2007 ISUZU KB P190 belt

ENGINE MECHANICAL (4JK1/4JJ1) 6A-13
Main Data and specifications
Item Engine model 4JK1 Engine model 4JJ1
Type Diesel/4-cycle/water cooling-type in-line DOHC
Combustion chamber type Direct injection type
Cylinder liner type Liner less
Number of cylinders -cylinder
bore × strokes mm (in) 4-95.4 (3.76) × 87.4 (3.44) 4-95.4(3.76) × 104.9(4.13)
Displacement
cc (cu.in) 2499 (152) 2999 (183)
Compression ratio 18.3 17.5
Compression pressure MPa (psi)/rpm 3 (435)/200
Idling speed rpm 700 ± 25
Valve clearance Intake 0.15 (0.006) (cold)
mm (in) Exhaust 0.15 (0.006) (cold)
Ignition type Compressed ignition
Injection order 1 - 3 - 4 - 2
Lubricating system
Lubricating type Pressure delivery type
Oil pump type Gear type
Volume of lubricating oil L (qts) 8.0 (8.5)
Oil filter type Full flow filter (cartridge type)
Oil cooling type Built-in-type, water cooling
Cooling system
Cooling type W ater cooling type
Radiator type Corrugated fin (pressure type)
W ater pump type Centrifugal, belt drive type
Thermostat type W ax-type units
Thermostat valve-opening temperature °C ( °F) 85 (185)
Volume of coolant L (qts) M/T8.7 (9.2) A/T 8.6 (9.1) (incl. radiator)
Fuel system
Injection pump type Fuel supply pump fuel rail type
Fuel injector type Electronic control injector
6-hole
Fuel pump type Into the fuel tank type
Charging system
Generator type AC type
Power output V-A 12 - 90

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ISUZU KB P190 2007

6A-16 ENGINE MECHANICAL (4JK1/4JJ1)

RTW 76ASH001401
14. Remove the breather hose and lower hose of the
radiator.
15. Remove the fan guide.
16. Remove the drive belt.
17. Remove the fan assembly.
18.Remove the radiator.
19.Remove the A/C compressor.





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Legend
1. A/C Compressor Bracket
2. A/C Compressor

• Disconnect the connector.
• Disconnect the A/C generator harness.
• Disconnect the terminal B cable and harness
connector from the generator.

20.Remove the power steering pump.
• Remove the bracket of power steering oil hose
(1).






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21.Remove the harness of engine, battery and earth
from the body side.
22.Remove the connector of the shift on the fly (4 ×4).
23.Remove the vacuum hose of brake master-vac.
24.Remove the front exhaust pipe.
25.Disconnect the fuel hose on the feed and return sides.
26.Install the engine hanger (special tool 5-8840- 2823-0).




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Legend
1. Engine Hanger (Front Side)



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ISUZU KB P190 2007

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



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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

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).





RTW 56ASH024801
Legend
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

ENGINE MECHANICAL (4JK1/4JJ1) 6A-31
Installation
1. Install the intake manifold gasket.
2. Install the intake manifold. • Tighten the nuts and bolts in the orde
r
described in the drawing.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)







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3. Install the throttle assembly and gasket.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
4. Install the vacuum hose of swirl control valve.
5. Install the injection pipe (fuel rail - fuel injector). • It installs sequentially from No. 4 cylinder.
Tightening torque: 29 N ⋅
⋅⋅
⋅
m (3.0 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
6. Install the EGR valve. • Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)
7. Install the engine oil level guide tube.
Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
8. Install the intercooler (High output).
9. Connect the connector of other parts. • Fuel Injector
• Throttle Assembly
• EGR Valve
• Glow Plug
• Barometric Sensor
• A/C Compressor Connector
10. Install the leak-off hose.




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Legend
1. Injector Leek-off Hose

11. Install the intake air duct.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
12.Install the A/C compressor bracket. Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
13.Install the A/C compressor and A/C compresso
r
connector.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
14.Install the A/C belt.
Check the A/C belt tension.
Depress the A/C belt mid-portion with 98 N (10 kg
/
22 lb) force.
Standard deflection: 7.6 - 9.2 mm (0.29 - 0.36 in)



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15. Install the engine cover.



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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

ENGINE MECHANICAL (4JK1/4JJ1) 6A-57
6. Remove the M6 bolt from the idle gear A.
7. Install the gear case cover. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).


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Legend
1. Apply the liquid gasket

• Install the gasket in slot of the gear case cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)




RTW 56ASH012101
8. Install the vacuum pump.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the oil pipe (feed side and return side) o
f
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
9. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Connect the bracket (1) of power steering oil
hose.




LTW 56ASH000101

10. Install the crank pulley.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
11. Install the A/C compressor drive belt and fan belt.
Refer to drive belt tension check procedure fo
r
Heating and air conditioning and Engine cooling in
this manual.
12. Install the cooling fan.
13. Install the fan guide.
14. Install the radiator upper hose.
15. Replenish the engine coolant.



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-73
3. Remove the radiator upper hose.








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4. Remove the fan guide.




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


5. Remove the cooling Fan.





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6. Rotate the crankshaft to make the No.1 cylinder
meet the compression top dead center (TDC).





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Legend
1. TDC

7. Remove the A/C compressor drive belt.

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ISUZU KB P190 2007