2007 ISUZU KB P190 Harness

6A-26 ENGINE MECHANICAL (4JK1/4JJ1)





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Legend
1. 3.0 - 5.0 mm (0.118 - 0.197 in)
2. 3.0 - 5.0 mm (0.118 - 0.197 in)

3. Install the cylinder head cover.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
• Tighten the nut and bolts in order shown in the
illustration.







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4. Install the blow-by hose.
5. Install the leak-off hose and the fuel injecto
r
connector.
6. Install the harness bracket to the cylinder head cover.
7. Install the intercooler (High output). • Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.


8. Install the intake air duct.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb in)
9. Install the engine cover.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-29
Removal
1. Remove the engine cover.
2. Disconnect the connectors. • Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
3. Remove the A/C belt
4. Remove the A/C compressor.
5. Remove the A/C compressor bracket.
6. Remove the intake air duct (Standard output).





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1. A/C Compressor Bracket
2. Intake Air Duct
3. A/C Compressor

7. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).





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8. Remove the injector leak-off hose (1).



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9. Remove the engine oil level gauge guide tube.
10. Remove the EGR valve.

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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

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-74 ENGINE MECHANICAL (4JK1/4JJ1)
8. Remove the A/C compressor adjust pulley.








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Legend
1. Bolt
2. Nut


9. Remove the battery.
10. Disconnect the A/C compressor connector and A/C compressor with hose.
11. Remove the A/C compressor bracket.





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Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor






12. Remove the intercooler (High output).
• Disconnect the BARO sensor harness
connector (2).
• Remove the two intake hoses.
• Remove the intercooler (1).




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13. Remove the intake hose and duct (Standard
output).




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Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-75
14. Disconnect the fuel injector connector (2).
15. Remove the fuel leak off hose (1).







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Note:
Do not reuse the fuel leak off hose clips.
16. Disconnect each connector. • Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• W ater temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.


22. Loosen the nuts of catalyst converter and
turbocharger.



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Legend
1. Catalyst Converter
2. Turbocharger

23. Remove the exhaust front pipe.





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Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension, 4×4)
2. Exhaust Front Pipe (4×2 Except High Ride Suspension)




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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).






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ISUZU KB P190 2007

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.




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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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ISUZU KB P190 2007