2007 ISUZU KB P190 engine

EXHAUST SYSTEM 6F – 17

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.






















Turbocharger pressure check
1. Remove the hose between the waste gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To compressor outlet pipe.
3. Start the engine and gradually increase the engine speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to approximately 141.3 Kpa (1060 mmHg).
Pressure Gauge : 5-8840-0075-0
150RY00030

Waste gate operation check
1. Remove the hose between the waste gate and the compressor outlet pipe.
2. Connect the pressure gauge. To waste gate actuator.
3. Check to see that the rod begins to move when a pressure of approximately 118 Kpa (885 mmHg) is
applied to the waste gate.
Note:
Do not apply a pressure greater than 150Kpa (1125
mmHg) to the waste gate during this check.
150RY00031
Unit Inspection (Remove Turbo. from engine)
Check to see the pressure required to move the control
rod 2 mm is within the limits shown below.
Kpa/mmHg
4JH1TC 134.8/1011
4JA1TC 147.7/1108



150RY00032
Contact the “ISUZU MOTORS LIMITED” Dealer service
department or “IHI SERVICE FACILITY” for major repairs
and maintenance.
Important wheel shaft end play and bearing clearance
standards and limits are included below for your reference.

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ISUZU KB P190 2007

6H – 6 ACCELERATOR CONTROL




RTW 46HMH000201

























Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90 °.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if
any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should not be damage or
corrosion.

Installation
1. Install the accelerator control cable to accelerator control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90 °
until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.

NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.




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PAGE
Section 6A Engine Mechanical .................................................................................... 1361
Section 6B Engine Cooling .......................................................................................... 1524
Section 6C Fuel System ............................................................................................... 1542
Section 6D Engine Electrical ....................................................................................... 1589
Section 6E Engine Control System ............................................................................ 1618
Section 6F Exhaust System ........................................................................................ 1986
Section 6H Engine Speed Control System ................................................................ 1998
SECTION 6
ENGINE
TA BLE OF CONTENTS
ENGINE 6
4JK
1/4J J1 MODELS

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-1
SECTION 6A
ENGINE MECHANICAL (4JK1/4JJ1)
TABLE OF CONTENTS

ISUZU DIESEL ENGINE (4JK1/4JJ1) ................ 6A-3
Service Precautions ........................................ 6A-3
Trouble Shooting ............................................. 6A-8
Main Data and Specifications .......................... 6A-13
Special Tools ................................................... 6A-14
Engine Assembly................................................ 6A-15 Removal .......................................................... 6A-15
Installation ....................................................... 6A-17
Special Tools ................................................... 6A-19
Engine Mount ..................................................... 6A-20 Components .................................................... 6A-20
Removal .......................................................... 6A-21
Installation ....................................................... 6A-21
Torque Specifications...................................... 6A-22
Special Tools ................................................... 6A-22
Cylinder Head Cover .......................................... 6A-23 Components .................................................... 6A-23
Removal .......................................................... 6A-24
Installation ....................................................... 6A-25
Intake Manifold ................................................... 6A-27 Components (Standard Output) ...................... 6A-27
Components (High Output) ............................. 6A-28
Removal .......................................................... 6A-29
Installation ....................................................... 6A-31
Torque Specifications...................................... 6A-32
Turbocharger and Exhaust Manifold (Standard Output) ........................................... 6A-33
Components .................................................... 6A-33
Removal .......................................................... 6A-34
Inspection ........................................................ 6A-36
Installation ....................................................... 6A-37
Torque Specifications...................................... 6A-40
Turbocharger (High Output) ............................... 6A-41 Components .................................................... 6A-41
Removal .......................................................... 6A-42
Inspection ........................................................ 6A-43
Installation ....................................................... 6A-44
Torque Specifications...................................... 6A-45
Exhaust Manifold (High Output) ......................... 6A-46 Components .................................................... 6A-46
Removal .......................................................... 6A-47
Inspection ........................................................ 6A-47
Installation ....................................................... 6A-47
Torque Specifications...................................... 6A-49
Timing Gear Train .............................................. 6A-50 Components .................................................... 6A-50
Removal .......................................................... 6A-51
Disassembly .................................................... 6A-53
Reassembly .................................................... 6A-53
Inspection ........................................................ 6A-54
Installation ....................................................... 6A-55
Torque Specifications...................................... 6A-58
Camshaft Assembly ........................................... 6A-59 Components .................................................... 6A-59
Removal .......................................................... 6A-60
Disassembly .................................................... 6A-61
Reassembly .................................................... 6A-63
Installation ....................................................... 6A-64
Torque Specifications...................................... 6A-66
Special Tools................................................... 6A-66
Valve Stem Seal and Valve Spring .................... 6A-67 Components .................................................... 6A-67
Removal .......................................................... 6A-68
Inspection ........................................................ 6A-69
Installation ....................................................... 6A-70
Special Tools................................................... 6A-71
Cylinder Head..................................................... 6A-72 Components .................................................... 6A-72
Removal .......................................................... 6A-72
Disassembly .................................................... 6A-81
Inspection ........................................................ 6A-83
Reassembly .................................................... 6A-87
Installation ....................................................... 6A-89
Torque Specifications...................................... 6A-100
Special Tools................................................... 6A-100
Piston and Connecting Rod................................ 6A-101 Components .................................................... 6A-101
Removal .......................................................... 6A-101
Disassembly .................................................... 6A-102
Reassembly .................................................... 6A-107
Installation ....................................................... 6A-108
Torque Specifications...................................... 6A-110

