ISUZU KB P190 2007 Workshop Repair Manual

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

6A-52 ENGINE MECHANICAL (4JK1/4JJ1)





LTW 56ASH000101
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.






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9. Remove the front cover.



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10. Install the M6 bolt to the idle gear A.
11. Remove the idle gear A and idle gear A flange, idle gear A shaft.





RTW 56ASH011301


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-53
12. Remove the idle gear C and idle gear C shaft.




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13. Remove the crankshaft gear.





RTW 56ASH021501





Disassembly
1. Remove the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Use a pair of snap ring pliers to remove the
scissor gear assembly.






RTW 56ASH022001
Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A

Reassembly
1. Install the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Press against the pin on the left side of the idle
gear A spring to make a gap on the right side o
f
the spring. Push the spring into place.


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6A-54 ENGINE MECHANICAL (4JK1/4JJ1)
• Align the sub gear pin with the hole in the right
side of the idle gear A spring. Press the sub-
gear into place.






RTW 56ASH022001
Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A

• Use a pair of snap ring pliers to snuggly install
the snap ring.
Inspection
1. Measurement of idle gear backlash • Apply a dial gauge on the teeth of the idle gea
r
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
• If the measurement exceeds the limit, replace
the idle gear.
Backlash of the idle gear mm (in)
Standard 0.10 − 0.17 (0.004 − 0.006)
Limit 0.30 (0.01)
• Measure backlash of the idle gear before
removing the idle gear A.
2. Measurement of end clearance of the idle gear. • Insert a thickness gauge between the idle gea
r
and the thrust collar to measure a clearance.

• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
End clearance of the idle gear mm (in)
Standard 0.080 − 0.155 (0.003 − 0.006)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear
before removing the idle gear B.
3. External diameter of the idle gear shaft. • Use a micrometer to measure an external
diameter of each idle gear shaft.
• If the measurement exceeds the limit, replace
the shaft.
External diameter of the idle gear A shaft mm (in)
Standard 44.950 − 44.957 (1.7697 − 1.7700)
Limit 44.80 (1.764)

External diameter of the idle gear C shaft mm (in)
Standard 24.959 − 24.980 (0.9826 − 0.9835)
Limit 24.80 (0.976)






RTW 56ASH021601
4. Clearance between the idle gear and the idle gear
shaft
• Measure an inside diameter of the idle gea
r
bush to calculate a clearance between the idle
gear and the idle gear shaft.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-55
• If the measurement exceeds the limit, replace
either the idle gear or the shaft.
Clearance between the idle gear A and the shaft
mm (in)
Standard 0.020 − 0.062 (0.0007 − 0.0024)
Limit 0.200 (0.0079)

Clearance between the idle gear C and the shaft
mm (in)
Standard 0.025 − 0.075 (0.0010 − 0.0030)
Limit 0.200 (0.0079)


LNW 21BSH003601
Installation
1. Install the crankshaft gear.
2. Install the idle gear C. •
Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.

•
Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).





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3. Install the idle gear A.
4. Tighten sub gear setting bolt. • Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt
hole between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.






RTW 56ASH011501



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ISUZU KB P190 2007

6A-56 ENGINE MECHANICAL (4JK1/4JJ1)
• Align the oil hole of the cylinder body (2) with
the oil hole of the idle gear A shaft (3).
• Install the flange so that the front mark (1) face
toward the front.
• Install the idle gear A and idle gear A flange,
idle gear A shaft at the position shown in the
figure.
•
Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.
•
Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).




LNW 71BSH000501
• Attach, aligning with the gear crank: idle A and
timing mark.





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5. Tighten the bolts of idle gear A and idle gear C to
the specified torque.
Tightening torque: idle gear A 32 N ⋅
⋅⋅
⋅
m (3.3 kg ⋅
⋅⋅
⋅
m / 24 lb ft)
idle gear C 59 N ⋅
⋅⋅
⋅
m (6.0 kg ⋅
⋅⋅
⋅
m / 43 lb ft)





RTW 56ASH011701
Legend
1. Idle Gear A Bolt
2. Idle Gear C Bolt


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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)




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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.




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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-58 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications





LNW 76ALF000601


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-59
Camshaft Assembly
Components









RTW 56ALF000901
Legend 1. Snap Ring
2. Sub Gear
3. Knock Pin
4. Damper Spring 5. Camshaft Gear and Camshaft
6. Camshaft Bearing Cap
7. Bolt


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ISUZU KB P190 2007

6A-60 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Rotate the crankshaft to make the No. 1 cylinder
meet the compression TDC.




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Legend
1. TDC


2. Remove the engine cover.
3. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
4. Install the M5 lock bolt of fixing sub gear.






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5. Remove the baffle plate (1).





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6. Remove the camshaft bearing cap and camshaft.
• Check the engraved making on the camshaft
bearing caps.






RTW 56ASH018401



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