engine coolant ISUZU KB P190 2007 Workshop Owners Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-39
9. Tighten the oil return pipe bolts and nuts to the
specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
10.Install the EGR cooler. • Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
11. Install the heat protector. • Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
12. Install the intake hose between the intercooler and the intake throttle (7).
13. Install the intake hose between the turbocharge
r
and the intercooler (9).
14. Install the intake duct between the turbocharge
r
and the air cleaner (8).
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
15.Replenish the coolant.



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ISUZU KB P190 2007

6A-42 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Drain the engine coolant.
2. Remove the engine cover.
3. Remove the intercooler. • Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




RTW 76ASH000501
4. Disconnect the vacuum hose from the
turbocharger actuator.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the front exhaust pipe.




RTW 56ASH018301

Legend
1. Gasket
2. Front Exhaust Pipe (4 ×2 High Ride Suspention,
4 ×4)
3. Gasket
4. Front Exhaust Pipe (4 ×2 Except High Ride
Suspention)

7. Remove the heat protector of the turbocharger.
• Remove the mud cover of front RH fender skirt
(4×4 only).
• Loosen the bolt of Turbocharger bracket.
8. Remove the catalyst converter.
9. Remove the turbocharger bracket.
10. Remove the oil feed and return pipe.
11. Remove the water feed and return pipe from the turbocharger.






RTW 76ASH001001
12. Remove the turbocharger from the exhaust
manifold.

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ISUZU KB P190 2007

6A-44 ENGINE MECHANICAL (4JK1/4JJ1)
3. Place a vernier caliper on the end of the control
rod of actuator. Release the vacuum pressure and
check the control rod moves. Measure the length
of the control rod moving.

Standard length mm (in)
12 (0.48)

Installation
1. Install the gasket and the turbocharger to the
exhaust manifold. Temporarily tighten nuts.
2. Install the oil feed and return pipe and temporaril
y
tighten.
3. Tighten the turbocharger nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Tighten the oil feed and return pipe bolts and nuts to the specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
5. Install the water feed and return pipe to the turbocharger.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
6. Install the heat protector to the turbocharger. Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
7. Install the turbocharger bracket.
8. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
9. Install the mud cover of front RH fender skirt (4 ×4
only).
10. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅
⋅⋅
⋅m (6.8 kg⋅
⋅⋅
⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N
⋅
⋅⋅
⋅
m (4.4 kg ⋅
⋅⋅
⋅
m / 32lb ft)
11. Install the intercooler. • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
12. Install the intake duct between the turbocharge
r
and the air cleaner.
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
13.Replenish the coolant.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-47
Removal
1. Drain the engine coolant.
2. Remove the turbocharger. • Refer to “Turbocharger”.
3. Remove the EGR cooler heat protector.
4. Disconnect the water hoses from the EGR coole
r
water pipes.
5. Remove the EGR cooler.
6. Remove the exhaust manifold.







RTW 76ASH002101
Inspection
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the
manifold and the cylinder head are to be
installed.

Manifold installation plane surface mm (in)
Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)

Caution:
If the plane surface exceeds the limit, replace it.




LNW 21BSH022301
• Check a crack in the exhaust manifold visually.
Carefully inspect the turbocharger for abrasion and/o
r
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.
Installation
1. Put the gasket in to install the exhaust manifold.
• Tighten up with the 8 nuts according to the
order given in the illustration.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
Caution:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.









RTW 76ASH002201


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ISUZU KB P190 2007

6A-48 ENGINE MECHANICAL (4JK1/4JJ1)
2. Install the EGR cooler.
• Install the gaskets.
• Install the EGR cooler.
• Temporary tightening order.
1 →2→ 3→ 4→ 5→ 6
• Fully tightening order.
3 →4→ 5→ 1→ 2→ 6
Tighten the nut and bolts to the specified torque.
Tightening torque: Nuts and bots 1-5: 27 N·m (2.8 kg·m / 20 lb ft)
Bolt 6: 52 N·m (5.3 kg·m / 38 lb ft)


6
543
1
2

RTW 76FSH000201
3. Install the water hoses to the EGR cooler water
pipes.
4. Heat protector.
Tighten the bolts to the specified torque.
Tightening torque: 25 N·m (2.5 kg·m / 18 lb ft)




RTW 76FSH000101
5. Install the turbocharger.
• Refer to “Turbocharger”.
6. Replenish the engine coolant.



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-51
Removal
1. Partially drain the engine coolant.
2. Remove the radiator upper hose.






RTW 56FSH000101
3. Remove the fan guide.




RTW 46BSH000101
Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling fan and fan pulley.




RTW 56ASH025401
5. Remove the A/C compressor drive belt and fan
belt.
6. Remove the crank pulley.
7. Remove the power steering pump with hose.




RTW 56ASH021101
Legend
1. Power Steering Pump
2. Nut

• Disconnect the bracket (1) of power steering oil
hose.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-57
6. Remove the M6 bolt from the idle gear A.
7. Install the gear case cover. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).


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Legend
1. Apply the liquid gasket

• Install the gasket in 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
8. Install the vacuum pump.
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.
9. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.




LTW 56ASH000101

10. Install the crank pulley.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure fo
r
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.



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ISUZU KB P190 2007

6A-72 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Head
Components





RTW 56ALF001001
Legend 1. Fuel Injector Clamp
2. Fuel Injector Assembly
3. Glow Plug
4. Intake and Exhaust Valves 5. Cylinder Head
6. Timing Chain Tension Lever
7. Timing Chain Guide
8. Timing Chain Tensioner

Note:
To avoid electric shock;
Set the switch to the 'OFF' position and disconnect the
negative battery cable before checking or repairing the
fuel injector, wiring or/and connectors. Removal
1. Remove the engine head cover.
2. Drain the engine coolant.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-99
67.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
68. Install the intake hose.




RTW 56ASH022501
Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler

69. Install the engine head cover.
70. Replenish the coolant.



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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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ISUZU KB P190 2007