2007 ISUZU KB P190 engine

6A-14 ENGINE MECHANICAL (4JK1/4JJ1)

Item Engine model 4JK1 Engine model 4JJ1
Regulator type IC
Starting system Engage magnet type
Starter type Reduction type
Power output V-kW12 – 2.3
Preheat system type Glow plug
Glow plug standard voltage/electric current V-A 12 - 3.5


Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2822-0
Valve clearance
adjust nut wrench

5-8840-2675-0
Compression gauge

5-8840-2815-0
Compression gauge adapter





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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-15
Engine Assembly
Removal
1. Disconnect the negative battery cable.
2. Remove the engine hood.
3. Drain the coolant.
4. Remove the starter motor.
5. Remove the transmission assembly.
Refer to removal procedure for “TRANSMISSION” in this manual.
6. Disconnect the ECM harness connector.
7. Remove the ECM.
8. Remove the air cleaner. • Disconnect the MAF sensor harness connector.
• Remove the intake pipe with the lid of ai
r
cleaner box.
• Remove the air cleaner box.




RTW 76ASH000401
Legend
1. ECM Harness Connector
2. ECM
3. Air Cleaner Box
4. MAF Sensor Harness Connector

9. Remove the intake hose (intercooler - intake
throttle) (Standard output).
10. Remove the intake hose (turbocharger - intercooler) (Standard output).
Remove the harness connector.






RTW 56ASH004001
Legend
1. Intake Hose (intercooler - intake throttle)
2. Intake Hose (turbocharger - intercooler)

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




RTW 76ASH000501
12. Remove the radiator upper hose.
13. Remove the engine harness clip (1).


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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.





RTW 76ASH000701
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).






LTW 56ASH000101
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).




RTW 56ASH004301
Legend
1. Engine Hanger (Front Side)



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ISUZU KB P190 2007

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).

RTW 76ASH001401
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-18 ENGINE MECHANICAL (4JK1/4JJ1)
21.Install the intake hose (intercooler - intake throttle)
(Standard output).





RTW 56ASH004001
22.Install the intercooler (High output).
• Install the intercooler.
• Install the two intake hoses.
• Connect the BARO sensor harness connector.
23.Install the air cleaner.
• Install the intake pipe with the lid of air cleane
r
box.
• Install the air cleaner box.
• Connect the MAF sensor harness connector.
24.Install the ECM.
25.Connect the ECM harness connector.
26.Install the transmission assembly.
Refer to installation procedure fo
r
“TRANSMISSION”.
27.Install the starter motor.
Tightening torque: 94 N ⋅
⋅⋅
⋅
m (9.6kg ⋅
⋅⋅
⋅
m / 69 lb ft)
28.Replenish the coolant.
29.Install the engine hood.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0kg ⋅
⋅⋅
⋅
m / 87 lb in)
30.Connect the negative battery cable.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-19
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2823-0
Engine hanger


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ISUZU KB P190 2007

6A-20 ENGINE MECHANICAL (4JK1/4JJ1)
Engine Mount
Components




RTW 56ALF001801
Legend 1. Nut
2. Bolt (L = 80 mm / 3.15 in)
3. Bolt (L = 30 mm / 1.18 in)
4. Bolt (L = 30 mm / 1.18 in)
5. Engine Foot RH
6. Engine Mount RH
7. Bolt (L = 25 mm / 0.98 in) 8. Bolt (L = 45 mm / 1.77 in)
9. Bolt (L = 30 mm / 1.18 in)
10. Bolt (L = 40 mm / 1.57 in)
11. Bolt (L = 20 mm / 0.78 in)
12. Bolt (L = 100 mm / 3.94 in)
13. Engine Foot LH
14. Engine Mount LH


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-21
Removal
1. Remove the engine hood.
2. Remove the engine cover.
3. Set the hoist and the engine hanger of the special tool (special tool 5-8840-2823-0).
4. Remove the engine mount.
• Before removing the engine mount, hang the engine with a hoist.
• Remove the bolts of the engine mount.
• Hoist the engine assembly slightly to remove the engine mount.











RTW 56ASH004501

Installation
1. Install the engine mount and tighten up with the
specified torque.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
2. Install the engine cover.
3. Install the engine hood. • Check if nothing is wrong with the engine
mount by starting the engine.


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ISUZU KB P190 2007