engine ISUZU KB P190 2007 Workshop Repair Manual

6A-76 ENGINE MECHANICAL (4JK1/4JJ1)
24. Disconnect the Front drive shaft (1). (4×4)





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25. Remove the catalyst converter.

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26. Remove the A/T oil cooler pipe bracket (A/T).





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Legend
1. A/T Oil Cooler Pipe Bracket


27. Remove the turbocharger water return pipe and
hose.






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ENGINE MECHANICAL (4JK1/4JJ1) 6A-77
28. Remove the turbocharger water feed pipe (1) and
hose.





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29. Remove the turbocharger engine oil feed pipe.
30. Remove the engine oil level gauge guide tube.
31. Remove the fuel return pipe and hose (1).





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32. Remove the fuel injection pipe clip.
33. Remove the fuel injection pipe.
34. Remove the vacuum hose (1).






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35. Remove the noise cover (1).






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6A-78 ENGINE MECHANICAL (4JK1/4JJ1)
36. Remove the timing chain cover lower.
37. Remove the timing chain cover upper.




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Legend
1. Timing Chain Cover Upper
2. Timing Chain Cover Lower


38. Remove the water by pass pipe (1).





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39. Remove the glow plug (1).



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40. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
41. Install the lock bolt for camshaft scissor gear.








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42. Remove the fuel injector assembly.
43. Remove the baffle plate.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-79
44. Remove the camshaft bearing cap.





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45. Remove the camshaft.
46. Remove the rocker arm shaft assembly.
Note:
Keep the removed rocker arm shaft assembly properl
y
so that they may be put back to the original place.



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Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Front


Note:
Pay full attention so as not to drop the parts in the gea
r
case of the front part of the cylinder head or a hole into
which oil pours back in the front.
Note:
Remember the original position.
47. Remove the timing chain tensioner.



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Legend
1. Timing Chain Tensioner
2. Gasket
3. Nut


48. Remove the idle gear D.
• Timing chain is dropped behind.



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ISUZU KB P190 2007

6A-80 ENGINE MECHANICAL (4JK1/4JJ1)
49. Remove the timing chain tension lever pivot.





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50. Remove the timing chain from supply pump
sprocket.
51. Remove the chain guide bolt from cylinder head.



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52. Remove the cylinder head gear case nuts (1) and
bolts (2).




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53. Remove the cylinder head bolt (1).


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Note:
Do not reuse the cylinder head bolt.



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-81
54. Remove the cylinder head assembly.
• Loosen the cylinder head bolts in the order
described in the drawing.
• Remove the cylinder head gasket.
Note:
Replace the head gasket with a new one once it is
removed.






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Disassembly
1. Remove the throttle assembly.
• Refer to procedure for Intake Manifold in this
manual.
2. Remove the intake manifold assembly. • Refer to procedure for Intake Manifold in this
manual.
3. Remove the turbocharger. • Refer to “Turbocharger and Exhaust Manifold”.
4. Remove the exhaust manifold assembly. • Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
5. Remove the water outlet pipe.
6. Remove the valve stem cap.
Refer to procedure for valve stem and valve in this manual.
7. Remove the split collar. • Use a replacer to compress the valve spring to
remove the split collar.
Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)




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8. Remove the spring upper seat.
• Remove the special tool to remove the uppe
r
seat.
9. Remove the valve spring. • Put the removed valve springs in order b
y
cylinder number.


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6A-82 ENGINE MECHANICAL (4JK1/4JJ1)
10. Remove the intake and exhaust valve.
• Sort the removed valves according to cylinders
by using tags others.







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11. Remove the valve stem oil seal.
• Refer to procedure for valve stem and valve in
this manual.
12. Remove the spring lower seat.
13. Remove the valve guide. • Use the valve guide replacer to press out the
valve guides from the bottom side of the
cylinder head.
Special tool
Valve guide remover and installer:
5-8840-2816-0






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14. Remove the cam end gasket (1).



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15. Remove the oil seal.




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ENGINE MECHANICAL (4JK1/4JJ1) 6A-83
Inspection
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Cylinder Head Lower Face Warpage
1. Use a straight edge and a thickness gauge to
measure the four sides and the two diagonals o
f
the cylinder head lower face.
2. The cylinder head lower surface warpage is more than the limit, it should be replaced.




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Cylinder Head Lower Face W arpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.0079)
NOTE:
The cylinder head lower face cannot be regrind.









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Cylinder Head Height (H) (Reference) mm (in)
Standard 143.4 (5.646)





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Manifold Fitting Face Warpage
Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but
less than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.



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6A-84 ENGINE MECHANICAL (4JK1/4JJ1)

Manifold Fitting Face W arpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.008)
Maximum Grinding Allowance 0.40 (0.016)









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Exhaust Manifold Warpage
Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the
manifold must be replaced.
Exhasut Manifold W arpage mm (in)
Standard 0.05 (0.002) or less
Limit 0.20 (0.008)







027RY00002

Valve Stem Cap

Make the necessary part replacements.
If excessive wear or damage is discovered during
inspection.
Valve Stem Outside Diameter
Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Valve Stem Outside Diameter mm (in)
Intake Valve Exhaust Valve
Standard 6.955 – 6.970
(0.2738 – 0.2744) 6.939 – 6.949
(0.2732 – 0.2736)
Limit 6.935
(0.2730) 6.920
(0.2724)






011LX027
Valve Stem and Valve Guide Clearance
1. Measure the valve stem outside diameter.
Refer to the item “Valve Stem Outside Diameter”.
2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.
If the measured values exceed the specified limit, the valve and the valve guide must be replaced as
a set.
Valve Stem Clearance mm (in)
Intake Valve Exhaust Valve
Standard0.039 – 0.071
(0.0015 – 0.0028) 0.064 – 0.096
(0.0025 – 0.0038)
Limit 0.200
(0.008) 0.250
(0.0098)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-85




011RY00023
Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Intake and Exhasut Valve Thickness mm (in)
Standard 1.32 (0.052)
Limit 1.1 (0.043)






014RY00020

Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.
Valve Depression mm (in)
Standard 1.8 (0.07)
Limit 2.5 (0.098)







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Valve Contact Width
1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact
surfaces.
2. Measure the valve contact width.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.

Valve Contact W idth
mm (in)
Intake Exhaust
Standard 1.7 (0.067) 2.0 (0.079)
Limit 2.2 (0.087) 2.5 (0.098)



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