2007 ISUZU KB P190 engine oil

ENGINE MECHANICAL (4JK1/4JJ1) 6A-41
Turbocharger (High Output)
Components




RTW 76ALF000401
Legend 1. Turbocharger Assembly Gasket
2. Turbocharger Assembly
3. Turbocharger Heat Protecter
4. W ater Feed and Return Pipe Gasket
5. W ater Feed and Return Pipe 6. Oil Feed and Return Pipe Gasket
7. Oil Feed and Return Pipe
8. Catalyst Converter Gasket
9. Catalyst Converter



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ISUZU KB P190 2007

6A-42 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Drain the engine coolant.
2. Remove the engine cover.
3. Remove the intercooler. • Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




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4. Disconnect the vacuum hose from the
turbocharger actuator.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the front exhaust pipe.




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Legend
1. Gasket
2. Front Exhaust Pipe (4 ×2 High Ride Suspention,
4 ×4)
3. Gasket
4. Front Exhaust Pipe (4 ×2 Except High Ride
Suspention)

7. Remove the heat protector of the turbocharger.
• Remove the mud cover of front RH fender skirt
(4×4 only).
• Loosen the bolt of Turbocharger bracket.
8. Remove the catalyst converter.
9. Remove the turbocharger bracket.
10. Remove the oil feed and return pipe.
11. Remove the water feed and return pipe from the turbocharger.






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12. Remove the turbocharger from the exhaust
manifold.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-43
Inspection
Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft pla
y
when a force of 12 N (1.2kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)




LNW 21BSH022201

Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW 21BSH022301
Legend
1. Oil Outlet
2. Oil Intake

Actuator operation
1. Install a vacuum pump (2) to the actuator (1).







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2. Operate the vacuum pump and apply vacuum
pressure to the actuator.

W orking vacuum pressure kPa (mmHg / psi)
52.8 (396 / 7.66)









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ISUZU KB P190 2007

6A-44 ENGINE MECHANICAL (4JK1/4JJ1)
3. Place a vernier caliper on the end of the control
rod of actuator. Release the vacuum pressure and
check the control rod moves. Measure the length
of the control rod moving.

Standard length mm (in)
12 (0.48)

Installation
1. Install the gasket and the turbocharger to the
exhaust manifold. Temporarily tighten nuts.
2. Install the oil feed and return pipe and temporaril
y
tighten.
3. Tighten the turbocharger nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
4. Tighten the oil feed and return pipe bolts and nuts to the specified torque.
Tightening torque (Turbocharger side): 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
Tightening torque (Crank case side): 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
5. Install the water feed and return pipe to the turbocharger.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
6. Install the heat protector to the turbocharger. Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
7. Install the turbocharger bracket.
8. Install the catalyst converter.
Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
9. Install the mud cover of front RH fender skirt (4 ×4
only).
10. Install the front exhaust pipe.
Tighten the nuts to the specified torque.
Tightening torque
Exhaust Manifold Side: 67 N⋅
⋅⋅
⋅m (6.8 kg⋅
⋅⋅
⋅m / 49 lb ft)
Exhaust Pipe Side: 43 N
⋅
⋅⋅
⋅
m (4.4 kg ⋅
⋅⋅
⋅
m / 32lb ft)
11. Install the intercooler. • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
12. Install the intake duct between the turbocharge
r
and the air cleaner.
Tightening torque: 6 N ⋅
⋅⋅
⋅
m (0.6 kg ⋅
⋅⋅
⋅
m / 52 lb in)
13.Replenish the coolant.


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ISUZU KB P190 2007

6A-50 ENGINE MECHANICAL (4JK1/4JJ1)
Timing Gear Train
Components






RTW 56ALF001101
Legend 1. Oil Pump Gear
2. Crankshaft Gear
3. Idle Gear D
4. Exhaust Camshaft Gear
5. Intake Camshaft Gear
6. Idle Gear D Sprocket
7. Timing Chain 8. Injection Pump Sprocket
9. Injection Pump Gear
10. Idle Gear A
11. Vacuum Pump Gear
12. Power Steering Oil Pump Gear
13. Idle Gear C




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-51
Removal
1. Partially drain the engine coolant.
2. Remove the radiator upper hose.






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3. Remove the fan guide.




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Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling fan and fan pulley.




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5. Remove the A/C compressor drive belt and fan
belt.
6. Remove the crank pulley.
7. Remove the power steering pump with hose.




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Legend
1. Power Steering Pump
2. Nut

• Disconnect the bracket (1) of power steering oil
hose.


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ISUZU KB P190 2007

6A-52 ENGINE MECHANICAL (4JK1/4JJ1)





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8. Remove the vacuum pump.
• Remove the vacuum pipe bracket and vacuum
pipe.
• Remove the oil pipe (feed side and return side)
of vacuum pump.






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9. Remove the front cover.



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10. Install the M6 bolt to the idle gear A.
11. Remove the idle gear A and idle gear A flange, idle gear A shaft.





RTW 56ASH011301


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-55
• If the measurement exceeds the limit, replace
either the idle gear or the shaft.
Clearance between the idle gear A and the shaft
mm (in)
Standard 0.020 − 0.062 (0.0007 − 0.0024)
Limit 0.200 (0.0079)

Clearance between the idle gear C and the shaft
mm (in)
Standard 0.025 − 0.075 (0.0010 − 0.0030)
Limit 0.200 (0.0079)


LNW 21BSH003601
Installation
1. Install the crankshaft gear.
2. Install the idle gear C. •
Apply engine oil over the part where the gear of
the idle gear shaft is to be put together.

•
Apply engine oil to the bolt screw thread and
seat, and temporarily tighten together with the
flange (tighten fully in later process).





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3. Install the idle gear A.
4. Tighten sub gear setting bolt. • Use the M6 bolts and lever to turn sub gear to
right direction until it aligns with the M6 bolt
hole between idle gear A and sub gear.
• Tighten the M6 bolt to a suitable torque to
prevent the sub gear from moving.






RTW 56ASH011501



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ISUZU KB P190 2007