2007 ISUZU KB P190 service

ENGINE MECHANICAL (4JK1/4JJ1) 6A-1
SECTION 6A
ENGINE MECHANICAL (4JK1/4JJ1)
TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JK1/4JJ1) ................ 6A-3
Service Precautions ........................................ 6A-3
Trouble Shooting ............................................. 6A-8
Main Data and Specifications .......................... 6A-13
Special Tools ................................................... 6A-14
Engine Assembly................................................ 6A-15 Removal .......................................................... 6A-15
Installation ....................................................... 6A-17
Special Tools ................................................... 6A-19
Engine Mount ..................................................... 6A-20 Components .................................................... 6A-20
Removal .......................................................... 6A-21
Installation ....................................................... 6A-21
Torque Specifications...................................... 6A-22
Special Tools ................................................... 6A-22
Cylinder Head Cover .......................................... 6A-23 Components .................................................... 6A-23
Removal .......................................................... 6A-24
Installation ....................................................... 6A-25
Intake Manifold ................................................... 6A-27 Components (Standard Output) ...................... 6A-27
Components (High Output) ............................. 6A-28
Removal .......................................................... 6A-29
Installation ....................................................... 6A-31
Torque Specifications...................................... 6A-32
Turbocharger and Exhaust Manifold (Standard Output) ........................................... 6A-33
Components .................................................... 6A-33
Removal .......................................................... 6A-34
Inspection ........................................................ 6A-36
Installation ....................................................... 6A-37
Torque Specifications...................................... 6A-40
Turbocharger (High Output) ............................... 6A-41 Components .................................................... 6A-41
Removal .......................................................... 6A-42
Inspection ........................................................ 6A-43
Installation ....................................................... 6A-44
Torque Specifications...................................... 6A-45
Exhaust Manifold (High Output) ......................... 6A-46 Components .................................................... 6A-46
Removal .......................................................... 6A-47
Inspection ........................................................ 6A-47
Installation ....................................................... 6A-47
Torque Specifications...................................... 6A-49
Timing Gear Train .............................................. 6A-50 Components .................................................... 6A-50
Removal .......................................................... 6A-51
Disassembly .................................................... 6A-53
Reassembly .................................................... 6A-53
Inspection ........................................................ 6A-54
Installation ....................................................... 6A-55
Torque Specifications...................................... 6A-58
Camshaft Assembly ........................................... 6A-59 Components .................................................... 6A-59
Removal .......................................................... 6A-60
Disassembly .................................................... 6A-61
Reassembly .................................................... 6A-63
Installation ....................................................... 6A-64
Torque Specifications...................................... 6A-66
Special Tools................................................... 6A-66
Valve Stem Seal and Valve Spring .................... 6A-67 Components .................................................... 6A-67
Removal .......................................................... 6A-68
Inspection ........................................................ 6A-69
Installation ....................................................... 6A-70
Special Tools................................................... 6A-71
Cylinder Head..................................................... 6A-72 Components .................................................... 6A-72
Removal .......................................................... 6A-72
Disassembly .................................................... 6A-81
Inspection ........................................................ 6A-83
Reassembly .................................................... 6A-87
Installation ....................................................... 6A-89
Torque Specifications...................................... 6A-100
Special Tools................................................... 6A-100
Piston and Connecting Rod................................ 6A-101 Components .................................................... 6A-101
Removal .......................................................... 6A-101
Disassembly .................................................... 6A-102
Reassembly .................................................... 6A-107
Installation ....................................................... 6A-108
Torque Specifications...................................... 6A-110

