engine ISUZU KB P190 2007 Workshop Repair Manual

6A-156 ENGINE MECHANICAL (4JK1/4JJ1)
Oil Pump
Components




RTW 66AMF000701
Legend 1. Bolt 2. Oil Pump Assembly

Removal
1. Drain the engine coolant.
2. Remove the radiator upper hose.
3. Remove the upper fan shroud.
4. Remove the fan and fan clutch. • Loosen the fan clutch nuts.
• Remove the fan together with the fan clutch.
Take care not to damage the radiator core.
5. Remove the fan drive belt and pulley. • Loosen the tension adjust bolt on the generato
r
and A/C.
• Remove the fan drive belt with the fan pulley.
6. Remove the lower fan shroud.
7. Disconnect the power steering pump. • Disconnect the bracket of the power steering oil
hose clip (1).






LTW 56ASH000101


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-157
8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.
9. Remove the noise cover (1).






RTW 56CSH001401
10. Remove the crank pulley.
11. Remove the front cover.




RTW 56ASH019701
12. Remove the oil pump (1).





RTW 56ASH020001
Disassembly
1. Remove the spring pin.
2. Remove the spring seat.
3. Remove the spring.
4. Remove the valve.


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6A-158 ENGINE MECHANICAL (4JK1/4JJ1)
Reassembly
1. Install the valve.
2. Install the spring.
3. Install the spring seat.
4. Install the spring pin.







RTW 56ASH015901
Legend
1. Spring Pin
2. Spring Seat
3. Spring
4. Valve

Inspection
NOTE:
Think to match direction of ditch of gear when
assembling it.
1. Measure the clearance between the driven gear/drive gear shaft and the bush.
• Measure the outside diameter of the driven
gear shaft using a micrometer.
Outside diameter of the driven gear shaft/drive
gear shaft mm (in)
Standard 15.989 - 16.000 (0.62949 - 0.62992)
Limit 15.900 (0.62598)






RTW 56ASH025601
• Measure the inside diameter of the bushes of
the cylinder block using the dial gauge.
• If the clearance between the driven gea
r
shaft/drive gear shaft and bush exceeds the
limit, replace the oil pump assembly.
Clearance between the driven gear shaft/drive gear
shaft and bush mm (in)
Standard 0.04 - 0.07 (0.0016 - 0.0028)
Limit 0.20 (0.0079)



RTW 56ASH014701
2. Measure the clearance between the gear side
surface and the gear side surface of the oil pump
housing.
• Measure the width size the driven gear/drive
gear.
W idth size the driven gear/drive gear mm (in)
Standard 14.5 (0.5709)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-159




RTW 56ASH025501
• Measure the Depth size of the gear case
housing surface and the oil pump housing gea
r
case side.
Depth size the gear case housing surface and the oil
pump housing gear case side
mm (in)
Standard 14.500 - 14.527 (0.5709 - 0.5719)




RTW 56ASH014801

Clearance between the gear side surface and the
gear side surface of the oil pump housing mm (in)
Standard 0.063 - 0.027 (0.0025 - 0.0011)
Limit 0.20 (0.0079)

Installation
1. Install the oil pump.
•
Apply engine oil to the oil pump attachment
gearbox.
• Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Installed pump gear should be smooth to
rotate.
2. Install the gear case cover. • Apply the liquid gasket (Threebond TB-1207B
or equivalent) mount within 5 minutes.


RTW 56ASH020101
Legend
1. Apply the liquid gasket in area



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ISUZU KB P190 2007

6A-160 ENGINE MECHANICAL (4JK1/4JJ1)
• Install the gasket in the slot of the gear case
cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)





RTW 56ASH012101
3. Install the crank pulley.
• Tighten the bolts to the specified torque.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
4. Install the noise cover to the timing chain cove
r
lower.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
5. Install the vacuum pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the oil pipe (feed side and return side) o
f
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
6. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose
clip (1).






LTW 56ASH000101
7. Install the lower fan shroud.
8. Install the fan drive belt and pulley. • Install the fan drive belt with the fan pulley.
9. Install the fan and fan clutch. • Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
10.
Adjust the drive belt of generator and A/C
compressor.
• Apply tension to the fan drive belt by moving
the generator.
•
Apply a force of 98 N (10 kg / 22 lb) to the drive
belt mid portion to check the drive belt
deflection.
Generator drive belt deflection mm (in)
New belt 5 - 6 (0.20 – 0.24)
Reuse belt 7 - 8 (0.28 – 0.31)

A/C compressor drive belt deflection mm (in)
New belt 6 - 7 (0.24 – 0.28)
Reuse belt 8 - 9 (0.31 – 0.35)
11. Install the upper fan shroud.
12. Install the radiator upper hose.
13. Replenish the engine coolant.

