cooling ISUZU KB P190 2007 Workshop Manual PDF

ENGINE MECHANICAL (4JK1/4JJ1) 6A-87
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve seat
insert.
• Cool the valve seat insert for two to three minutes.
Contraction due to cooling makes it easier to
remove the valve seat insert.
• Remove the valve seat insert, using a scre
w
driver . Be sure not to harm the cylinder head.


LNW 21BSH056001
Legend
1. Arc-W eld
2. Valve Seat Insert
3. Screw Driver

Install the valve seat insert
• Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on the
washer, thereby pushing the valve seat insert.
Note:
Do not apply too much pressure with the press. Attach
compound on the valve seat surface, rotate the valve
and hit it lightly to grind it, and confirm that it has even
contact all round.






LNW 21BSH018601
Legend
1. Attach Compound
2. Valve Seat
3. Press

Reassembly
1. Install the oil seal.
• Install on the surface of the injection pipe insert.
• Hammer it in so that the seal does not incline.
Note:
Be sure not to harm the lip.
Special tool
Injection pipe oil seal installer: 5-8840-2820-0




RTW 56ASH008801


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ISUZU KB P190 2007

6A-98 ENGINE MECHANICAL (4JK1/4JJ1)
52. Install the turbocharger water feed pipe.





RTW 56ASH019101
Legend
1. Turbocharger W ater Feed Pipe


53. Install the turbocharger water return pipe.






RTW 56ASH019001
Legend
1. Turbocharger W ater Return Pipe

54 Install the A/T oil cooler pipe bracket.
Refer to procedure for automatic transmission in this manual.
55. Install the catalyst converter.
Refer to procedure for Turbocharger and Exhaust Manifold in this manual.
56. Connect the front drive shaft. (4 ×4)
Refer to procedure for front propeller shaft in this manual.

57. Install the exhaust front pipe.
• Refer to procedure for “Exhaust System” in this
manual.
58. Install the EGR cooler. • Refer to procedure for “Exhaust System” in this
manual.
59. Install the EGR cooler water pipe. • Refer to procedure for “Exhaust System” in this
manual.
60. Install the EGR cooler heat protector. • Refer to procedure for “Exhaust System” in this
manual.
61. Install the cooling fan. • Refer to procedure for “Engine Cooling” in this
manual.
62.Install the A/C drive belt. • Refer to procedure for “Intake Manifold” in this
manual.
63. Install the radiator fan shroud. Upper and lower.
64. Install the radiator upper hose. • Refer to procedure for engine cooling in this
manual.
65. Install the harness bracket.
66. Install the fuel leak off hose (1), and the fuel injector connector (2).






RTW 76ASH000101


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-121
3. Remove the crankshaft pulley.
Note:
Do not reuse the bolt and the washer.








LNW 61ASH005301
4. Remove the crankshaft front oil seal.
• Remove only the oil seal with a screwdriver o
r
the like, avoiding damage to the oil seal contact
surface on the front cover and the shaft.
Installation
1. Install the crankshaft front oil seal. • Use the special tool to install the front oil seal.
Front Oil Seal
Installer: 5-8840-2821-0 (1)




RTW 56ASH016501


• Apply engine oil to the lip of the oil seal.
• W ith the seal pressed in check the dimension
of the oil seal section.
Standard Dimension = 1.5 mm (0.06 in)







RTW 56ASH016601
2. Install the crankshaft damper pulley.
• Install the crankshaft pulley aligning with the
key on the crankshaft.
• Hold the flywheel ring gear stationary to prevent
the crankshaft from turning when tightening the
damper pulley bolt.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30 kg ⋅
⋅⋅
⋅
m/217 lb ft)
• Take care not to damage the crankshaft
damper pulley boss.







014R100014
3. Install the fan belt.
• Refer to “Engine Cooling”


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-127
Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail" in the fuel system section.
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
8. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
9. Remove the timing gear train.
Refer to "Timing Gear Train".
10.Remove the oil pump.
Refer to "Oil Pump".
11. Remove the gear case assembly.
Refer to “Gear Case Assembly”.
12. Remove the crankshaft gear.









901R100008
13. Remove the crank case.
Refer to "Crank Case and Oil Pan".
14.Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the bearing cap. • Loosen the crankshaft bearing cap bolts in
numerical order a little at a time.







015RY00003
16.Remove the lower crankshaft bearings.
17.Remove the crankshaft assembly.
18.Remove the thrust bearing.
19.Remove the upper crankshaft bearings.
Disassembly
1. Remove the crank angle sensor rotor (1). • Confirm that the pin (2) is not removed.




RTW 76ASH001501


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ISUZU KB P190 2007

6A-134 ENGINE MECHANICAL (4JK1/4JJ1)
7. Install the crank case.
Refer to "Crank Case and Oil Pan".
8. Install the crankshaft gear.





