oil filter ISUZU KB P190 2007 Workshop User Guide

ENGINE MECHANICAL 6A – 25
Replenished Engine Oil MAX lit (US/UK gal)
Condition


Model Engine Dry
W ith oil filter
replacement W ithout oil
filter
replacement
4 × 2
4 × 4
(4JA1L/TC)6.2 (1.64/1.36) 5.2 ∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 2
(4JH1TC)
6.2 (1.64/1.36) 5.2
∼ 4.2
(1.37 ∼ 1.11
/ 1.14 ∼ 0.92) 4.5
∼ 3.5
(1.19 ∼ 0.93
/ 0.99 ∼ 0.77)
4 × 4
(4JH1TC) 7.0 (1.85/1.54) 6.2 ∼ 5.2
(1.64 ∼ 1.37
/ 1.36 ∼ 1.14) 5.3
∼ 4.3
(1.72 ∼ 1.14
/ 1.17 ∼ 0.95)

9. Start the engine and check for oil leakage from the
main oil filter.



RTW 66ASH003201




FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise with a filter wrench.
Filter W rench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.




RTW 66ASH003301








2. Clean the fuel filter cartridge fitting faces. This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a filter wrench.
Filter W rench : 5-8840-0253-0 (J-22700)




6. Operate the priming pump until the air discharged completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.

041RY00009

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ISUZU KB P190 2007

6A – 42 ENGINE MECHANICAL

ENGINE REPAIR KIT




RTW 36ALF000601

Removal Steps
1. Cylinder head gasket
2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket
11. Vacuum pump gasket
12. W ater pump O-ring
13. W ater outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal

NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW 36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure W arning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler W ater Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. W ater Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


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ENGINE MECHANICAL 6A – 45




4JA1L
RTW 46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the EGR valve assembly.





4JA1TC RTW 46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level gauge.


6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.




4JH1TC RTW 36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW 36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

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6A – 46 ENGINE MECHANICAL
13. Injection Pump
Refer to section 6C-19 (Injection Pump)

14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector


20. Catalytic Converter




21. Turbocharger 1) Disconnect the water hose between thermostat housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.


22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


027R100007
037RY00001

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ISUZU KB P190 2007

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW 36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. W ater Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler W ater Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure W arning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

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ENGINE MECHANICAL 6A – 119












Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque N·m(kg·m/Ib ft)
24 (2.4/17)




3) Install the exhaust manifold bracket to the manifold
and the cylinder body.
Manifold Bracket Bolt Torque N·m(kg·m/Ib ft)
19 (1.9/14)






RTW 46ASH001301









2. Oil Cooler with Oil Filter
1) Install the O-ring to the oil filter body flange groove.
2) Install the oil filter body to cylinder block and tighten to the specified torque.
Oil Filter Body Bolt and Nut
Torque N·m(kg·m/Ib ft)
BOLT 19 (1.9/14)
NUT 24 (2.4/17)









3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque N·m(kg·m/Ib ft)
40 (4.1/30)




027R100003
027R100004
066RY00001

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6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10 ×1.25
37 (3.8/28)
2
3M8×1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position. Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)



















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

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6A – 126 ENGINE MECHANICAL


LUBRICATION SYSTEM
LUBRICATING OIL FLOW









1. Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8 kg/cm
2 (608 – 764 kPa)
2. Regulating Valve Operating Pressure: 5.7 - 6.3 kg/cm2 (558.6 - 617.4 kPa)
3. Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4 kg/cm2 (270 – 330 kPa)
4. Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2 kg/cm2 (78.4 - 117.6 kPa)
5. Oil Pressure Switch Operating Pressure: 0.3 - 0.5 kg/cm2 (29.4 - 49.0 kPa)
6. Regulating Valve: 1.8 - 2.2 kg/cm2 (176 – 216 kPa)

The 4J series engine has a full flow type lubricating system.
Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 127

OIL PUMP AND OIL FILTER




RTW 46ALF001501

The 4J series engine is equipped with a gear type oil pump.
The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.



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