2007 ISUZU KB P190 engine

6A-70 ENGINE MECHANICAL (4JK1/4JJ1)
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal. •
Apply engine oil over the peripheral part of the
valve guide and install the oil seal by using a
valve stem seal installer.
Note:
After installing the valve stem oil seal, check if it is
inserted nice and deep and the oil seal is not tilted o
r
the garter spring has not come off.
Special tool
Valve stem seal installer: 5-8840-2817-0





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3. Install the valve spring.
4. Install the spring upper seat.
5. Install the split collar.
• Use a replacer to compress the valve spring
and install the split collar.

Special tool
Valve spring replacer: 5-8840-2818-0 (1)
Pivot assembly: 5-8840-2819-0 (2)





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Note:
Move it up and down to check if it moves smoothly.
6. Install the cylinder head.
Refer to “Cylinder Head”.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-71
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2818-0
Valve spring replacer

5-8840-2819-0
Pivot assembly

5-8840-2817-0
Valve stem seal installer


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ISUZU KB P190 2007

6A-72 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Head
Components





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Legend 1. Fuel Injector Clamp
2. Fuel Injector Assembly
3. Glow Plug
4. Intake and Exhaust Valves 5. Cylinder Head
6. Timing Chain Tension Lever
7. Timing Chain Guide
8. Timing Chain Tensioner

Note:
To avoid electric shock;
Set the switch to the 'OFF' position and disconnect the
negative battery cable before checking or repairing the
fuel injector, wiring or/and connectors. Removal
1. Remove the engine head cover.
2. Drain 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

6A-74 ENGINE MECHANICAL (4JK1/4JJ1)
8. Remove the A/C compressor adjust pulley.








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Legend
1. Bolt
2. Nut


9. Remove the battery.
10. Disconnect the A/C compressor connector and A/C compressor with hose.
11. Remove the A/C compressor bracket.





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Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor






12. 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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13. Remove the intake hose and duct (Standard
output).




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Legend
1. Intake Hose for Intercooler and Intake Throttle
2. Intake Duct for Turbocharger and Air Cleaner
3. Intake Hose for Turbocharger and Intercooler




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-75
14. Disconnect the fuel injector connector (2).
15. Remove the fuel leak off hose (1).







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Note:
Do not reuse the fuel leak off hose clips.
16. Disconnect each connector. • Glow Plug
• EGR Valve
• Throttle Assembly
• Barometric Sensor
• W ater temperature sensor
• Camshaft Position sensor
17. Remove the harness bracket.
18. Remove the cylinder head cover.
Refer to “Cylinder Head Cover”.
19. Remove the EGR cooler heat protector.
20. Remove the EGR cooler water pipe.
21. Remove the EGR cooler.


22. Loosen the nuts of catalyst converter and
turbocharger.



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Legend
1. Catalyst Converter
2. Turbocharger

23. Remove the exhaust front pipe.





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Legend
1. Exhaust Front Pipe (4×2 High Ride Suspension, 4×4)
2. Exhaust Front Pipe (4×2 Except High Ride Suspension)




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ISUZU KB P190 2007

6A-76 ENGINE MECHANICAL (4JK1/4JJ1)
24. Disconnect the Front drive shaft (1). (4×4)





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25. Remove the catalyst converter.

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26. Remove the A/T oil cooler pipe bracket (A/T).





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Legend
1. A/T Oil Cooler Pipe Bracket


27. Remove the turbocharger water return pipe and
hose.






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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-77
28. Remove the turbocharger water feed pipe (1) and
hose.





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29. Remove the turbocharger engine oil feed pipe.
30. Remove the engine oil level gauge guide tube.
31. Remove the fuel return pipe and hose (1).





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32. Remove the fuel injection pipe clip.
33. Remove the fuel injection pipe.
34. Remove the vacuum hose (1).






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35. Remove the noise cover (1).






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ISUZU KB P190 2007