2007 ISUZU KB P190 engine

6A-30 ENGINE MECHANICAL (4JK1/4JJ1)


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11. Remove the injection pipes.
• Remove sequentially from No.1 cylinder.
12. Disconnect the vacuum hose of swirl control valve (1).










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13. Remove the throttle assembly and gasket.




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Legend
1. Throttle Assembly
2. Intake Manifold

14. Remove the intake manifold.






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15. Remove the intake manifold gasket.


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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

6A-32 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications




RTW 76AMF000101


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-33
Turbocharger and Exhaust Manifold (Standard Output)
Components



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Legend 1. Turbocharger Assembly
2. Exhaust Manifold
3. Heat Protector
4. Catalyst Converter
5. Oil Feed Pipe 6. Oil Return Pipe
7. Intake Hose for Intercooler and Intake Throttle
8. Intake Duct for Turbocharger and Air Cleaner
9. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

6A-34 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Loosen the radiator drain plug to drain coolant.
2. Remove the engine cover.
3. Remove the intake hose from the intercooler and intake throttle.
4. Remove the intake hose from the turbocharge
r
and the intercooler.
5. Remove the air intake duct from the turbocharge
r
and the air cleaner.
6. Remove the EGR cooler.
Refer to “EGR Cooler” in EXHAUST SYSTEM Section.
7. Remove the oil feed pipe.
8. Remove the oil return pipe. • Loosen clamp (1) of A/T oil cooler pipe.






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9. Remove the water feed and return pipe.




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Legend
1. Oil Feed Pipe
2. EGR Cooler
3. W ater Feed Pipe
4. W ater Return Pipe
5. Oil Return Pipe

10. 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)

11. Disconnect the front propeller shaft flange (1)
(Front Diff Side, 4 ×4 only).





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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-35
12. Remove the catalyst converter.



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13. Remove the turbocharger from the exhaust
manifold.




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Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger

14. Remove the exhaust manifold.
• Remove the 8 nuts from the exhaust manifold.






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ISUZU KB P190 2007

6A-36 ENGINE MECHANICAL (4JK1/4JJ1)
Inspection
• Inspection of the exhaust manifold. Inspect the
plane surface of the plane on which the
manifold and the cylinder head are to be
installed.

Manifold installation plane surface mm (in)
Standard 0.3 (0.01) or lower
Limit 0.5 (0.02)
Note:
If the plane surface exceeds the limit, replace it.




LNW 21BSH022301
• Check a crack in the exhaust manifold visually.
Carefully inspect the turbocharger for abrasion and/o
r
excessive wear. Make any necessary adjustments,
repairs, and/or part replacements.

Wheel shaft axial play
Use a dial gauge to measure the wheel axle shaft pla
y
when a force of 12 N (1.2 kg / 2.6 lb) is alternately
applied to both sides of the compressor wheel.

Axial play mm (in)
Standard 0.03 − 0.06 (0.0012 − 0.0024)
Limit 0.09 (0.0035)




LNW 21BSH022201

Wheel shaft and bearing clearance
Use a dial gauge to measure the clearance between the
wheel shaft and the bearing.

Clearance mm (in)
Standard 0.056 − 0.127 (0.0022 − 0.0050)
Limit 0.14 (0.0055)

LNW 21BSH022301
Legend
1. Oil Outlet
2. Oil Intake



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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-37
Waste gate operation
1. Remove the hose from the waste gate actuator.
2. Install the pressure gauge (general tool). Refer to the illustration.





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Legend
1. W aste Gate Actuator
2. W aste Gate Hose
3. Pressure Gauge (General Tool)

3. Use the pressure gauge pump to apply pressure
(load) to the waste gate actuator (the engine must
be off).
4. Note the pressure at which the control rod moves 2 mm (0.078 in). This pressure must be within the
specified limit.

Control rod pressure range: kPa (mmHg / psi)
109 − 118 (818 − 885 / 16 − 17)

5. Inspect the hose for cracks and other damage.
Replace the hose if necessary.
6. Do not apply a pressure of more than 120 kPa (900 mmHg) to the waste gate actuator.

Installation
1. Put the gasket in to install the exhaust manifold.
• Tighten up with the 8 nuts according to the
order given in the figure.
Tightening torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
Note:
Do not tighten up too much because it hampers
expansion and contraction due to the heat from the
manifold.









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2. Install the gasket and turbocharger to the exhaust
manifold. Tighten the nuts to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)




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Legend
1. Exhaust Manifold
2. Gasket
3. Turbocharger


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ISUZU KB P190 2007