Isuzu KB P190. Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-3

ISUZU DIESEL ENGINE (4JK1/4JJ1)

Service Precautions

Matters that require attention in terms of
maintenance

To prevent damage to the engine and ensure reliability
of its performance, pay attention to the following in
maintaining the engine:

• When lifting up or supporting the engine, do not

apply a jack on the oil pan.

When taking down the engine on the ground, do

not make the bearing surface of the oil pan touch

the ground directly. Use a wooden frame, for

example, to support the engine with the engine

foot and the flywheel housing.

Because there is only a small clearance between

the oil pan and the oil pump strainer, it can

damage the oil pan and the oil strainer.

• When the air duct or air cleaner is removed, cover

the air intake opening to prevent foreign matter

from getting into the cylinder. If it gets

contaminated, it can considerably damage the

cylinder and others while the engine is operating.

• When maintaining the engine, never fail to remove

the battery earth cable. If not, it may damage the

wire harness or electrical parts. If you need

electricity on for the purpose of inspection, for

instance, watch out for short circuits and others.

• Apply engine oil to the sliding contact surfaces of

the engine before reassembling it. This ensures

adequate lubrication when the engine is first

started.

• When valve train parts, pistons, piston rings,

connecting rods, connecting rod bearings or

crankshaft journal bearings are removed, put them

in order and keep them.

• When installing them, put them back in the same

location they were removed from.

• Gaskets, oil seals, O-rings, etc. must be replaced

with new ones when the engine is reassembled.

• As for parts where a liquid gasket is used, remove

an old liquid gasket completely and clean it up

thoroughly so that no oil, water or dust is clinging

to them. Then, apply the designated liquid gasket

to each place anew before assembly.

• Surfaces covered with liquid gasket must be

assembled within 5 minutes of gasket application.

If more than 5 minutes has elapsed, remove the

existing liquid gasket and apply a new liquid

gasket.

• When assembling or installing parts, fasten them

with the prescribed tightening torque so that they

are installed properly.

Matters that require attention in specifically dealing
with this engine.

Holes or clearances in the fuel system, which serve as
a passage of fuel, including the inside of the injector,
are made with extreme precision. For this reason, they
are highly sensitive to foreign matter and, if it gets in, it
can lead to an accident on the road, for instance; thus,
make sure that foreign matter is prevented from getting
in.

When servicing the fuel system, every precaution must
be taken to prevent the entry of foreign material into the
system.

• Before beginning the service procedure, wash the

fuel line and the surrounding area.

• Perform the service procedures with clean hands.

Do not wear work gloves.

• Immediately after removing the fuel hose and/or

fuel pipe, carefully tape vinyl bags over the

exposed ends of the hose or pipe.

• If parts are to be replaced (fuel hose, fuel pipe,

etc.) do not open the new part packaging until

installation.

Work procedure

• The fuel opening must be quickly sealed when

removing the fuel pipe, injection pipe, fuel injector,

fuel supply pump, and fuel rail.

• The eyebolts and gasket must be stored in a clean

parts box with a lid to prevent adhesion of foreign

matter.

• Fuel leakage could cause fires. Therefore, after

finishing the work, wipe off the fuel that has leaked

out and make sure there is no fuel leakage after

starting the engine.

Isuzu KB P190. Manual - part 340