engine ISUZU KB P190 2007 Workshop Repair Manual

6A-36 ENGINE MECHANICAL (4JK1/4JJ1)
Inspection
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the
manifold and the cylinder head are to be
installed.

Manifold installation plane surface mm (in)
Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)
Note:
If the plane surface exceeds the limit, replace it.




LNW 21BSH022301
• Check a crack in the exhaust manifold visually.
Carefully inspect the turbocharger for abrasion and/o
r
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.

Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft pla
y
when a force of 12 N (1.2 kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)




LNW 21BSH022201

Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW 21BSH022301
Legend
1. Oil Outlet
2. Oil Intake



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-37
Waste gate operation
1. Remove the hose from the waste gate actuator.
2. Install the pressure gauge (general tool). Refer to the illustration.





RTW 56ASH005701
Legend
1. W aste Gate Actuator
2. W aste Gate Hose
3. Pressure Gauge (General Tool)

3. Use the pressure gauge pump to apply pressure
(load) to the waste gate actuator (the engine must
be off).
4. Note the pressure at which the control rod moves 2 mm (0.078 in). This pressure must be within the
specified limit.

Control rod pressure range: kPa (mmHg / psi)
109 − 118 (818 − 885 / 16 − 17)

5. Inspect the hose for cracks and other damage.
Replace the hose if necessary.
6. Do not apply a pressure of more than 120 kPa (900 mmHg) to the waste gate actuator.

Installation
1. Put the gasket in to install the exhaust manifold.
• Tighten up with the 8 nuts according to the
order given in the figure.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
Note:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.









RTW 56ASH005801
2. Install the gasket and turbocharger to the exhaust
manifold. Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)




RTW 56ASH005501
Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger


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ISUZU KB P190 2007

6A-38 ENGINE MECHANICAL (4JK1/4JJ1)
3. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Connect the front propeller shaft flange (Front Dif
f
Side, 4 ×4 only).
5. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅
⋅⋅
⋅m (6.8 kg⋅
⋅⋅
⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N
⋅
⋅⋅
⋅m (4.4 kg⋅
⋅⋅
⋅m / 32lb ft)
6. Install the water feed pipe to the turbocharger (1).
• Tighten the joint bolts to the specified torque.
Tightening torque: 54 N ⋅
⋅⋅
⋅
m (5.5 kg ⋅
⋅⋅
⋅
m / 40 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
• Install the rubber hose between the wate
r
return pipe and the thermostat housing.







RTW 56ASH019101
7. Install the water return pipe. Tighten the joint bolt
to the specified torque.
Tightening torque: 54 N ⋅
⋅⋅
⋅
m (5.5 kg ⋅
⋅⋅
⋅
m / 40 lb ft)









RTW 56ASH019001
8. Install the turbocharger oil feed pipe to the top of
the turbocharger. Tighten the joint bolts to the
specified torque.
Tightening torque (Turbo charger side): 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m / 17 lb ft)
Tightening torque (Oil cooler side): 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m / 17 lb ft)
• Install the pipe bracket and tighten the bolts to
the specified torque.
Tightening torque: (Clip) 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)



RTW 56ASH00610
Legend
1. Oil Feed Pipe
2. Clip
3. Oil Return Pipe




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ENGINE MECHANICAL (4JK1/4JJ1) 6A-39
9. Tighten the oil return pipe bolts and nuts to the
specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
10.Install the EGR cooler. • Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
11. Install the heat protector. • Refer to “EGR Cooler” in EXHAUST SYSTEM
section.
12. Install the intake hose between the intercooler and the intake throttle (7).
13. Install the intake hose between the turbocharge
r
and the intercooler (9).
14. Install the intake duct between the turbocharge
r
and the air cleaner (8).
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
15.Replenish the coolant.



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6A-40 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 76ALF000901


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-41
Turbocharger (High Output)
Components




RTW 76ALF000401
Legend 1. Turbocharger Assembly Gasket
2. Turbocharger Assembly
3. Turbocharger Heat Protecter
4. W ater Feed and Return Pipe Gasket
5. W ater Feed and Return Pipe 6. Oil Feed and Return Pipe Gasket
7. Oil Feed and Return Pipe
8. Catalyst Converter Gasket
9. Catalyst Converter



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6A-42 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Drain the engine coolant.
2. Remove the engine cover.
3. Remove the intercooler. • Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




RTW 76ASH000501
4. Disconnect the vacuum hose from the
turbocharger actuator.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the front exhaust pipe.




RTW 56ASH018301

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)

7. Remove the heat protector of the turbocharger.
• Remove the mud cover of front RH fender skirt
(4×4 only).
• Loosen the bolt of Turbocharger bracket.
8. Remove the catalyst converter.
9. Remove the turbocharger bracket.
10. Remove the oil feed and return pipe.
11. Remove the water feed and return pipe from the turbocharger.






RTW 76ASH001001
12. Remove the turbocharger from the exhaust
manifold.

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-43
Inspection
Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft pla
y
when a force of 12 N (1.2kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)




LNW 21BSH022201

Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW 21BSH022301
Legend
1. Oil Outlet
2. Oil Intake

Actuator operation
1. Install a vacuum pump (2) to the actuator (1).







LNW 71JSH000201
2. Operate the vacuum pump and apply vacuum
pressure to the actuator.

W orking vacuum pressure kPa (mmHg / psi)
52.8 (396 / 7.66)









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6A-44 ENGINE MECHANICAL (4JK1/4JJ1)
3. Place a vernier caliper on the end of the control
rod of actuator. Release the vacuum pressure and
check the control rod moves. Measure the length
of the control rod moving.

Standard length mm (in)
12 (0.48)

Installation
1. Install the gasket and the turbocharger to the
exhaust manifold. Temporarily tighten nuts.
2. Install the oil feed and return pipe and temporaril
y
tighten.
3. Tighten the turbocharger nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Tighten the oil feed and return pipe bolts and nuts to the specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
5. Install the water feed and return pipe to the turbocharger.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
6. Install the heat protector to the turbocharger. Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
7. Install the turbocharger bracket.
8. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
9. Install the mud cover of front RH fender skirt (4 ×4
only).
10. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅
⋅⋅
⋅m (6.8 kg⋅
⋅⋅
⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N
⋅
⋅⋅
⋅
m (4.4 kg ⋅
⋅⋅
⋅
m / 32lb ft)
11. Install the intercooler. • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
12. Install the intake duct between the turbocharge
r
and the air cleaner.
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
13.Replenish the coolant.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-45
Torque Specifications



RTW 76ALF000501


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