RTW 56ASH017001
9. Install the gear case assembly.
Refer to "Gear Case Assembly".
10.Install the oil pump.
Refer to "Oil Pump".
11.Install the timing gear train.
Refer to "Timing Gear Train".
12.Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
13.Install the front cover.
Refer to "Timing Gear Train".
14.Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
15.Install the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail".
16.Install the cylinder head.
Refer to "Cylinder Head".
17.Install the camshaft assembly.
Refer to "Camshaft Assembly".
18.Install the cylinder head cover.
Refer to "Cylinder Head Cover".
19.Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ISUZU KB P190 2007

6A-136 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Block
Components




RTW 76ASF000101
Legend
1. Cylinder Block



Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft assembly.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly" in FUEL SYSTEM Section.
6. Remove the oil filter assembly and oil cooler.
Refer to “Oil Filter Assembly and Oil Cooler”.
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
8. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
9. Remove the oil pan.
Refer to "Oil Pan".
10. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
11. Remove the front cover.
Refer to "Front Cover".
12. Remove the timing gear train.
Refer to "Timing Gear Train".
13. Remove the oil pump.
Refer to "Oil Pump".
14. Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the crankshaft.
Refer to "Crankshaft".


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-137
16. Remove the piston cooling pipe.



RTW 76ASH001101
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block. • Conduct color check and hydraulic (o
r
pneumatic) test and if you find a crack or other
damage, replace the cylinder block.





RTW 76ASH000801

5. Cylinder block wear measurement.
• Use a cylinder indicator to measure the cylinde
r
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft.
• Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder block must be replaced o
r
rebored.





012RY00010

Cylinder block bore diameter mm (in)
Standard 95.421 − 95.450 (3.7567 − 3.7579)
Limit 95.48 (3.7590)




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-139

Cylinder block height (H) (Reference) mm (in)
Standard 259.945 – 260.055 (10.2340 – 10.2384)







012R100009
Installation
1. Install the piston cooling pipe.
• Align the dowel pin of the piston cooling pipe
with the pin hole on the cylinder block and
tighten with the relief valve.
Tightening torque: Relief valve 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
bolts M8 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
bolts M6 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
Note:
Be careful not to deform or damage the piston cooling
pipe nozzle.



RTW 76ASH001101
2. Install the crankshaft.
Refer to "Crankshaft".
3. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".
4. Install the oil pump.
Refer to "Oil Pump".
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
Refer to "Front Cover".
7. Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
8. Install the oil pan.
Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
10. Install the crankshaft front oil seal. Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
12. Install the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly " in Fuel System Section.
13. Install the cylinder head.
Refer to "Cylinder Head".
14. Install the camshaft assembly.
Refer to "Camshaft Assembly".
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover".
16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ISUZU KB P190 2007

6A-140 ENGINE MECHANICAL (4JK1/4JJ1)
Lubrication System
Service Precautions
• During each disassembly, remove the old gasket
adhering to each part and mating part completel
y
using a scraper at the location, where the fluid
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton
and apply the specified new fluid gasket at each
location.
•
Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
• Always, the start and end of the application should
be overlapped.
Explanations on functions and operation
The lubrication system uses the filter element combined
with a full flow bypass, water-cooled oil cooler, and oil
jet for piston cooling.
Lubricating system diagram






LNW 76ALF000201
1. Oil Pump Relief Valve Operating Pressure: 490 – 686 kPa (5.0 – 7.0 kg/cm2 / 71 – 100 psi)
2. Oil Cooler Relief Valve Opening Pressure: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)
3. Oil Filter Relief Valve Opening Pressure: 80 – 120 kPa (0.8 – 1.2 kg/cm2 / 11 – 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 – 49.0 kPa (0.3 – 0.5 kg/cm2 / 4.3 – 7.1 psi)
5. Regulating Valve: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)


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ENGINE COOLING (4JK1/4JJ1) 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS

Main Data and Specifications ............................. 6B-2
General Description............................................ 6B-3 Coolant Flow ................................................... 6B-3
W ater Pump .................................................... 6B-4
Thermostat ...................................................... 6B-4
Radiator ........................................................... 6B-5
Antifreeze Solution .......................................... 6B-5
Diagnosis............................................................ 6B-6
Draining and Refilling Cooling System ............... 6B-7
W ater Pump ....................................................... 6B-8 Removal .......................................................... 6B-8
Inspection and Repair ..................................... 6B-9
Installation ....................................................... 6B-9
Thermostat ......................................................... 6B-11 Removal .......................................................... 6B-11
Inspection and Repair ..................................... 6B-11
Operating Test of Thermostat ......................... 6B-11
Installation ....................................................... 6B-12

Radiator .............................................................. 6B-13 Radiator and Associated Parts........................ 6B-13
Removal .......................................................... 6B-14
Inspection and Repair ..................................... 6B-15
Radiator Cap ................................................... 6B-15
Radiator Core .................................................. 6B-15
Flushing the Radiator ...................................... 6B-15
Cooling System Leakage Check ..................... 6B-15
Installation ....................................................... 6B-16
Engine Coolant Change .................................. 6B-16
Fan Clutch with Cooling Fan .............................. 6B-17 Inspection and Repair ..................................... 6B-17
Special Tools................................................... 6B-18

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