2007 ISUZU KB P190 drain bolt

POWER-ASSISTED STEERING SYSTEM 3B-17
Power Steering Pump (4JH1-TC, 4JA1-T)
Power Steering Pump and Associated Parts


RTW 53BMF000401
Legend (1) Pump Assembly
(2) Suction Hose
(3) Flexible Hose
(4) Bolt
(5) Bracket


Removal
1. Remove the drive belt.
2. Remove the pulley
3. Place a drain pan below the pump.
4. Disconnect the suction hose.
5. Disconnect the flexible hose.
6. Remove the power steering fixing bolt and remove the pump assembly.

Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
Torque: 40 N·m (4.1 kgf·m/30 lb·ft)
2. Install the flexible hose.
Tighten the nut to specified torque.
Torque: 20 N·m (2.0 kgf·m/14 lb·ft)
3. Install the pulley and tighten the bolt to the specified torque.
Torque: 28 N·m (2.9 kgf·m/21 lb·ft)
4. Install the drive belt.
5. Connect the suction hose, then fill and bleed system.
Refer to Bleeding the Power Steering System in this section.

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ISUZU KB P190 2007

3B-22 POWER-ASSISTED STEERING SYSTEM
Power Steering Pump (4JJ1-TC, 4JK1-TC)
Power Steering Pump and Associated Parts

RTW 53BMF000201
Legend
(1) Pump Assembly
(2) Flexible Hose
(3) Bolt
(4) Suction Hose
(5) Nut


Removal
1. Remove the cooler compressor drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing nut, and remove the pump assembly.

Installation
1. Install the pump assembly. Tighten the fixing nut to
the specified torque.
Torque: 25 N·m (2.5 kgf·m/18 lb·ft)
2. Install the flexible hose.
Tighten the bolts to the specified torque.
Torque: 8 N·m (0.8 kgf·m/69 lb·in)
3. Install the cooler compressor drive belt.
4. Connect the suction hose, then fill the power steering fluid and bleed the power steering system.
Refer to Bleeding the Power Steering System in this section.

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ISUZU KB P190 2007

REAR AXLE 4B-53
2) Axle Case Leakage

Checkpoint Trouble Cause Countermeasure

Tighten the drain plug and/or
replace the gasket(s)Loose drain plug and/or
defective gasket(s)
NG
Reapply the liquid gasket
Tighten the bolts to the
specified torque
Clean the air breather
Liquid gasket seal bad
Loose bolts
Air breatherClogged air breather
Differential carrier
Replace the axle caseAxle caseCracked axle case
NG
NG
NG
NG
OK
OK
OK
Oil filler and drain plug



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-37
















20. Differential Assembly
(1) Clean the faces of the front axle case and differential carrier.

Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2)
Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
26 (2.7/20)
(3) Install the axle shaft assemblies as instructed earlier in this section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just belo
w
the filler hole.
Lubricant capacity liter (US/UK gal)
1.4 (0.37/0.31)



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ISUZU KB P190 2007

SHIFT ON THE FLY SYSTEM 4C2-5



Disassembly
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear





412RW 017
10. Snap Ring
Remove snap ring from front axle case by using a snap ring pliers.
11.Inner Shaft
Take out inner shaft from front axle case.





412RW 016
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring pliers.





412RW 015
13.Inner Shaft Bearing
Remove inner shaft bearing by using a special tool and press.
Remover : 5-8840-2197-0
NOTE:
Be careful not to damage the shaft.

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ISUZU KB P190 2007

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the turbocharger? —

Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? —
Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged? — Replace the
damaged gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? —
Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? —
Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? —
Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? —
Repair or
replace the oil feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? —
Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/ 10W –30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? —
Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 39

18. Radiator 1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.
• TPS connector
• Oil pressure switch connector
• Thermo switch connector
• Injection pump connector
• Engine earth
• Thermometer unit connector
• TDC sensor
2) Remove the clips fixing engine harness.
P1010009

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ISUZU KB P190 2007

6A – 42 ENGINE MECHANICAL

ENGINE REPAIR KIT




RTW 36ALF000601

Removal Steps
1. Cylinder head gasket
2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket
11. Vacuum pump gasket
12. W ater pump O-ring
13. W ater outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal

NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.

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ISUZU KB P190 2007