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6A-2 ENGINE MECHANICAL (4JK1/4JJ1)
Special Tools ...................................................6A-110
Flywheel .............................................................6A-111 Components ....................................................6A-111
Removal ..........................................................6A-111
Inspection ........................................................6A-113
Installation .......................................................6A-113
Torque Specifications......................................6A-115
Special Tools ...................................................6A-115
Gear Case Assembly .........................................6A-116 Components ....................................................6A-116
Removal ..........................................................6A-117
Installation .......................................................6A-118
Torque Specifications......................................6A-119
Crankshaft Front Oil Seal ...................................6A-120 Components ....................................................6A-120
Removal ..........................................................6A-120
Installation .......................................................6A-121
Torque Specifications......................................6A-122
Special Tools ...................................................6A-122
Crankshaft Rear Oil Seal ...................................6A-123 Components ....................................................6A-123
Removal ..........................................................6A-124
Installation .......................................................6A-124
Special Tools ...................................................6A-125
Crankshaft ..........................................................6A-126 Components ....................................................6A-126
Removal ..........................................................6A-127
Disassembly ....................................................6A-127
Reassembly.....................................................6A-128
Inspection ........................................................6A-128
Installation .......................................................6A-132
Torque Specifications......................................6A-135
Cylinder Block ....................................................6A-136 Components ....................................................6A-136
Removal ..........................................................6A-136
Inspection ........................................................6A-137
Installation .......................................................6A-139
Lubrication System .............................................6A-140 Service Precautions ........................................6A-140
Functional Check ............................................6A-141
Oil Filter Cartridge ..............................................6A-143 Components ....................................................6A-143
Removal ..........................................................6A-143
Installation .......................................................6A-143
Special Tools ...................................................6A-144
Oil Filter Assembly and Oil Cooler .....................6A-145 Components ....................................................6A-145
Removal ..........................................................6A-145
Disassembly ....................................................6A-146
Reassembly.....................................................6A-147 Installation ....................................................... 6A-147
Crank Case and Oil Pan .................................... 6A-150 Components .................................................... 6A-150
Removal .......................................................... 6A-151
Disassembly .................................................... 6A-152
Reassembly .................................................... 6A-152
Installation ....................................................... 6A-153
Torque Specifications...................................... 6A-155
Oil Pump ............................................................ 6A-156 Components .................................................... 6A-156
Removal .......................................................... 6A-156
Disassembly .................................................... 6A-157
Reassembly .................................................... 6A-158
Inspection ........................................................ 6A-158
Installation ....................................................... 6A-159
Oil Pressure SW ................................................ 6A-161 Components .................................................... 6A-161
Removal .......................................................... 6A-162
Inspection ........................................................ 6A-162
Installation ....................................................... 6A-162
Circuit check.................................................... 6A-162
Air Cleaner Element ........................................... 6A-163 Removal .......................................................... 6A-163
Cleaning .......................................................... 6A-163
Installation ....................................................... 6A-163

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-3
ISUZU DIESEL ENGINE (4JK1/4JJ1)
Service Precautions
Matters that require attention in terms of
maintenance
To prevent damage to the engine and ensure reliabilit
y
of its performance, pay attention to the following in
maintaining the engine:
• W hen lifting up or supporting the engine, do not
apply a jack on the oil pan.
W hen taking down the engine on the ground, do not make the bearing surface of the oil pan touch
the ground directly. Use a wooden frame, fo
r
example, to support the engine with the engine
foot and the flywheel housing.
Because there is only a small clearance between the oil pan and the oil pump strainer, it can
damage the oil pan and the oil strainer.
• W hen the air duct or air cleaner is removed, cove
r
the air intake opening to prevent foreign matter
from getting into the cylinder. If it gets
contaminated, it can considerably damage the
cylinder and others while the engine is operating.
• W hen maintaining the engine, never fail to remove
the battery earth cable. If not, it may damage the
wire harness or electrical parts. If you need
electricity on for the purpose of inspection, fo
r
instance, watch out for short circuits and others.
•
Apply engine oil to the sliding contact surfaces of
the engine before reassembling it. This ensures
adequate lubrication when the engine is first
started.
• W hen valve train parts, pistons, piston rings,
connecting rods, connecting rod bearings o
r
crankshaft journal bearings are removed, put them
in order and keep them.
• W hen installing them, put them back in the same
location they were removed from.
• Gaskets, oil seals, O-rings, etc. must be replaced
with new ones when the engine is reassembled.
•
As for parts where a liquid gasket is used, remove
an old liquid gasket completely and clean it up
thoroughly so that no oil, water or dust is clinging
to them. Then, apply the designated liquid gasket
to each place anew before assembly.

