2007 ISUZU KB P190 Engine

6A-22 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 56ALF003801


Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2823-0
Engine hanger



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-23
Cylinder Head Cover
Components






RTW 76ALF000101
Legend 1. Oil Filler Cap
2. Oil Filler Cap Gasket
3. Cylinder Head Cover
4. Bolt 5. Head Cover Mounting Rubber
6. Nozzle Seal Cover
7. Head Cover Gasket
8. Nut



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ISUZU KB P190 2007

6A-24 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the engine cover.
2. Remove the intake air duct (3) (Standard output).
3. Remove the harness bracket (6).




RTW 56ASH025001
Legend
1. Blow-by Hose
2. Leak-off Hose
3. Intake Air Duct
4. Fuel Injector Connector
5. Leak-off Hose
6. Harness Bracket

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




RTW 76ASH000501
5. Disconnect the fuel injector connector (2).
6. Remove the fuel leak off hose (1).




RTW 76ASH000101
Note: Do not reuse the clips (1).



LNW 76ASH002101
7. Disconnect the blow-by hose.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-25
8. Remove the cylinder head cover.




LNW 71BSH000401
9. Remove the nozzle seal cover from the cylinder
head cover.
• Remove from the lower side of cylinder head
cover.
10. Remove the cam end gasket (1). • Remove the liquid gasket that has adhered to
cylinder head completely.




RTW 56ASH020501

Installation
1. Install the nozzle seal cover.
• Insert from the lower side of cylinder head
cover.
•
Apply soapy water or engine oil to the surface
of cylinder head cover side.
• Insert the nozzle seal cover as far as it will go.
2. Install the cam end gasket. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent) and mount.



RTW 56ASH020601
Legend
1. Cam End Gasket
2. Apply The Liquid Gasket
3. 2.0 - 3.0 mm (0.079 - 0.118 in)

• Apply attaching cam end gasket.
Apply the liquid gasket (ThreeBond TB-1207B or equivalent).


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ISUZU KB P190 2007

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





RTW 56ASH022701
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.







RTW 56ASH004801
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-27
Intake Manifold
Components (Standard Output)




RTW 76ALF000201
Legend 1. Intake Duct
2. Throttle Assembly
3. Intake Manifold Gasket 4. Intake Manifold
5. EGR Valve Assembly Gasket
6. EGR Valve Assembly



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ISUZU KB P190 2007

6A-28 ENGINE MECHANICAL (4JK1/4JJ1)
Components (High Output)




RTW 76ALF000301
Legend 1. Intake Duct
2. Intake Throttle
3. Intake Throttle Gasket
4. Intake Manifold Gasket 5. Intake Manifold
6. EGR Valve Assembly Gasket
7. EGR Valve Assembly
8. Bracket




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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).





RTW 76ASH000501
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