engine ISUZU KB P190 2007 Workshop Repair Manual

6A-26 ENGINE MECHANICAL (4JK1/4JJ1)





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Legend
1. 3.0 - 5.0 mm (0.118 - 0.197 in)
2. 3.0 - 5.0 mm (0.118 - 0.197 in)

3. Install the cylinder head cover.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
• Tighten the nut and bolts in order shown in the
illustration.







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4. Install the blow-by hose.
5. Install the leak-off hose and the fuel injecto
r
connector.
6. Install the harness bracket to the cylinder head cover.
7. Install the intercooler (High output). • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.


8. Install the intake air duct.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb in)
9. Install the engine cover.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-27
Intake Manifold
Components (Standard Output)




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Legend 1. Intake Duct
2. Throttle Assembly
3. Intake Manifold Gasket 4. Intake Manifold
5. EGR Valve Assembly Gasket
6. EGR Valve Assembly



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ISUZU KB P190 2007

6A-28 ENGINE MECHANICAL (4JK1/4JJ1)
Components (High Output)




RTW 76ALF000301
Legend 1. Intake Duct
2. Intake Throttle
3. Intake Throttle Gasket
4. Intake Manifold Gasket 5. Intake Manifold
6. EGR Valve Assembly Gasket
7. EGR Valve Assembly
8. Bracket




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-29
Removal
1. Remove the engine cover.
2. Disconnect the connectors. • Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
3. Remove the A/C belt
4. Remove the A/C compressor.
5. Remove the A/C compressor bracket.
6. Remove the intake air duct (Standard output).





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Legend
1. A/C Compressor Bracket
2. Intake Air Duct
3. A/C Compressor

7. 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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8. Remove the injector leak-off hose (1).



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9. Remove the engine oil level gauge guide tube.
10. Remove the EGR valve.

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ISUZU KB P190 2007

6A-30 ENGINE MECHANICAL (4JK1/4JJ1)


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11. Remove the injection pipes.
• Remove sequentially from No.1 cylinder.
12. Disconnect the vacuum hose of swirl control valve (1).










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13. Remove the throttle assembly and gasket.




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Legend
1. Throttle Assembly
2. Intake Manifold

14. Remove the intake manifold.






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15. Remove the intake manifold gasket.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-31
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold. • Tighten the nuts and bolts in the orde
r
described in the drawing.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)







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3. Install the throttle assembly and gasket.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
4. Install the vacuum hose of swirl control valve.
5. Install the injection pipe (fuel rail - fuel injector). • It installs sequentially from No. 4 cylinder.
Tightening torque: 29 N ⋅
⋅⋅
⋅
m (3.0 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
6. Install the EGR valve. • Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
7. Install the engine oil level guide tube.
Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
8. Install the intercooler (High output).
9. Connect the connector of other parts. • Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
10. Install the leak-off hose.




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Legend
1. Injector Leek-off Hose

11. Install the intake air duct.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
12.Install the A/C compressor bracket. Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
13.Install the A/C compressor and A/C compresso
r
connector.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
14.Install the A/C belt.
Check the A/C belt tension.
Depress the A/C belt mid-portion with 98 N (10 kg
/
22 lb) force.
Standard deflection: 7.6 - 9.2 mm (0.29 - 0.36 in)



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15. Install the engine cover.



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6A-32 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications




RTW 76AMF000101


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-33
Turbocharger and Exhaust Manifold (Standard Output)
Components



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Legend 1. Turbocharger Assembly
2. Exhaust Manifold
3. Heat Protector
4. Catalyst Converter
5. Oil Feed Pipe 6. Oil Return Pipe
7. Intake Hose for Intercooler and Intake Throttle
8. Intake Duct for Turbocharger and Air Cleaner
9. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

6A-34 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Loosen the radiator drain plug to drain coolant.
2. Remove the engine cover.
3. Remove the intake hose from the intercooler and intake throttle.
4. Remove the intake hose from the turbocharge
r
and the intercooler.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the EGR cooler.
Refer to “EGR Cooler” in EXHAUST SYSTEM Section.
7. Remove the oil feed pipe.
8. Remove the oil return pipe. • Loosen clamp (1) of A/T oil cooler pipe.






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9. Remove the water feed and return pipe.




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Legend
1. Oil Feed Pipe
2. EGR Cooler
3. W ater Feed Pipe
4. W ater Return Pipe
5. Oil Return Pipe

10. Remove the front exhaust pipe.




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Legend
1. Gasket
2. Front Exhaust Pipe (4 ×2 High Ride Suspention,
4 ×4)
3. Gasket
4. Front Exhaust Pipe (4 ×2 Except High Ride
Suspention)

11. Disconnect the front propeller shaft flange (1)
(Front Diff Side, 4 ×4 only).





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ENGINE MECHANICAL (4JK1/4JJ1) 6A-35
12. Remove the catalyst converter.



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13. Remove the turbocharger from the exhaust
manifold.




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Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger

14. Remove the exhaust manifold.
• Remove the 8 nuts from the exhaust manifold.






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ISUZU KB P190 2007