Page 1457 of 6020

ENGINE MECHANICAL (4JK1/4JJ1) 6A-97
47. Install the A/C compressor adjust pulley.
Tighten the bolt and nut to the specified torque.
Tightening torque: bolt 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
Tightening torque: nut 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
RTW 56ASH010601
Legend
1. Bolt
2. Nut
48. Install the A/C compressor and connector.
Tighten the bolt to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
49. Connect each connector. • Barometric Sensor
• EGR Valve
• Glow plug
• W ater temperature sensor
• Camshaft Position sensor
• Throttle Assembly
50. Install the turbocharger engine oil return pipe (1).
Tighten the bolt and nut to the specified torque.
Tightening torque: nut: 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
bolt: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)
RTW 56ASH010701
51. Install the turbocharger engine oil feed pipe (1).
Tighten the bolt to the specified torque.
Tightening torque: bolt 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m/17 lb ft)
RTW 56ASH010801
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ISUZU KB P190 2007
Page 1458 of 6020

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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Page 1459 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-99
67.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
68. Install the intake hose.
RTW 56ASH022501
Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler
69. Install the engine head cover.
70. Replenish the coolant.
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Page 1460 of 6020
6A-100 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications
RTW 76AMF000201
Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME
5-8840-2820-0
Injection pipe oil seal installer
5-8840-0266-0
Angle gauge
5-8840-2816-0
Valve guide remover and installer
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ISUZU KB P190 2007
Page 1461 of 6020
ENGINE MECHANICAL (4JK1/4JJ1) 6A-101
Piston and Connecting Rod
Components
RTW A56ALF001601
Legend 1. Piston Pin Snap Ring
2. Piston Pin
3. Piston Ring 4. Piston
5. Connecting Rod
6. Bearing
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 gear case assembly.
Refer to “Gear Case Assembly”.
6. Remove the oil pan.
Refer to “Oil Pan” .
7. Remove the connecting rod cap.
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Page 1462 of 6020

6A-102 ENGINE MECHANICAL (4JK1/4JJ1)
Note:
Sort the removed bearings according to cylinders b
y
using tags.
LNW 21BSH004901
8. Remove the piston and connecting rod.
• Remove carbon on the upper side of the
cylinder block with a scraper.
• Pull out the piston and connecting rod towards
the cylinder head.
Note:
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod.
9. Remove the connecting rod bearing.
Note:
Sort the bearings in the order of cylinders when reusing
them so that they are not confused with the bearings o
f
other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Note:
Sort the piston rings in the same order as the cylinders
when reusing them so that they are not confused with
the pistons and piston rings of other cylinders.
LNW 21BSH005101
2. Remove the snap ring.
3. Remove the piston pin.
Note:
Sort the disassembled piston pins, pistons and
connecting rods together in the same order as the
cylinders.
LNW 21BSH005201
4. Remove the connecting rods from the piston.
5. Clean the piston. • Carefully clean carbon that is adhered to the
head of the piston and the groove of the piston
ring.
Note:
Do not use a wire brush to clean the piston because it
scratches the piston.
Visually inspect the piston for cracks, burns and othe
r
excessive wear, and replace it if there is an
y
abnormality.
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Page 1463 of 6020

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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Page 1464 of 6020
6A-104 ENGINE MECHANICAL (4JK1/4JJ1)
4JK1
RTW 56ASH025701
Legend
1. Grade
2. Front Mark Cut
4JJ1
LNW 76ASH001401
Legend
1. Grade
2. Front Mark Cut
8. Inspect the piston ring.
• Insert the piston ring horizontally (in the position
it would assume if it were installed to the
piston) into the cylinder block.
LNW 21BSH009301
• Push the piston ring into the cylinder bore until
it reaches the measuring point 1 or 2 where the
cylinder block bore is the smallest.
Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or Measuring Point 2 120 mm (4.7 in).
LNW 61ASH004401
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