engine ISUZU KB P190 2007 Workshop Repair Manual

6A-146 ENGINE MECHANICAL (4JK1/4JJ1)
6. Remove the water intake pipe.




RTW 56ASH012601
Legend
1. W ater Intake Pipe
2. Bracket
3. Bracket
4. Bolt

7. Remove the oil cooler.





RTW 66ASH009101

Disassembly
1. Remove the element mounting nut (1).





RTW 56ASH012901
2. Remove the element (1).
3. Remove the gasket (2).





RTW 56ASH013001


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-147
Reassembly
1. Install the gasket on the element.
2. Install the element.
3. Tighten the element fixing nut using the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)

Installation
1. Install the oil filter and cooler.
• Install the O-ring on the oil filter and cooler,
apply grease.
•
Apply the liquid gasket and mount within 5
minutes. Apply liquid gasket (ThreeBond TB-
1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.079 and 0.118 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).






RTW 56ASH013101
Legend
1. Liquid Gasket
2. O-ring

• Align the oil filter and cooler holes with the
cylinder block studs. Install the oil cooler to the
cylinder clock.


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ISUZU KB P190 2007

6A-148 ENGINE MECHANICAL (4JK1/4JJ1)







RTW 56ASH013201
Legend
1. Bolt 45 mm (1.77 in)
2. Bolt 110 mm (4.33 in)
3. Bolt 70 mm (2.76 in)
4. Nut

• Tighten the bolts to the specified torque in the
order shown in the illustration.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)








RTW 56ASH013301

2. Install the water intake pipe.
a. Temporarily tighten the bolt (6).
b. Install the O-ring (2) to the water intake pipe (7).
c. Apply soapy water to the O-ring (2) and install the water intake pipe (7). • Take care not to twist the O-ring.
d. Temporarily tighten the bolts.
Temporary tightening order: 1 →3→ 4→ 5
e. Tighten the bolts to the specified torque.
Fully tightening order: 3 →4→ 1→ 5→ 6
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)




RTW 76ASH001701
3. Install the water bypass pipe (1).
• After applying soapy water to O-ring, set it on
bypass pipe and insert into the cylinder head.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-149


RTW 56ASH008401
4. Install the bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 51 N ⋅
⋅⋅
⋅
m (5.2 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
5. Install the adjustment bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
6. Install the generator.
Refer to Installation procedure for generator in this manual.
7. Install the exhaust manifold.
Refer to Installation procedure for turbocharge
r
and exhaust manifold in this manual.




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6A-150 ENGINE MECHANICAL (4JK1/4JJ1)
Crank Case and Oil Pan
Components



RTW 76ALF000801
Legend 1. Gasket
2. Oil Strainer
3. Bolt
4. Crank Case 5. Rear Plate
6. Bolt
7. Oil Pan
8. Bolt


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-151
Removal
1. Remove the engine assembly.
Refer to “Engine Assembly”.
2. Remove the oil level gage guide tube.




RTW 56ASH015601
3. Remove the oil pan.





RTW 56ASH015001


4. Disconnect the earth terminal (1) of crank case
side.




RTW 76ASH001801
5. Remove the flywheel.
Refer to “Flywheel”.
6. Remove the rear plate.




RTW 76ASH001901
Legend
1. Rear Plate
2. Bolt



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6A-152 ENGINE MECHANICAL (4JK1/4JJ1)
7. Remove the cylinder head.
Refer to “Cylinder Head”.
8. Remove the timing gear case.
Refer to “Timing Gear Case”.
9. Remove the retainer.



RTW 76ASH002001
Legend
1. Retainer
2. Bolt

10. Remove the crank case.






RTW 56ASH021901
Legend
1. O-ring
2. Crank Case

Note:
Take care not to damage the O-ring.

Disassembly
1. Remove the oil strainer.



RTW 66ASH009201
Legend
1. Gasket
2. Oil Strainer
3. Bolt
4. Crank Case

Reassembly
Install the oil strainer.
• Install the gasket on the strainer.
• Tighten the bolts to the specified torque.
Tightening torque: 22 N ⋅
⋅⋅
⋅
m (2.2 kg ⋅
⋅⋅
⋅
m / 16 lb ft)


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-153
Installation
1. Install the crank case.
• Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)




RTW 56ASH015301
Legend
1. 2.0 - 3.0 mm (0.079 - 0.118 in)
2. 4.0 - 5.0 mm (0.157 - 0.197 in)

2. Install the oil pan.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent)and mount within 5 minutes.
Tightening torque: 22 N ⋅
⋅⋅
⋅
m (2.2 kg ⋅
⋅⋅
⋅
m / 16 lb ft)








RTW 56ASH015201
Legend
1. 2.0 mm (0.079 in)
2. 3.0 mm (0.118 in)


3. Install the retainer.
• Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)







RTW 56ASH017701
Legend
1. 2 - 2.5 mm (0.079 - 0.098 in)
2. 2 - 2.5 mm (0.079 - 0.098 in)



RTW 76ASH002001
Legend
1. Retainer
2. Bolt

4. Install the timing gear case.
Refer to “Gear Case Assembly”.
5. Install the cylinder head.
Refer to “Cylinder Head”.

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6A-154 ENGINE MECHANICAL (4JK1/4JJ1)
6. Install the rear plate.
• Tighten the bolts to the specified torque.
Tightening torque: 82 N ⋅
⋅⋅
⋅
m (8.4 kg ⋅
⋅⋅
⋅
m / 61 lb ft)
7. Install the flywheel.
Refer to “Flywheel”.
8. Connect the earth terminal of crank case side.
Note:
Do not allow the caulked portion of the terminal to
interfere with nearby parts.
9. Install the oil level gage guide tube. • Apply the engine oil to the O-ring.
• Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
10. Install the engine assembly.
Refer to “Engine Assembly”.



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-155
Torque Specifications



RTW 56AMF001901



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