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-161
Oil Pressure SW
Components






RTW 76AMF000401
Legend 1. Cylinder Block
2. Gasket
3. Nipple; Oil Pressure W arning SW 4. Oil Pressure SW
5. Nipple; Oil Gallery



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6A-162 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the oil pressure SW .
2. Remove the nipple; oil gallery.
3. Remove the nipple; oil pressure warning SW and gasket.
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.
If there is no connectivity, replace with normal parts.





LNW 21HSH003301

Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the circuit between the meter and the oil pressure
switch, and repair the disconnected locations.






LNW 21HSH003401
Installation
1. Install the nipple; oil gallery, oil pressure warning
SW and gasket.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
2. Install the Nipple. Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)
3. Install the oil pressure SW . Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-163
Air Cleaner Element
Removal
1. Remove the air cleaner cover fixing clip.
2. Remove the air cleaner element assembly.
Cleaning
Dry type element
• Rotate the element with your hand while applying
compressed air to the inside of the element. This
will blow the dust free.

Compressed air pressure kPa (kg/cm2 /psi)
392 − 490 (4 − 5/57 − 71)

Standard Output



LNW 46ASH003201

High Output





LNW 71BSH000201
Installation
1. Install the air cleaner element assembly.
2. Install the air cleaner cover.




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ENGINE COOLING (4JK1/4JJ1) 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS

Main Data and Specifications ............................. 6B-2
General Description............................................ 6B-3 Coolant Flow ................................................... 6B-3
W ater Pump .................................................... 6B-4
Thermostat ...................................................... 6B-4
Radiator ........................................................... 6B-5
Antifreeze Solution .......................................... 6B-5
Diagnosis............................................................ 6B-6
Draining and Refilling Cooling System ............... 6B-7
W ater Pump ....................................................... 6B-8 Removal .......................................................... 6B-8
Inspection and Repair ..................................... 6B-9
Installation ....................................................... 6B-9
Thermostat ......................................................... 6B-11 Removal .......................................................... 6B-11
Inspection and Repair ..................................... 6B-11
Operating Test of Thermostat ......................... 6B-11
Installation ....................................................... 6B-12

Radiator .............................................................. 6B-13 Radiator and Associated Parts........................ 6B-13
Removal .......................................................... 6B-14
Inspection and Repair ..................................... 6B-15
Radiator Cap ................................................... 6B-15
Radiator Core .................................................. 6B-15
Flushing the Radiator ...................................... 6B-15
Cooling System Leakage Check ..................... 6B-15
Installation ....................................................... 6B-16
Engine Coolant Change .................................. 6B-16
Fan Clutch with Cooling Fan .............................. 6B-17 Inspection and Repair ..................................... 6B-17
Special Tools................................................... 6B-18

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6B-2 ENGINE COOLING (4JK1/4JJ1)
Main Data and Specifications
Description Item
M/T A/T
Cooling system
W ater pump type
Pump to crankshaft speed ratio (To 1)
Delivery volume lit (US/UK gal)/min
Pump speed at 5600 rpm
W ater temperature at 30 °C (86 °F)
Pump bearing type

Thermostat type
Valve initial opening temperature °C ( °F)
Valve full opening temperature °C ( °F)
Valve lift at fully open position mm (in) Engine coolant forced circulation
Centrifugal impeller type 1.25
240 (63.1/53.3)

Double row shaft
W ax pellet with jiggle valve 85 (185)
100 (212) 10 (0.39)
Radiator Tube type corrugated
Heat radiation capacity kW (kcal/h) 93 (80.2)
Heat radiation area m2 (ft2) 11.63 (125.2)
Radiator front area m2 (ft2) 0.28 (3)
Radiator dry weight N (kg/lb) 52 53
Radiator cap valve opening pressure kPa (kg/cm2/psi) 93.3 - 122.7 (0.95 - 1.25/13.5 - 17.8)
Engine coolant capacity lit (U.S pint) 4.0 (8.5) 4.0 (8.5)
Engine coolant total capacity lit (U.S pint) 8.7 (18.4) 8.6 (18.2)


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