Isuzu KB P190. Manual - part 349

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. 

 

 
 

 

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•  Check a crack in the exhaust manifold visually. 

Carefully inspect the turbocharger for abrasion and/or
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 play
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) 

 

 

 
  

 

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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) 

  

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Legend 

  1.  Oil Outlet  

  2.  Oil Intake  

  

 

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.  Waste Gate Actuator 

  2.  Waste 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 

  

6A-38  ENGINE MECHANICAL (4JK1/4JJ1) 

3.  Install the catalyst converter. 

 

Tighten the nuts to the specified torque. 

Tightening torque: 27 N

⋅⋅⋅⋅m (2.8 kg⋅⋅⋅⋅m / 20 lb ft) 

4.  Connect the front propeller shaft flange (Front Diff

Side, 4

×4 only). 

5.  Install the front exhaust pipe. 

 

 Tighten the nuts to the specified torque. 

Tightening torque 

Exhaust Manifold Side: 67 N

⋅⋅⋅⋅m (6.8 kg⋅⋅⋅⋅m / 49 lb ft)

Exhaust Pipe Side: 43 N

⋅⋅⋅⋅m (4.4 kg⋅⋅⋅⋅m / 32lb ft) 

6.  Install the water feed pipe to the turbocharger (1). 

•  Tighten the joint bolts to the specified torque. 

Tightening torque: 54 N

⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft) 

•  Install the pipe bracket and tighten the bolts to

the specified torque. 

Tightening torque: 10 N

⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in) 

•  Install the rubber hose between the water

return pipe and the thermostat housing. 

 

 
 
 

 

 
 

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7.  Install the water return pipe. Tighten the joint bolt

to the specified torque. 

Tightening torque: 54 N

⋅⋅⋅⋅m (5.5 kg⋅⋅⋅⋅m / 40 lb ft) 

 

 

 

 
 
 

 

 
 
 

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8.  Install the turbocharger oil feed pipe to the top of 

the turbocharger. Tighten the joint bolts to the

specified torque. 

Tightening torque (Turbo charger side):  

23 N

⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft) 

Tightening torque (Oil cooler side): 

23 N

⋅⋅⋅⋅m (2.3 kg⋅⋅⋅⋅m / 17 lb ft) 

•  Install the pipe bracket and tighten the bolts to 

the specified torque. 

Tightening torque: (Clip) 

10 N

⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in) 

 

 

 

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Legend 

  1.  Oil Feed Pipe 

 2. Clip 

  3.  Oil Return Pipe 

 

 
 

ENGINE MECHANICAL (4JK1/4JJ1)  6A-39 

9.  Tighten the oil return pipe bolts and nuts to the 

specified torque. 

Tightening torque (Turbocharger side): 

10 N

⋅⋅⋅⋅m (1.0 kg⋅⋅⋅⋅m / 87 lb in) 

Tightening torque (Crank case side): 

25 N

⋅⋅⋅⋅m (2.5 kg⋅⋅⋅⋅m / 18 lb ft) 

10.Install the EGR cooler. 

•  Refer to “EGR Cooler” in EXHAUST SYSTEM

section. 

11. Install the heat protector. 

•  Refer to “EGR Cooler” in EXHAUST SYSTEM

section. 

12. Install the intake hose between the intercooler and

the intake throttle (7). 

13. Install the intake hose between the turbocharger

and the intercooler (9). 

14. 

Install the intake duct between the turbocharger

and the air cleaner (8). 

Tightening torque: 6 N

⋅⋅⋅⋅m (0.6 kg⋅⋅⋅⋅m / 52 lb in) 

15.Replenish the coolant.