ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-71
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2818-0
Valve spring replacer

5-8840-2819-0
Pivot assembly

5-8840-2817-0
Valve stem seal installer


BACK TO CHAPTER INDEX
TO MODEL INDEX
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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-73
3. Remove the radiator upper hose.








RTW 56FSH000101
4. Remove the fan guide.




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


5. Remove the cooling Fan.





RTW 56ASH025401
6. Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).





RTW 76ASH001301
Legend
1. TDC

7. Remove the A/C compressor drive belt.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A-74 ENGINE MECHANICAL (4JK1/4JJ1)
8. Remove the A/C compressor adjust pulley.








RTW 56ASH010601
Legend
1. Bolt
2. Nut


9. Remove the battery.
10. Disconnect the A/C compressor connector and A/C compressor with hose.
11. Remove the A/C compressor bracket.





RTW 56ASH024201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor






12. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




RTW 76ASH000501
13. Remove the intake hose and duct (Standard
output).




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




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-75
14. Disconnect the fuel injector connector (2).
15. Remove the fuel leak off hose (1).







RTW 76ASH000101
Note:
Do not reuse the fuel leak off hose clips.
16. Disconnect each connector. • Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• W ater temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.


22. Loosen the nuts of catalyst converter and
turbocharger.



RTW 56ASH006201
Legend
1. Catalyst Converter
2. Turbocharger

23. Remove the exhaust front pipe.





RTW 56ASH007701
Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension, 4×4)
2. Exhaust Front Pipe (4×2 Except High Ride Suspension)




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A-76 ENGINE MECHANICAL (4JK1/4JJ1)
24. Disconnect the Front drive shaft (1). (4×4)





RTW 76ASH002301
25. Remove the catalyst converter.

RTW 56ALH000201

26. Remove the A/T oil cooler pipe bracket (A/T).





RTW 56ASH025101
Legend
1. A/T Oil Cooler Pipe Bracket


27. Remove the turbocharger water return pipe and
hose.






RTW 56ASH019001


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-77
28. Remove the turbocharger water feed pipe (1) and
hose.





RTW 56ASH019101
29. Remove the turbocharger engine oil feed pipe.
30. Remove the engine oil level gauge guide tube.
31. Remove the fuel return pipe and hose (1).





RTW 56ASH019201
32. Remove the fuel injection pipe clip.
33. Remove the fuel injection pipe.
34. Remove the vacuum hose (1).






RTW 66ASH003101
35. Remove the noise cover (1).






RTW 56CSH001401

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A-78 ENGINE MECHANICAL (4JK1/4JJ1)
36. Remove the timing chain cover lower.
37. Remove the timing chain cover upper.




RTW 56CSH001501
Legend
1. Timing Chain Cover Upper
2. Timing Chain Cover Lower


38. Remove the water by pass pipe (1).





RTW 56ASH008401
39. Remove the glow plug (1).



RTW 56ASH019301
40. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
41. Install the lock bolt for camshaft scissor gear.








RTW 56ASH007101
42. Remove the fuel injector assembly.
43. Remove the baffle plate.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-79
44. Remove the camshaft bearing cap.





RTW 56ASH018401
45. Remove the camshaft.
46. Remove the rocker arm shaft assembly.
Note:
Keep the removed rocker arm shaft assembly properl
y
so that they may be put back to the original place.



RTW 56ASH012201
Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Front


Note:
Pay full attention so as not to drop the parts in the gea
r
case of the front part of the cylinder head or a hole into
which oil pours back in the front.
Note:
Remember the original position.
47. Remove the timing chain tensioner.



RTW 56CSH003701
Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut


48. Remove the idle gear D.
• Timing chain is dropped behind.



RTW 56ASH022101


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A-80 ENGINE MECHANICAL (4JK1/4JJ1)
49. Remove the timing chain tension lever pivot.





RTW 56ASH019401
50. Remove the timing chain from supply pump
sprocket.
51. Remove the chain guide bolt from cylinder head.



RTW 56ASH019501

52. Remove the cylinder head gear case nuts (1) and
bolts (2).




RTW 56ASH020801
53. Remove the cylinder head bolt (1).


RTW 56ASH008501
Note:
Do not reuse the cylinder head bolt.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007