fuel pump ISUZU KB P190 2007 Workshop Repair Manual

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE
Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I (DIESEL) I I I I I I I R I I I I I I I R I I I I * Engine oil (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - R - R - R - R - R - R - R - R - R - R

(4JA1-T) R R R R R R R R R R R R R R R R R R R R * Engine oil filter (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination (GASOLINE) - I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage
I I - I - I - I - I - I - I - I - I - I Fuel tank - - - I - - - I - - - I - - - I - - - I O2 Sensor (C24SE) Replace every 160,000km (HFV6)
MIL diagnostic Indicates O2 Sensor Valve clearances (6VE1) Check and adjust if noisy (4JH1-TC, 4JA1-T) A - - A - - - A - - - A - - - A - - - A (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - A - - - - - - - A - - - -
Spark plugs (C24SE) (for leaded fuel
use) - R - R - R - R - R - R - R - R - R - R
Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
Spark plugs
(HFV6) Replace every 120,000km Spark plug wire - - - - - - - - - - - - - - - - - - - I Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R (4JH1-TC, 4JA1-T) - - R - - R - - R - - R - - R - - R - - ** (4JJ1 (Standard Output),
4JJ1 (High Output)) Replace the fuel filter when the fuel filter indicator light is lit.
Fuel pump in fuel tank
(4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - I - - - - - - - I - - - -
Engine / Accessory drive belt
(C24SE) - - - - - - - - - I - - - - - - - - - I

(HFV6) Replace every 100,000km Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system
I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (HFV6) - I - I - I - I - I - I - I - I - I - R (C24SE) - I - I - I - I - R - I - I - I - I - R (DESEL) - I - I - I - I - I - I - I - I - I - I Engine coolant
(4JJ1 (Standard Output),
4JJ1 (High Output)) Change every 2 years
Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
Timing belt
(C24SE) - - - - - - - - - - - - - - - I - - - - Replace every 120,000km Timing belt (6VE1) Replace every 160,000km

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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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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 – 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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6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several times and check for fuel leakage.
5. Check the water separator indicator light. It should be off.



Except EURO III model
RTW 46ASH002901




For EURO III model
RTW 46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is felt.
2. W ait 1 minute, and operate the priming pump until strong resistance is felt.
3. Once more wait, and operate the priming pump until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. W ait until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

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6A – 36 ENGINE MECHANICAL
GENERAL DESCRIPTION









RTW 46AMF000401

The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.

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6A – 40 ENGINE MECHANICAL
140R300001
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).




RTW 46ASH000501
Remove the fuel hose from injection pump (EURO III
only).

27. Exhaust Pipe Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.

28. Engine Assembly
1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine compartment.






Installation
To reassemble, follow the removal steps in the reverse
order.


022R300002
F06R300008

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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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ENGINE MECHANICAL 6A – 45




4JA1L
RTW 46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the EGR valve assembly.





4JA1TC RTW 46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level gauge.


6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.




4JH1TC RTW 36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW 36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

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