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ISUZU KB P190 2007

6A-2 ENGINE MECHANICAL (4JK1/4JJ1)
Special Tools ...................................................6A-110
Flywheel .............................................................6A-111 Components ....................................................6A-111
Removal ..........................................................6A-111
Inspection ........................................................6A-113
Installation .......................................................6A-113
Torque Specifications......................................6A-115
Special Tools ...................................................6A-115
Gear Case Assembly .........................................6A-116 Components ....................................................6A-116
Removal ..........................................................6A-117
Installation .......................................................6A-118
Torque Specifications......................................6A-119
Crankshaft Front Oil Seal ...................................6A-120 Components ....................................................6A-120
Removal ..........................................................6A-120
Installation .......................................................6A-121
Torque Specifications......................................6A-122
Special Tools ...................................................6A-122
Crankshaft Rear Oil Seal ...................................6A-123 Components ....................................................6A-123
Removal ..........................................................6A-124
Installation .......................................................6A-124
Special Tools ...................................................6A-125
Crankshaft ..........................................................6A-126 Components ....................................................6A-126
Removal ..........................................................6A-127
Disassembly ....................................................6A-127
Reassembly.....................................................6A-128
Inspection ........................................................6A-128
Installation .......................................................6A-132
Torque Specifications......................................6A-135
Cylinder Block ....................................................6A-136 Components ....................................................6A-136
Removal ..........................................................6A-136
Inspection ........................................................6A-137
Installation .......................................................6A-139
Lubrication System .............................................6A-140 Service Precautions ........................................6A-140
Functional Check ............................................6A-141
Oil Filter Cartridge ..............................................6A-143 Components ....................................................6A-143
Removal ..........................................................6A-143
Installation .......................................................6A-143
Special Tools ...................................................6A-144
Oil Filter Assembly and Oil Cooler .....................6A-145 Components ....................................................6A-145
Removal ..........................................................6A-145
Disassembly ....................................................6A-146
Reassembly.....................................................6A-147 Installation ....................................................... 6A-147
Crank Case and Oil Pan .................................... 6A-150 Components .................................................... 6A-150
Removal .......................................................... 6A-151
Disassembly .................................................... 6A-152
Reassembly .................................................... 6A-152
Installation ....................................................... 6A-153
Torque Specifications...................................... 6A-155
Oil Pump ............................................................ 6A-156 Components .................................................... 6A-156
Removal .......................................................... 6A-156
Disassembly .................................................... 6A-157
Reassembly .................................................... 6A-158
Inspection ........................................................ 6A-158
Installation ....................................................... 6A-159
Oil Pressure SW ................................................ 6A-161 Components .................................................... 6A-161
Removal .......................................................... 6A-162
Inspection ........................................................ 6A-162
Installation ....................................................... 6A-162
Circuit check.................................................... 6A-162
Air Cleaner Element ........................................... 6A-163 Removal .......................................................... 6A-163
Cleaning .......................................................... 6A-163
Installation ....................................................... 6A-163

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-3
ISUZU DIESEL ENGINE (4JK1/4JJ1)
Service Precautions
Matters that require attention in terms of
maintenance
To prevent damage to the engine and ensure reliabilit
y
of its performance, pay attention to the following in
maintaining the engine:
• W hen lifting up or supporting the engine, do not
apply a jack on the oil pan.
W hen taking down the engine on the ground, do not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, fo
r
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between the oil pan and the oil pump strainer, it can
damage the oil pan and the oil strainer.
• W hen the air duct or air cleaner is removed, cove
r
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
• W hen maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, fo
r
instance, watch out for short circuits and others.
•
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
• W hen valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings o
r
crankshaft journal bearings are removed, put them
in order and keep them.
• W hen installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
•
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.

• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• W hen assembling or installing parts, fasten them
with the prescribed tightening torque so that the
y
are installed properly.

Matters that require attention in specifically dealing
with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, the
y
are highly sensitive to foreign matter and, if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.

W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.

Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.


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ISUZU KB P190 2007

6A-96 ENGINE MECHANICAL (4JK1/4JJ1)
34. Inspection / adjustment of valve clearance.
• Refer to procedure for Service Precautions in
this manual.
35. Install the fuel injector. • Refer to procedure for Fuel System in this
manual.
36. Install the baffle cover. • Refer to procedure for Camshaft Assembly in
this manual.
37. Install the cam end gasket. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).



RTW 56ASH020601
Legend
1. Cam End Gasket
2. 2.0 - 3.0 mm (0.078 - 0.118 in)


38. Install the cylinder head cover.
Refer to procedure for Cylinder Head Cover in this manual.

39. Install the glow plug .
Tighten the glow plug to the specified torque.
Tightening torque: 18 N ⋅
⋅⋅
⋅
m (1.8 kg ⋅
⋅⋅
⋅
m / 13 lb ft)
40. Install the glow plug connector.
Tighten the nut to the specified torque.
Tightening torque: 2 N ⋅
⋅⋅
⋅
m (0.2 kg ⋅
⋅⋅
⋅
m / 17 lb in)





RTW 56ASH010201
Legend
1. Glow Plug Connector
2. Nut




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ENGINE MECHANICAL (4JK1/4JJ1) 6A-103
6. Measure the gap between the piston and the inner
diameter of the cylinder block.
Inner diameter of the cylinder block. • Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
• Measurement position (from the upper surface
of the cylinder block) 20 mm (0.79 in)
• Measure the cylinder block inner diamete
r
based on the average value of the actual
measurement values on 6 positions.
Cylinder block inner diameter mm (in)
95.421 – 95.450 (3.75673 – 3.75787)






LNW 61ASH006401
Legend
1. 20 mm (0.79 in)
2. Radial
3. Thrust

Piston outside diameter
• Use a micrometer to measure the outside
diameter of the piston in the right angle to the
piston pin in the designated position.
• Measurement position (from the bottom surface
of the piston) 11.00 mm (0.43 in).






