engine ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL 6A – 125







25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque N·m(kg·m/Ib ft)
31 (3.1/23)

Connector the vacuum hose.


025R100008
RTW 36ASH000301













26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)

EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)

RTW 48ASH001801













26-2. EGR Cooler (EURO III model only)
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts N·m(kg·m/Ib ft)
24 (2.4/17)

EGR Pipe Bolts and Nuts N·m(kg·m/Ib ft)
27 (2.7/20)

27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only) Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct N·m(kg·m/Ib ft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)
RTW 36ASH000201












28. Clutch Assembly or Flex Plate

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ISUZU KB P190 2007

6A – 126 ENGINE MECHANICAL


LUBRICATION SYSTEM
LUBRICATING OIL FLOW









1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8 kg/cm
2 (608 – 764 kPa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3 kg/cm2 (558.6 - 617.4 kPa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4 kg/cm2 (270 – 330 kPa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2 kg/cm2 (78.4 - 117.6 kPa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5 kg/cm2 (29.4 - 49.0 kPa)
6. Regulating Valve: 1.8 - 2.2 kg/cm2 (176 – 216 kPa)

The 4J series engine has a full flow type lubricating system.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.

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ENGINE MECHANICAL 6A – 127

OIL PUMP AND OIL FILTER




RTW 46ALF001501

The 4J series engine is equipped with a gear type oil pump.
The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.



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6A – 128 ENGINE MECHANICAL
OIL PUMP
DISASSEMBLY



















Disassembly Steps
1.
Oil pipe 5.
Driven gear
2.
Strainer 6. Relief valve assembly
3. Pump cover 7. Pinion gear
4. Driven gear with bushing 8. Oil pump body
Disassembly procedure is shown in the illustration above numerical order.
051R100005

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ENGINE MECHANICAL 6A – 129

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Gear Teeth and Body Inner Wall Clearance
Use a feeler gauge to measure the clearance between the
gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, either the gear or the body
must be replaced.
Gear Teeth and Body Inner W all Clearance mm (in)
Standard Limit
051RY00001 0.14 (0.0055) 0.20 (0.0079)

Gear and Body Clearance
Use a feeler gauge to measure the clearance between the
body and the gear.
If the clearance between the gear and the body exceeds
the specified limit, the body must be replaced.
Gear and Body Clearance mm (in)
Standard Limit



RTW 46ASH002701
0.06 (0.024) 0.15 (0.0059)

Drive Shaft and Oil Pump Body Clearance
Use a micrometer to measure the drive shaft outside
diameter.
Use an inside dial indicator to measure the pump body
inside diameter.
If the clearance between the drive shaft and the oil pump
body exceeds the specified limit, the oil pump assembly
must be replaced.
Drive Shaft and Oil Pump Body Clearance mm (in)
Standard Limit
0.04 (0.0016) 0.20 (0.0079)
051RY00003

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6A – 130 ENGINE MECHANICAL

REASSEMBLY

























Reassembly Steps
1.
Oil pump body 5.
Pinion gear
2.
Drive gear 6. Strainer
3. Driven gear 7. Relief valve assembly
4. Pump cover 8.
Oil pipe
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 N·m (1.6 kg·m/12 lb ft)
051R100006

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ENGINE MECHANICAL 6A – 131

OIL FILTER AND OIL COOLER
DISASSEMBLY






























Disassembly Steps
1.
Oil filter cartridge 5.
Body
2.
Bolt 6. Oil cooler relief valve
3. Gasket 7. Regulating valve
4. Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
050R300004

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6A – 132 ENGINE MECHANICAL


INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
Oil Cooler
W ater Leakage at W ater Passage
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
3. Apply compressed air (200kPa (2kg/cm
2 / 28psi)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water leakage.
Should be replaced oil cooler assembly.
050RY00002

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ENGINE MECHANICAL 6A – 133

REASSEMBLY































Reassembly Steps
1.
Body 5.
Gasket
2.
Regulating valve 6. Bolt
3. Oil cooler relief valve 7. Oil filter cartridge
4. Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
050R300003

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6A – 134 ENGINE MECHANICAL


RTW 46ASH001701












1. Body
2. Oil Filter Safety Valve
3. Oil Cooler Safety Valve
Tighten the oil filter
A and oil cooler B relief valve to the
specified torque.
Regulating Valve N·m(kg·m/lb ft)
A 64 (6.5/48)













4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque N·m(kg·m/lb ft)
40 (4.1/30)





7. Oil Filter Cartridge
1) Apply engine oil to the O-ring.
2) Tighten the oil filter cartridge to the specified torque.
Filter wrench: 5-8840-0201-0
Oil Filter Cartride Torque N·m(kg·m/lb ft)
18 (1.8/13)

050R300006
050RY00004

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