wheel bolts ISUZU KB P190 2007 Workshop Owner's Guide

ANTI-LOCK BRAKE SYSTEM 5B-13
Front Sensor Rotor
Front Sensor Rotor and Associated Parts
411R300010
Legend
(1) Sensor Rotor
(2) Hub and Disc


(3) Disc Rotor fixing Bolt
(4) Hub and Disc Assembly
Removal
1. Remove the hub and disc assembly. (Refer to the
section Front wheel Drive).
2. Remove two disc rotor fixing bolts on a diagonal.
3. Drive out the sensor rotor using a metal bar and hammer through the two bolt holes.
• Discard the used sensor rotor.
4. Install disc rotor fixing bolts and tighten them to the specified torque.
Torque: 103 N ⋅m (10.5 kgf ⋅m / 76 lb·ft)



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the turbocharger? —

Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? —
Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged? — Replace the
damaged gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? —
Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? —
Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? —
Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? —
Repair or
replace the oil feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? —
Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/ 10W –30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? —
Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

TROUBLESHOOTING 6 – 15
12. Oil Leakage from Turbocharger
Step Action Value(s) Yes No
1 Inspect the oil leakage area.
Was the oil feed pipe eye bolt loose or the gasket
broken? —
Tighten the eye
bolt or replace the gasket. Go to Step 2
2 Were the V band fixing faces tight? — Tighten band or
replace the
turbocharger Go to Step 3
3 Was there oil leakage from the flange of the turbine
housing? —
Replace the
turbocharger Go to Step 4
4 Was there oil leakage from the flange of compressor
housing? —
Tighten the bolt
and/or hose clamp. Go to Step 5
5 Are any DTC stored? — Go to indicated
DTC Solved

13. Insufficient Acceleration and/or Lack of Power due to turbocharger
Step Action Value(s) Yes No
1 Inspect the air or exhaust route.
Was the air and/or exhaust gas piping loose? —
Tighten flange
bolts or hose clamp. Go to Step 2
2 Inspect the work of waste gate valve control.
Was there rust on the linkage rod or pin of the waste
gate valve? —

Replace the
turbocharger Go to Step 3
3 Was air leakage found from the actuator piping? — Repair or
replace the
actuator pipe or hose/ Go to Step 4
4 Inspect the inside of the turbocharger.
Was the turbine shaft end nut loose? —
Replace the
turbocharger Go to Step 5
5 Were the turbine blades bent? — Replace the
turbocharger Go to Step 6
6 Was the turbine wheel rubbing against housing? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 34 ENGINE MECHANICAL



RTW 46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8 °)
is aligned with the pointer.

Injection Timing : BTDC 8 ° ± 2 °

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket bolts.
11. Adjust the injection pump setting angle.
W hen large than standard value W hen smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.
12. Install the distributor head bolt.
Distributor head bolt torque N·m (kg·m /lb·ft)
29 (3.0/22)



ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant temperature reaches 70 - 80 °C (158 - 176 °F).


4. Disconnect the engine control cable from the control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 ± 25 rpm



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model) Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor.

14. Transmission member 1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing.
2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts.
16. Transmission coupling bolt 1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer) Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007
P1010025


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 52 ENGINE MECHANICAL


RTW 36ASH000801
Idler Gear "A" End Play Measurement
Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measured value exceeds the specified limit, the
thrust collar must be replaced.

Idler Gear End Play mm (in)
Standard Limit
0.07 (0.0028) 0.2 (0.0079)






4JA1T(L)
040R300009
14. Idle Gear Shaft
15. Crankshaft Timing Gear




4JA1TC/4JH1TC RTW 36ASH001301
16. Injection Pump
1. Remove the injection pump cover (4JA1TC/4JH1TC only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump timing gear free toward the rear of the engine.

NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.









17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0

18. Crank Case

19. Oil Pump With Oil Pipe

015RY00001

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.

Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown in the illustration.
Gear stoper: 5-8840-0214-0

Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the No.1 piston.
2. Apply engine oil to the idler gear and the idler gear shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are facing the front of the engine.


015LX113
020R100001
020RY00034
020RY00035

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 115



RTW 46ASH002201




















4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracket bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.


Injection pump Bracket Bolt Torque (6) N·m(kg·m/lbft)
19 (1.9/14)
Injection pump Bracket Bolt Torque (5) N·m(kg·m/lbft)
40 (4.1/30)



030RY00007














24. Water Pump
1. Apply the recommended liquid gasket or its equivalent to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.

W ater Pump Bolt Torque N·m(kg·m/lbft)
20 (2.0/14)













25.Timing Gear Case Cover
1.
Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified torque.

Gear Case Cover Bolt Torque N·m(kg·m/lbft)
M8 19 (1.9/14)
M12 76 (7.7/56)

























26. Crankshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.

Crankshaft Damper Pulley Bolt Torque N·m(kg·m/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.


014R100014
020R300004

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-3
ISUZU DIESEL ENGINE (4JK1/4JJ1)
Service Precautions
Matters that require attention in terms of
maintenance
To prevent damage to the engine and ensure reliabilit
y
of its performance, pay attention to the following in
maintaining the engine:
• W hen lifting up or supporting the engine, do not
apply a jack on the oil pan.
W hen taking down the engine on the ground, do not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, fo
r
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between the oil pan and the oil pump strainer, it can
damage the oil pan and the oil strainer.
• W hen the air duct or air cleaner is removed, cove
r
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
• W hen maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, fo
r
instance, watch out for short circuits and others.
•
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
• W hen valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings o
r
crankshaft journal bearings are removed, put them
in order and keep them.
• W hen installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
•
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.

• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• W hen assembling or installing parts, fasten them
with the prescribed tightening torque so that the
y
are installed properly.

Matters that require attention in specifically dealing
with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, the
y
are highly sensitive to foreign matter and, if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.

W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.

Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-111
Flywheel
Components











RTW 56ALF001701
Legend 1. Flywheel Assembly and Pilot Bearing
2. Driven Plate
3. Pressure Plate Assembly 4. Release Bearing
5. Shift Fork
6. Transmission Assembly

Removal
1. Remove the transmission assembly.
Refer to "transmission assembly removal and installation".
2. Remove the clutch pressure plate.
• Remove the pressure plate installation bolts in
the order shown in the drawing.
• Remove the pressure plate from the flywheel.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007