Battery Unstable Charging
Current ............................................. 6– 17

14-5. Charging System Noise ......... 6– 18

15. STARTER MOTOR PROBLEM ..... 6– 19

15-1. Starter Motor Pinion Engages
to Ring Gear But Engine Does
Not Turn Over .................................. 6– 19

15-2. Incorrect Pinion And Ring
Gear Engagement ........................... 6– 19

15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off........................................ 6– 20

15-4. Excessive Commutator
Sparking .......................................... 6– 20


SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE PAGE

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6 – 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump
Step Action Value(s) Yes No
1 Check clogged, damaged the fuel piping or the
connector loosen.
Was any problem found? —

Repair replace problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved

Incase of the fuel is being delivered to the injection pump
Step Action Value(s) Yes No
1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 5 Bleed the air
3 Was the injection spray condition complete? —
Go to Step 4 Replace the
injection nozzle
4 Was the injection nozzle injection starting pressure OK? (See below)
Go to Step 5 Replace the
injection nozzle
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? —
Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at 200rpm
Go to Step 11 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

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6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —

Go to Step 2 Clean or
replace the air cleaner
element.
2 Was the intake air leakage found from intake system? —
Repair or
replace the intake air system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —

Go to Step 4 Clean or
replace the fuel filter element.
4 Check the fuel injection pipes. Does the injection pipes have obstruction or any
damage? —
Repair or
replace the fuel injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —

Go to Step 7 Readjust the
injection nozzle pressure or replace the nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 8 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? —
Repair or
replace the exhaust system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? —
Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved


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TROUBLESHOOTING 6 – 7
4. Excessive Fuel Consumption
Step Action Value(s) Yes No
1 Was the air cleaner element clogged? — Clean or
replace the air cleaner
element. Go to Step 2
2 Was the air leakage found from the air intake side of
the turbocharger? —
Repair or
replace the air intake side of the
turbocharger. Go to Step 3
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger
4 Was there the fuel leakage? — Repair or
replace the fuel leakage part. Go to Step 5
5 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 6 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve
and valve seat
6 Was the injection nozzle pressure or spray pattern normal? —

Go to Step 7 Replace the
injection nozzle
7 Are any DTC stored? — Go to indicated
DTC Solved


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SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
4 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing ...................................................................................................................... .. 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6 A - 24
Lubricating System.................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 2 7
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ..................................................................... 6A - 32
General Description ...................................................................................................... 6A- 3 6
Removal and Installation .............................................................................................. 6A- 37 Removal ...................................................................................................................... 6 A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment ......................................................................................... 6A- 41
Engine Warm-Up .................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A - 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6 A- 43
External Parts ......................................................................................................... 6A- 43
E N GINE MECHA NICA L 6A – 1
Main Dat a and Specif ications ....................................................................................... 6A -
Torque Specif ications ................................................................................................... 6A -

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6A – 4 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JA1T (L)
4JA1TC
Engine type
Combustion chamber type
Cylinder liner type
Timing gear train system Four-cycle, overhead valve, water cooled
Direct injection
Dry type, chrome plated Gear drive
No. of cylinders-bore × stroke mm (in) 4 – 93 × 92 (3.66 × 3.62)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement cm3 (in3)
Compression ratio (to 1) 2,499 (152.4)
18.5
Compression pressure MPa (kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb)Approximately 239 (527)
Fuel injection order 1 – 3 – 4 - 2
Fuel injection timing BTDC deg8 -
Specified fuel type
Idling speed rpm

Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
730 ± 25 (A/C Off)
780 ± 25 (A/C ON)
0.4 (0.016)
0.4 (0.016) 24.5
55.5
54.0
26.0

Injection pump type BOSCH distributor VE type BOSCH distributor VP44 type
Governor type Mechanical (Half all speed
type) Electronically controled
Injection nozzle type
Injection nozzle opening pressure Hole with 5 orifices

MPa (kg/cm2/psi) 1st 19.1 (195 / 2,773) 1st 19.0 (194 / 2,755)
2nd (Reference)
25.5 ∼27.0
(260 ∼275 / 3,702 ∼3,920) 2nd (Reference)
34.0 ∼35.5
(347 ∼362 / 4,936 ∼5,154)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)

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6A – 6 ENGINE MECHANICAL
MAIN DATA AND SPECIFICATIONS
Engine model
Item 4JH1TC
Engine type
Four-cycle, overhead valve, water cooled
Combustion chamber type Direct injection
Cylinder liner type
Timing gear train system Dry type, chrome plated
Gear drive
No. of cylinders-bore × stroke mm (in) 4 – 95.4 × 104.9 (3.76 × 4.13)
No. of piston rings Compression ring: 2 / Oil ring: 1
Total piston displacement liter
Compression ratio (to 1) 2,999
18.3
Compression pressure MPa (kg/cm2/psi) 3.0 (31.0/441) – 200 rpm
Engine weight (dry) kg (lb)MT: Approximately 249 (549)
AT: Approximately 236 (520)
Fuel injection order 1 – 3 – 4 - 2
Specified fuel type JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed rpm
700 ± 25 (A/C OFF)
800 ± 25 (A/C ON)
Valve clearances (At cold): Intake mm (in)
Exhaust mm (in)
Intake valves Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves Open at (BBDC) deg
Close at (ATDC) deg
Fuel system
Injection pump type 0.4 (0.016)
0.4 (0.016) 24.5
55.5
54.0
26.0
BOSCH distributor VP44 type
Injection nozzle type
Injection nozzle opening pressure
MPa (kg/cm
2/psi) Hole with 5 orifices

1st 19.5 (199/2,828)
2nd (Reference) 34.3 ∼35.8 (350 ∼365/4,980 ∼5,197)
Main fuel filter type
Lubricating system
Lubricating method Cartridge paper element and water separator

Pressure circulation
Specified engine oil (API grade) ISUZU genuine 10W – 30 (API CD of ACEA B2/B3)
Oil pump type
Oil filter type Gear
Cartridge paper element
Oil capacity lit (US/UK gal)
6.2 (1.64/1.36) (For 4
× 2)
7.0 (1.85/1.54) (For 4 × 4)
Oil cooler type W ater cooled

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ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW 36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure W arning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler W ater Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. W ater Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


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6A – 46 ENGINE MECHANICAL
13. Injection Pump
Refer to section 6C-19 (Injection Pump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger 1) Disconnect the water hose between thermostat housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


027R100007
037RY00001

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