2007 ISUZU KB P190 check oil

6A – 98 ENGINE MECHANICAL


RTW 36ASH002001



































6. Piston Ring
1. Use a piston ring replacer to install the three piston rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring

NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the piston ring grooves





7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.




015R100006

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ENGINE MECHANICAL 6A – 105






5. Crankshaft Thrust Bearing
Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
















6. Crankshaft Bearing Cap With Lower Bearing
Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. Apply the recommended liquid gasket or its equivalent to the No. 5 crankshaft bearing cap cylinder body fitting
surfaces at the points shown in the illustration.
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket. Three bond 1207B Do not allow the liquid
gasket to obstruct the cylinder thread holes and
bearings.
ThreeBond 1207B is a fast-drying liquid gasket.
Tighten the bearing caps immediately after applying
the gasket.









2. Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.The bearing
cap numbers must be facing up.
3. Apply engine oil to the crankshaft bearing cap bolts.















4. Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence shown
in the illustration.

Crankshaft Bearing Cap Torque N·m(kg·m/lbft)
167 (17/123)
5. Check to see the crankshaft turns smoothly by rotating it manually.


015LX115
015LX127
015LX128
015LX129

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6A – 108 ENGINE MECHANICAL











10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of anglar tigthen method.

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step; 29.0–29.2 (3.00/22.0–3.01/22.2) 4JH1TC
2nd step; 45°-60 °






13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified torque.

Oil Jet Bolt Torque N·m(kg·m/lb ft)
M8 × 1.25 19 (1.9/14)
M6
× 1.00 8 (0.8/6)


Relief Valve Torque N·m(kg·m/lb ft)
29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.
















14. Oil Pump with Oil Pipe Apply a coat of the molybdenum disul fide and engine oil
enough on the pinion gear.
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.

Oil Pump Bolt Torque N·m(kg·m/lb ft)
19 (19/14)
NOTE:
Take care not to damage the O-rings when tightening
the oil pipe bolts.







15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer: 5-8840-2359-0


015LX130
015LX112
052LX010
051R100004

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 117


RTW 46ASH001201
33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder bracket to the cylinder head.










3. Tighten the nozzle holder bracket bolt to the specified
torque.


Injection Nozzle Holder Bracket Bolt
Torque N·m(kg·m/lbft)
37 (3.8/28)













Note on Valve Clearance Adjustment
Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.

Valve Clearance (At Cold) mm(in)
0.4 (0.0157)


RTW 46ASH001101















34. Cylinder Head Cover
1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical order shown in the illustration.


Cylinder Head Cover Bolt Torque N·m(kg·m/lbft)
13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose to the cylinder head cover.




014RY00015

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ISUZU KB P190 2007

6B – 8 ENGINE COOLING
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the “MIN" and “MAX" lines o
f
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the “MAX" line.
There should not be any excessive deposit of rust or scales
around the radiator cap or radiator filler hole, and the EC
should also be free from oil.
Replace the EC if excessively dirty.


P1010064
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.

2. Remove the radiator cap.
WARNING: To avoid the danger of being burned, do not
remove the cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out unde
r
pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it.
Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change)
• Make sure that the engine is cool.
• Open radiator cap pour coolant up to filler neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the radiato
r
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to reduce
the pressure when the coolant has become cooler.


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6B – 18 ENGINE COOLING




110RS005
• Check the rubber hoses for swelling.

Installation
1. Install radiator assembly (9) with hose, taking care not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the engine.




RTW 36BMH000101
6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.

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6C – 2 FUEL SYSTEM

MAIN DATA AND SPECIFICATIONS
Description Item
4JA1T (L) 4JA1TC 4JH1TC
Injection pump type Bosch distributor
VE type Bosch distributor VP44 type
Governor type
Mechanical variable
(Half speed oil pressure) Electrical controled
Timer type
Oil pressure Electrical controled
Fuel feed pump type Vane with input shaft
Injection nozzle type Hole type
Number of injection nozzle orifices 5
Injection nozzle orifices
Inside diameter mm (in) 0.19 (0.0075) 0.17 (0.0067) 0.21 (0.0083)
19.1 (195) 19.0 (194) 19.5 (199) Injection nozzle designed operating
pressure MPa (kg/cm2) 1st
2nd 25.0 (255)
33.5 (328) 33.8 (331)
Main fuel filter type Disposable cartridge paper element


Precautions
When working on the fuel system, there are several things
to keep in mind:
•
Any time the fuel system is being worked on,
disconnect the negative battery cable except fo
r
those tests where battery voltage is required.
•
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
• Replace all pipes with the same pipe and fittings that
were removed.
• Clean and inspect “O” rings. Replace if required.
•
Always relieve the line pressure before servicing any
fuel system components.
• Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
• Adhere to all Notices and Cautions.

NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.


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ISUZU KB P190 2007

FUEL SYSTEM 6C – 15


140R100037
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.





140R100028
Cover the connectors that was removed with a plastic bag,
to prevent dust or rain water from entering.






140R100036
Reuse of Quick–Connector
• Replace the port and connector if scratch, dent or crack is
found.
• Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms o
f
rust, dent, scratch.
• After cleaning the port, insert it straight into the connecto
r
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.


Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface – which may decrease sealing ability). Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.





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