• Surfaces covered with liquid gasket must be
assembled within 5 minutes of gasket application.
If more than 5 minutes has elapsed, remove the
existing liquid gasket and apply a new liquid
gasket.
• W hen assembling or installing parts, fasten them
with the prescribed tightening torque so that the
y
are installed properly.

Matters that require attention in specifically dealing
with this engine.
Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, the
y
are highly sensitive to foreign matter and, if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.

W hen servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.
• Before beginning the service procedure, wash the
fuel line and the surrounding area.
• Perform the service procedures with clean hands.
Do not wear work gloves.
• Immediately after removing the fuel hose and/o
r
fuel pipe, carefully tape vinyl bags over the
exposed ends of the hose or pipe.
• If parts are to be replaced (fuel hose, fuel pipe,
etc.) do not open the new part packaging until
installation.

Work procedure
• The fuel opening must be quickly sealed when
removing the fuel pipe, injection pipe, fuel injector,
fuel supply pump, and fuel rail.
• The eyebolts and gasket must be stored in a clean
parts box with a lid to prevent adhesion of foreign
matter.
• Fuel leakage could cause fires. Therefore, afte
r
finishing the work, wipe off the fuel that has leaked
out and make sure there is no fuel leakage afte
r
starting the engine.


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6A-4 ENGINE MECHANICAL (4JK1/4JJ1)
How to read the model (This illustration is 4JK1 engine)





RTW 56ALF004701
Legend
1. Engine Model (Stamped)
2. Engine Number (Stamped)
3. Front

Explanation of functions and operations
Electronic engine control
W ith the control unit, the range from injection to ai
r
intake/exhaust, including fuel injection quantity, injection
timing, intake air restriction, EGR, and idling rpm, is
controlled.
Piston
The piston is aluminum-alloy and a thermal flow piston
with a strut cast, while the combustion chamber is a
round reentrant type.

Cylinder head
The cylinder head is aluminum-alloy and there are 4
valves per cylinder. The angular tightening method o
f
the cylinder head bolt further increases reliability and
durability.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-5
EGR system
Based upon data, including water temperature, engine
speeds or engine loads, it is controlled via Engine
Control Module (ECM) to purify exhaust by recycling
part of it.
Its main components include an EGR valve, an EGR
cooler and various sensors.

Connecting rod cap bolt
The angular tightening method of the connecting rod
cap bolt further increases reliability and durability.

Fuel rail-type electronic control injection system
The fuel rail-type electronic control injection system is
composed of a fuel supply pump that sets the target
pressure of high-pressure fuel and supply it, a fuel rail
that measures such high-pressure fuel and a fuel
injector that turns it into a fine spray and injects it. Each
is controlled via ECM based upon various signals, while
injection timing or fuel injection quantity is controlled
under every possible driving condition.

Fuel injector
The fuel injector is a 6-hole nozzle that adjusts fuel
injection quantity or injection timing by opening o
r
closing an electromagnetic valve on the head of the fuel
injector.
ECM corrects the dispersion of fuel injection quantit
y
between fuel injector according to ID code data in
memory. At the replacement of fuel injector, ID code
data should be stored in ECM.


Fuel filter with sedimenter
It is a fuel filter with sedimenter that gets rid of water by
making use of the difference in specific gravity between
light oil and water, which comes with an indicator that
notifies you that it is filled with water.

Preheating system
The preheating system consists of the ECM, the glow
relay, glow plugs and the glow indicator lamp. The
preheating system is operated when the engine coolant
temperature is low, and makes the engine easy to start.

Lubrication system
It is an oil filter with full-flow bypass, which uses a
water-cool oil cooler and oil jet to cool the piston.

Functional inspection
Inspection/adjustment of valve clearance 1. Inspection of valve clearance
• Remove the fuel injector harness assembly.
• Remove the leak off hose.
• Remove the cylinder head cover.
• Rotate the crankshaft to make the No.1
cylinder meet the compression top dead cente
r
(TDC).





RTW 76ASH001301
Legend
1. TDC



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