engine ISUZU KB P190 2007 Workshop Repair Manual

6A-16 ENGINE MECHANICAL (4JK1/4JJ1)

RTW 76ASH001401
14. Remove the breather hose and lower hose of the
radiator.
15. Remove the fan guide.
16. Remove the drive belt.
17. Remove the fan assembly.
18.Remove the radiator.
19.Remove the A/C compressor.





RTW 76ASH000701
Legend
1. A/C Compressor Bracket
2. A/C Compressor

• Disconnect the connector.
• Disconnect the A/C generator harness.
• Disconnect the terminal B cable and harness
connector from the generator.

20.Remove the power steering pump.
• Remove the bracket of power steering oil hose
(1).






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21.Remove the harness of engine, battery and earth
from the body side.
22.Remove the connector of the shift on the fly (4 ×4).
23.Remove the vacuum hose of brake master-vac.
24.Remove the front exhaust pipe.
25.Disconnect the fuel hose on the feed and return sides.
26.Install the engine hanger (special tool 5-8840- 2823-0).




RTW 56ASH004301
Legend
1. Engine Hanger (Front Side)



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-17



RTW 56ASH004401
Legend
1. Engine Hanger (Rear Side)

27.Hang wire on the engine hanger and hoist to lift up
the engine slightly.
28.Remove the engine mount.
• Remove the fastening bolts for the engine mount
on the engine side.
29.Remove the engine assembly.
• Hoist the engine slightly to provide space to
remove the catalytic converter.
Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N ⋅
⋅⋅
⋅
m (4.9kg ⋅
⋅⋅
⋅
m / 35 lb ft)
3. Remove the engine hanger.
4. Install the catalytic converter.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8kg ⋅
⋅⋅
⋅
m /20 lb ft)
5. Install the front exhaust pipe. Tightening torque: 67 N ⋅
⋅⋅
⋅
m (6.8kg ⋅
⋅⋅
⋅
m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4 ×4).
9. Install the harness of engine, battery and earth to the body side.
10.Install the power steering pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
14.Install the fan assembly. Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8kg ⋅
⋅⋅
⋅
m / 69 lb in)
15.Install the drive belt.
Refer to removal procedure for drive belt in this manual.
16.Install the fan guide.
17.Install the breather hose and lower hose of the radiator.
18.Install the engine harness clip (1).

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19.Install the radiator upper hose.
20.Install the intake hose (turbocharger -intercooler) (Standard output).
• Install the harness connector.


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6A-18 ENGINE MECHANICAL (4JK1/4JJ1)
21.Install the intake hose (intercooler - intake throttle)
(Standard output).





RTW 56ASH004001
22.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
23.Install the air cleaner.
• Install the intake pipe with the lid of air cleane
r
box.
• Install the air cleaner box.
• Connect the MAF sensor harness connector.
24.Install the ECM.
25.Connect the ECM harness connector.
26.Install the transmission assembly.
Refer to installation procedure fo
r
“TRANSMISSION”.
27.Install the starter motor.
Tightening torque: 94 N ⋅
⋅⋅
⋅
m (9.6kg ⋅
⋅⋅
⋅
m / 69 lb ft)
28.Replenish the coolant.
29.Install the engine hood.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0kg ⋅
⋅⋅
⋅
m / 87 lb in)
30.Connect the negative battery cable.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-19
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2823-0
Engine hanger


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6A-20 ENGINE MECHANICAL (4JK1/4JJ1)
Engine Mount
Components




RTW 56ALF001801
Legend 1. Nut
2. Bolt (L = 80 mm / 3.15 in)
3. Bolt (L = 30 mm / 1.18 in)
4. Bolt (L = 30 mm / 1.18 in)
5. Engine Foot RH
6. Engine Mount RH
7. Bolt (L = 25 mm / 0.98 in) 8. Bolt (L = 45 mm / 1.77 in)
9. Bolt (L = 30 mm / 1.18 in)
10. Bolt (L = 40 mm / 1.57 in)
11. Bolt (L = 20 mm / 0.78 in)
12. Bolt (L = 100 mm / 3.94 in)
13. Engine Foot LH
14. Engine Mount LH


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-21
Removal
1. Remove the engine hood.
2. Remove the engine cover.
3. Set the hoist and the engine hanger of the special tool (special tool 5-8840-2823-0).
4. Remove the engine mount.
• Before removing the engine mount, hang the engine with a hoist.
• Remove the bolts of the engine mount.
• Hoist the engine assembly slightly to remove the engine mount.











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Installation
1. Install the engine mount and tighten up with the
specified torque.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
2. Install the engine cover.
3. Install the engine hood. • Check if nothing is wrong with the engine
mount by starting the engine.


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6A-22 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 56ALF003801


Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2823-0
Engine hanger



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-23
Cylinder Head Cover
Components






RTW 76ALF000101
Legend 1. Oil Filler Cap
2. Oil Filler Cap Gasket
3. Cylinder Head Cover
4. Bolt 5. Head Cover Mounting Rubber
6. Nozzle Seal Cover
7. Head Cover Gasket
8. Nut



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6A-24 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the engine cover.
2. Remove the intake air duct (3) (Standard output).
3. Remove the harness bracket (6).




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Legend
1. Blow-by Hose
2. Leak-off Hose
3. Intake Air Duct
4. Fuel Injector Connector
5. Leak-off Hose
6. Harness Bracket

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




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5. Disconnect the fuel injector connector (2).
6. Remove the fuel leak off hose (1).




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Note: Do not reuse the clips (1).



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7. Disconnect the blow-by hose.

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-25
8. Remove the cylinder head cover.




LNW 71BSH000401
9. Remove the nozzle seal cover from the cylinder
head cover.
• Remove from the lower side of cylinder head
cover.
10. Remove the cam end gasket (1). • Remove the liquid gasket that has adhered to
cylinder head completely.




RTW 56ASH020501

Installation
1. Install the nozzle seal cover.
• Insert from the lower side of cylinder head
cover.
•
Apply soapy water or engine oil to the surface
of cylinder head cover side.
• Insert the nozzle seal cover as far as it will go.
2. Install the cam end gasket. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.



RTW 56ASH020601
Legend
1. Cam End Gasket
2. Apply The Liquid Gasket
3. 2.0 - 3.0 mm (0.079 - 0.118 in)

• Apply attaching cam end gasket.
Apply the liquid gasket (ThreeBond TB-1207B or equivalent).


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