engine ISUZU KB P190 2007 Workshop Repair Manual

6A-46 ENGINE MECHANICAL (4JK1/4JJ1)
Exhaust Manifold (High Output)
Components




RTW 76FMF000101
Legend
1. EGR Cooler
2. EGR Cooler Gasket
3. EGR Cooler Gasket 5. Heat Protector
6. Exhaust Manifold




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-47
Removal
1. Drain the engine coolant.
2. Remove the turbocharger. • Refer to “Turbocharger”.
3. Remove the EGR cooler heat protector.
4. Disconnect the water hoses from the EGR coole
r
water pipes.
5. Remove the EGR cooler.
6. Remove the exhaust manifold.







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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)

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









RTW 76ASH002201


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ISUZU KB P190 2007

6A-48 ENGINE MECHANICAL (4JK1/4JJ1)
2. Install the EGR cooler.
• Install the gaskets.
• Install the EGR cooler.
• Temporary tightening order.
1 →2→ 3→ 4→ 5→ 6
• Fully tightening order.
3 →4→ 5→ 1→ 2→ 6
Tighten the nut and bolts to the specified torque.
Tightening torque: Nuts and bots 1-5: 27 N·m (2.8 kg·m / 20 lb ft)
Bolt 6: 52 N·m (5.3 kg·m / 38 lb ft)


6
543
1
2

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3. Install the water hoses to the EGR cooler water
pipes.
4. Heat protector.
Tighten the bolts to the specified torque.
Tightening torque: 25 N·m (2.5 kg·m / 18 lb ft)




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5. Install the turbocharger.
• Refer to “Turbocharger”.
6. Replenish the engine coolant.



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-49
Torque Specifications



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6A-50 ENGINE MECHANICAL (4JK1/4JJ1)
Timing Gear Train
Components






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Legend 1. Oil Pump Gear
2. Crankshaft Gear
3. Idle Gear D
4. Exhaust Camshaft Gear
5. Intake Camshaft Gear
6. Idle Gear D Sprocket
7. Timing Chain 8. Injection Pump Sprocket
9. Injection Pump Gear
10. Idle Gear A
11. Vacuum Pump Gear
12. Power Steering Oil Pump Gear
13. Idle Gear C




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ENGINE MECHANICAL (4JK1/4JJ1) 6A-51
Removal
1. Partially drain the engine coolant.
2. Remove the radiator upper hose.






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3. Remove the fan guide.




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Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling fan and fan pulley.




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5. Remove the A/C compressor drive belt and fan
belt.
6. Remove the crank pulley.
7. Remove the power steering pump with hose.




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Legend
1. Power Steering Pump
2. Nut

• Disconnect the bracket (1) of power steering oil
hose.


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6A-52 ENGINE MECHANICAL (4JK1/4JJ1)





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8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.






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9. Remove the front cover.



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10. Install the M6 bolt to the idle gear A.
11. Remove the idle gear A and idle gear A flange, idle gear A shaft.





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ENGINE MECHANICAL (4JK1/4JJ1) 6A-53
12. Remove the idle gear C and idle gear C shaft.




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13. Remove the crankshaft gear.





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Disassembly
1. Remove the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Use a pair of snap ring pliers to remove the
scissor gear assembly.






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Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A

Reassembly
1. Install the scissor gear assembly.
• Clamp the vise. Insert soft metal protectors
(aluminum) between the vise and component.
Press against the pin on the left side of the idle
gear A spring to make a gap on the right side o
f
the spring. Push the spring into place.


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6A-54 ENGINE MECHANICAL (4JK1/4JJ1)
• Align the sub gear pin with the hole in the right
side of the idle gear A spring. Press the sub-
gear into place.






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Legend
1. Snap Ring
2. Sub-gear
3. Spring
4. Idle Gear A

• Use a pair of snap ring pliers to snuggly install
the snap ring.
Inspection
1. Measurement of idle gear backlash • Apply a dial gauge on the teeth of the idle gea
r
to be measured and move the gear to right and
left lightly to read how much the dial gauge
shook (never fail to fix the gear).
• If the measurement exceeds the limit, replace
the idle gear.
Backlash of the idle gear mm (in)
Standard 0.10 − 0.17 (0.004 − 0.006)
Limit 0.30 (0.01)
• Measure backlash of the idle gear before
removing the idle gear A.
2. Measurement of end clearance of the idle gear. • Insert a thickness gauge between the idle gea
r
and the thrust collar to measure a clearance.

• If the measurement exceeds the limit, replace
either the idle gear or the thrust collar.
End clearance of the idle gear mm (in)
Standard 0.080 − 0.155 (0.003 − 0.006)
Limit 0.20 (0.008)
• Measure an end clearance of the idle gear
before removing the idle gear B.
3. External diameter of the idle gear shaft. • Use a micrometer to measure an external
diameter of each idle gear shaft.
• If the measurement exceeds the limit, replace
the shaft.
External diameter of the idle gear A shaft mm (in)
Standard 44.950 − 44.957 (1.7697 − 1.7700)
Limit 44.80 (1.764)

External diameter of the idle gear C shaft mm (in)
Standard 24.959 − 24.980 (0.9826 − 0.9835)
Limit 24.80 (0.976)






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4. Clearance between the idle gear and the idle gear
shaft
• Measure an inside diameter of the idle gea
r
bush to calculate a clearance between the idle
gear and the idle gear shaft.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-55
• If the measurement exceeds the limit, replace
either the idle gear or the shaft.
Clearance between the idle gear A and the shaft
mm (in)
Standard 0.020 − 0.062 (0.0007 − 0.0024)
Limit 0.200 (0.0079)

Clearance between the idle gear C and the shaft
mm (in)
Standard 0.025 − 0.075 (0.0010 − 0.0030)
Limit 0.200 (0.0079)


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Installation
1. Install the crankshaft gear.
2. Install the idle gear C. •
Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.

•
Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).





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3. Install the idle gear A.
4. Tighten sub gear setting bolt. • Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt
hole between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.






RTW 56ASH011501



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