RTW 56ASH023101
Legend
1. 11 mm (0.43 in)

Gap between the piston and the inner
diameter of the cylinder block mm (in)
Standard 0.082 – 0.100 (0.0032 – 0.0039)
NOTE:
If the gap exceeds the standard value, replace the
piston or rebore the cylinder block.
7. Piston replacement • The head of piston has a marking of grade A, B
or C.
• Refer to “Cylinder Block” if over size piston is
installed.

Piston Grade (Service Part) mm (in)
A 95.330 – 95.339 (3.75314 – 3.75350)
B 95.340 – 95.349 (3.75354 – 3.75389)
C 95.350 – 95.359 (3.75393 – 3.75428)


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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-7
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 of the 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 o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.

1. Remove the radiator skid plate.
2. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.




RTW 56BSH000301
3. 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
under pressure.
4. 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.

5. 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 and pour coolant up to fille
r
neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and
reopen the 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 radiator cap.
Otherwise you might get scalded by hot vapor o
r
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.
• After tightening the radiator cap, warm up the
engine at about 2000 rpm. Set heater adjustment
to the highest temperature position, and let the
coolant circulate also into heater water system.
• Check to see the thermostat has opened through
the needle position of the water thermometer,
conduct a 5–minute idling again and stop the
engine.
• W hen the engine has been cooled, check fille
r
neck for water level and replenish if required.
Should extreme shortage of coolant be found,
check the cooling system and reservoir tank hose
for leakage.
• Pour coolant into the reservoir tank up to “MAX"
line.

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FUEL SYSTEM (4JK1/4JJ1) 6C-1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS

Fuel System ....................................................... 6C-2 Service Precautions ........................................ 6C-2
Trouble Shooting ............................................. 6C-8
Fuel System Check ......................................... 6C-10
Fuel Filter Assembly ........................................... 6C-12 Components .................................................... 6C-12
Removal .......................................................... 6C-12
Installation ....................................................... 6C-12
Fuel Filter Cartridge............................................ 6C-13 Removal .......................................................... 6C-13
Installation ....................................................... 6C-13
Fuel Injector........................................................ 6C-14 Components .................................................... 6C-14
Removal .......................................................... 6C-15
Installation ....................................................... 6C-15
Torque Specifications...................................... 6C-18
Fuel Rail Pressure Sensor ................................. 6C-19 Removal .......................................................... 6C-19
Installation ....................................................... 6C-19
Fuel Pressure Limiter ......................................... 6C-20 Removal .......................................................... 6C-20
Installation ....................................................... 6C-20
Fuel Rail Assembly............................................. 6C-21 Components .................................................... 6C-21
Removal .......................................................... 6C-22
Disassembly .................................................... 6C-24
Reassembly..................................................... 6C-24
Installation ....................................................... 6C-24
Torque Specifications...................................... 6C-26
Fuel Supply Pump .............................................. 6C-27 Components .................................................... 6C-27
Removal .......................................................... 6C-28
Installation ....................................................... 6C-33
Torque Specifications...................................... 6C-38
Fuel Sedimenter Switch ..................................... 6C-39 Inspection ........................................................ 6C-39
Fuel Tank and Fuel Cooler ................................. 6C-40 Fuel Tank and Associated Parts ..................... 6C-40
Removal .......................................................... 6C-41
Installation ....................................................... 6C-41

Fuel Gauge Unit ................................................. 6C-42 Fuel Gauge Unit and Associated Parts ........... 6C-42
Removal .......................................................... 6C-43
Installation ....................................................... 6C-43
Special Tool .................................................... 6C-43
Fuel Tube/Quick-Connector Fittings .................. 6C-44 Precautions ..................................................... 6C-44
Cautions During W ork ..................................... 6C-44
Removal .......................................................... 6C-44
Reuse of Quick-Connector.............................. 6C-45
Assembling Advice .......................................... 6C-45
Filler Neck .......................................................... 6C-46 Removal .......................................................... 6C-46
Installation ....................................................... 6C-46
Fuel Filler Cap .................................................... 6C-47 General Description ........................................ 6C-47
Inspection ........................................................ 6C-47

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