2007 ISUZU KB P190 transmission oil

ENGINE MECHANICAL (4JK1/4JJ1) 6A-17



RTW 56ASH004401
Legend
1. Engine Hanger (Rear Side)

27.Hang wire on the engine hanger and hoist to lift up
the engine slightly.
28.Remove the engine mount.
• Remove the fastening bolts for the engine mount
on the engine side.
29.Remove the engine assembly.
• Hoist the engine slightly to provide space to
remove the catalytic converter.
Installation
Notice:
Be absolutely sure that each harness is reconnected to
its original position.
1. Install the engine assembly.
• Hang wire on the engine hanger and hoist to lift up
the engine.
• Operate a hoist slowly to move the engine to the
place where it is to be installed.
• Make the transmission side lower and operate a
hoist slowly, pulling it backward to the engine.
2. Install the engine mount.
Tightening torque: 48 N ⋅
⋅⋅
⋅
m (4.9kg ⋅
⋅⋅
⋅
m / 35 lb ft)
3. Remove the engine hanger.
4. Install the catalytic converter.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8kg ⋅
⋅⋅
⋅
m /20 lb ft)
5. Install the front exhaust pipe. Tightening torque: 67 N ⋅
⋅⋅
⋅
m (6.8kg ⋅
⋅⋅
⋅
m / 49 lb ft)
6. Install the fuel hose on the feed and return sides.
7. Install the vacuum hose of brake master-vac.
8. Install the connector of the shift on the fly (4 ×4).
9. Install the harness of engine, battery and earth to the body side.
10.Install the power steering pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose.
11.Install the A/C compressor.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the connector.
12.Install the A/C generator harness.
• Install the terminal B cable and the harness
connector to the generator.
13.Install the radiator.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5kg ⋅
⋅⋅
⋅
m / 18 lb ft)
14.Install the fan assembly. Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8kg ⋅
⋅⋅
⋅
m / 69 lb in)
15.Install the drive belt.
Refer to removal procedure for drive belt in this manual.
16.Install the fan guide.
17.Install the breather hose and lower hose of the radiator.
18.Install the engine harness clip (1).

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19.Install the radiator upper hose.
20.Install the intake hose (turbocharger -intercooler) (Standard output).
• Install the harness connector.


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ISUZU KB P190 2007

6A-98 ENGINE MECHANICAL (4JK1/4JJ1)
52. Install the turbocharger water feed pipe.





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Legend
1. Turbocharger W ater Feed Pipe


53. Install the turbocharger water return pipe.






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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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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-123
Crankshaft Rear Oil Seal
Components











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Legend 1. Crankshaft Rear Oil Seal
2. Flywheel
3. Driven Plate 4. Clutch Pressure Plate
5. Transmission Assembly



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ISUZU KB P190 2007

6B-14 ENGINE COOLING (4JK1/4JJ1)
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Remove the engine cover.
5. Disconnect radiator inlet hose and outlet hose from the engine.




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6. Remove fan guide (1), clips (2) on both sides and
the bottom lock, then remove lower fan guide (3)
with fan shroud (4).



PTW 46BSH000101

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

7. Disconnect the reserve tank hose (1) from
radiator.
8. Remove bracket (9).




RTW 76BMH000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket

9. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.

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ISUZU KB P190 2007

6B-16 ENGINE COOLING (4JK1/4JJ1)
Installation
1. Install radiator assembly (6) with hose, taking care
not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (9) and secure the radiator.
3. Connect reserve tank hose (1).
4. Install lower fan guide (4).
5. Connect radiator inlet hose and outlet hose (3) to the engine.
6. Install the engine cover.
7. Connect oil cooler hose to automatic transmission.
8. Connect battery ground cable.



RTW 76BMH000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket


9. Pour engine coolant up to filler neck of radiator,
and up to MAX mark of reserve tank.
Important operation (in case of 100% engine coolant change) procedure for filling with engine
coolant.







RTW 76BSH000101
Engine coolant change
Refer to change procedure for Draining and Refilling
Cooling System in this section.

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ISUZU KB P190 2007

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-75
31. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Accelerate the engine between idle and W.O.T. (accelerator pedal full travel) many
times while observing the DTC Information
with a scan tool.
Does the DTC fail this ignition? —
Go to Step 4 Go to Diagnostic
Aids
4 1. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 5 Go to Step 10
5 1. Start the engine.
2. Perform the Cylinder Balance Test with a scan tool.
3. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 12 Go to Step 6
6 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Start the engine and check for high side fuel system leaks at the fuel supply pump and fuel
rail.
Notice: Fuel may leak under the cylinder head
cover from the inlet high pressure line. In such
case, the engine oil level will rise. Inspect for fuel
leakage into the engine oil.
3. Repair any fuel system leaks as necessary.
Did you find and correct the condition? —
Go to Step 14 Go to Step 7
Step
Action Value(s)Yes No

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6E-80 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
21. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the DTC Information with a scan tool.
Is DTC P0089, P0091, P0092, P0192, P0193,
P0201 - P0204, P0219, P1064, P1065, P124B or
P2146 - P2151 set? —
Go to Applicable DTC Go to Step 3
3 1. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Accelerate the engine between idle and W.O.T. (accelerator pedal full travel) many
times while observing the Fuel Rail Pressure
parameter with a scan tool.
Does the Fuel Rail Pressure parameter ever
exceed the specified value? 190 MPa
(27,600 psi)
Go to Step 4 Go to Step 11
4 1. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 5 Go to Step 10
5 1. Start the engine.
2. Perform the Cylinder Balance Test with a scan tool.
3. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 13 Go to Step 6
6 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Start the engine and check for high side fuel system leaks at the fuel supply pump and fuel
rail.
Notice: Fuel may leak under the cylinder head
cover from the inlet high pressure line. In such
case, the engine oil level will rise. Inspect for fuel
leakage into the engine oil.
3. Repair any fuel system leaks as necessary.
Did you find and correct the condition? —
Go to Step 15 Go to Step 7
Step
Action Value(s)Yes No

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ISUZU KB P190 2007

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-227
31. Turn OFF the ignition.
2. Wait 1 minute for the fuel pressure to bleed down from the fuel rail.
3. Turn ON the ignition, with the engine OFF. DO NOT start the engine.
4. Observe the Fuel Rail Pressure (FRP) Sensor parameter with the scan tool.
Does the scan tool indicate within the specified
value? 0.9 to 1.0 volt
Go to Step 4 Go to Step 10
4 1. Turn OFF the ignition.
2. Place the transmission in Neutral and set the parking brake.
3. Start the engine.
4. Accelerate the engine between idle and W.O.T. (accelerator pedal full travel) many
times.
5. Let idle for at least 3 minutes while observing the DTC Information with a scan tool.
Is DTC P1094 set? —
Go to Step 14 Go to Step 5
5 1. Start the engine.
2. Perform the Cylinder Balance Test with a scan tool.
3. Command each injector OFF and verify an engine speed change for each injector.
Is there an injector that does not change engine
speed when commanded OFF? —
Go to Step 12 Go to Step 6
6 1. Check the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: Air in the fuel system will cause fuel rail
pressure fluctuations especially at high engine
speed and load, which may set this DTC.
2. Start the engine and check for high side fuel system leaks at the fuel supply pump and fuel
rail.
Notice: Fuel may leak under the cylinder head
cover from the inlet high pressure line. In such
case, the engine oil level will rise. Inspect for fuel
leakage into the engine oil.
3. Repair any fuel system leaks as necessary.
Did you find and correct the condition? —
Go to Step 15 Go to Step 7
Step
Action Value(s)Yes No

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ISUZU KB P190 2007