ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-31
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold. • Tighten the nuts and bolts in the orde
r
described in the drawing.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)







RTW 56ASH018001
3. Install the throttle assembly and gasket.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
4. Install the vacuum hose of swirl control valve.
5. Install the injection pipe (fuel rail - fuel injector). • It installs sequentially from No. 4 cylinder.
Tightening torque: 29 N ⋅
⋅⋅
⋅
m (3.0 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
6. Install the EGR valve. • Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
7. Install the engine oil level guide tube.
Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
8. Install the intercooler (High output).
9. Connect the connector of other parts. • Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
10. Install the leak-off hose.




RTW 56ASH024301
Legend
1. Injector Leek-off Hose

11. Install the intake air duct.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
12.Install the A/C compressor bracket. Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
13.Install the A/C compressor and A/C compresso
r
connector.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
14.Install the A/C belt.
Check the A/C belt tension.
Depress the A/C belt mid-portion with 98 N (10 kg
/
22 lb) force.
Standard deflection: 7.6 - 9.2 mm (0.29 - 0.36 in)



RTW 510SH000201
15. Install the engine cover.



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ISUZU KB P190 2007

6A-32 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications




RTW 76AMF000101


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-33
Turbocharger and Exhaust Manifold (Standard Output)
Components



RTW 56ALF002101
Legend 1. Turbocharger Assembly
2. Exhaust Manifold
3. Heat Protector
4. Catalyst Converter
5. Oil Feed Pipe 6. Oil Return Pipe
7. Intake Hose for Intercooler and Intake Throttle
8. Intake Duct for Turbocharger and Air Cleaner
9. Intake Hose for Turbocharger and Intercooler




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6A-34 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Loosen the radiator drain plug to drain coolant.
2. Remove the engine cover.
3. Remove the intake hose from the intercooler and intake throttle.
4. Remove the intake hose from the turbocharge
r
and the intercooler.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the EGR cooler.
Refer to “EGR Cooler” in EXHAUST SYSTEM Section.
7. Remove the oil feed pipe.
8. Remove the oil return pipe. • Loosen clamp (1) of A/T oil cooler pipe.






RTW 56ASH025101
9. Remove the water feed and return pipe.




RTW 56ASH005401

Legend
1. Oil Feed Pipe
2. EGR Cooler
3. W ater Feed Pipe
4. W ater Return Pipe
5. Oil Return Pipe

10. 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)

11. Disconnect the front propeller shaft flange (1)
(Front Diff Side, 4 ×4 only).





RTW 76ASH002301


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-35
12. Remove the catalyst converter.



RTW 56ALH000201
13. Remove the turbocharger from the exhaust
manifold.




RTW 56ASH005501
Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger

14. Remove the exhaust manifold.
• Remove the 8 nuts from the exhaust manifold.






RTW 56ASH005601


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6A-36 ENGINE MECHANICAL (4JK1/4JJ1)
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)
Note:
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.

Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft pla
y
when a force of 12 N (1.2 kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)




LNW 21BSH022201

Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW 21BSH022301
Legend
1. Oil Outlet
2. Oil Intake



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-37
Waste gate operation
1. Remove the hose from the waste gate actuator.
2. Install the pressure gauge (general tool). Refer to the illustration.





RTW 56ASH005701
Legend
1. W aste Gate Actuator
2. W aste Gate Hose
3. Pressure Gauge (General Tool)

3. Use the pressure gauge pump to apply pressure
(load) to the waste gate actuator (the engine must
be off).
4. Note the pressure at which the control rod moves 2 mm (0.078 in). This pressure must be within the
specified limit.

Control rod pressure range: kPa (mmHg / psi)
109 − 118 (818 − 885 / 16 − 17)

5. Inspect the hose for cracks and other damage.
Replace the hose if necessary.
6. Do not apply a pressure of more than 120 kPa (900 mmHg) to the waste gate actuator.

Installation
1. Put the gasket in to install the exhaust manifold.
• Tighten up with the 8 nuts according to the
order given in the figure.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
Note:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.









RTW 56ASH005801
2. Install the gasket and turbocharger to the exhaust
manifold. Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)




RTW 56ASH005501
Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger


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6A-38 ENGINE MECHANICAL (4JK1/4JJ1)
3. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Connect the front propeller shaft flange (Front Dif
f
Side, 4 ×4 only).
5. 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)
6. Install the water feed pipe to the turbocharger (1).
• Tighten the joint bolts to the specified torque.
Tightening torque: 54 N ⋅
⋅⋅
⋅
m (5.5 kg ⋅
⋅⋅
⋅
m / 40 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
• Install the rubber hose between the wate
r
return pipe and the thermostat housing.







RTW 56ASH019101
7. Install the water return pipe. Tighten the joint bolt
to the specified torque.
Tightening torque: 54 N ⋅
⋅⋅
⋅
m (5.5 kg ⋅
⋅⋅
⋅
m / 40 lb ft)









RTW 56ASH019001
8. Install the turbocharger oil feed pipe to the top of
the turbocharger. Tighten the joint bolts to the
specified torque.
Tightening torque (Turbo charger side): 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m / 17 lb ft)
Tightening torque (Oil cooler side): 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m / 17 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: (Clip) 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)



RTW 56ASH00610
Legend
1. Oil Feed Pipe
2. Clip
3. Oil Return Pipe




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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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6A-40 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 76ALF000901


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