2007 ISUZU KB P190 engine mount

6A – 22 ENGINE MECHANICAL
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacturer Remarks
RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C Three Bond
Three Bond
W ater Base
ThreeBond 1141E
ThreeBond 1215 Three Bond
Three Bond
Solvent
ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402 Three Bond
Isuzu
Isuzu
Isuzu
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 262 Loctite
Loctite
Loctite Recommended for
transaxle repairs

* RTV : Room Temperature Vulcanizer

Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface. Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model) Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor.

14. Transmission member 1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing.
2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts.
16. Transmission coupling bolt 1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer) Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007
P1010025


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 40 ENGINE MECHANICAL
140R300001
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).




RTW 46ASH000501
Remove the fuel hose from injection pump (EURO III
only).

27. Exhaust Pipe Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.

28. Engine Assembly
1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine compartment.






Installation
To reassemble, follow the removal steps in the reverse
order.


022R300002
F06R300008

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW 36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure W arning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler W ater Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. W ater Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 45




4JA1L
RTW 46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the EGR valve assembly.





4JA1TC RTW 46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level gauge.


6. Fuel Filter Assembly (Except EURO III model) 1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.




4JH1TC RTW 36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW 36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 66 ENGINE MECHANICAL


Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve
seat insert (2).
NOTE:
The smooth side of the attachment must contact the
valve seat insert.

2. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place.

NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.








Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15 °, 45 °, and 75 ° blades) to minimize
scratches and other rough areas. This will bring the
contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away unblemished
areas of the valve seat surface.









Valve Seat Angle Degree
45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.











3. Apply abrasive compound to the valve seat insert surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.



011LX063
014RY00026
011LX037011LX038

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 77


CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.














Camshaft Journal Diameter
Use a micrometer to measure each camshaft journal diameter
in two directions (1 and 2). If the measured value is less than
the specified limit, the camshaft must be replaced.

Camshaft Journal Diameter mm (in)
Standard Limit
49.945 - 49.975
(1.9663 - 1.9675) 49.60 (1.953)














Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.

Cam Height (H) mm (in)
Standard Limit
42.016 (1.6542) 41.65 (1.640)



















Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the
camshaft must be replaced.

Camshaft Run-Out mm (in)
Standard Limit
0.02 (0.0008) 0.10 (0.004)

014RY00032
014RY00033 014LX092

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 89


RTW36ASH001701
Piston Head Projection Measuring Point
1. Use a dial indicator to measure the piston projection
amount.
2. Refer to the illustration for the piston head projection measuring positions.
All measuring positions should be as close as possible to
the cylinder liner.



3. Measure the points 1, 2, 3, 4 and obtain two differences 1- 2 and 3-4 on each cylinder.
Calculate the average value of the piston head projection
on each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum value described above in accordance with the following
table.

Cylinder Head Gasket Combination mm (in)

Cylinder Head Gasket Combination
4JA1T (L), 4JA1TC mm (in)
Gasket Grade Mark Piston Projection Gasket Thickness
(Reference)
A 0.718-0.773
(0.0283-0.0304) 1.6
(0.0630)
B 0.773-0.819
(0.0304-0.0322) 1.65
(0.0650)
C 0.819-0.874
(0.0322-0.0344) 1.70
(0.0669)


4JH1TC mm (in)
Gasket Grade Mark Piston Projection Gasket Thickness
(Reference)
A 0.215-0.265
(0.0085-0.0104) 1.3
(0.5118)
B 0.265-0.315
(0.0104-0.0124) 1.35
(0.5315)
C 0.315-0.365
(0.0124-0.0144) 1.4
(0.5512)
NOTE:
Difference of the each piston projection and must be
equal or within 0.1 mm (0.004 in).


011RY00027
011RY00030

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007