Isuzu KB P190. Manual — part 212

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL

REMOVAL

EXTERNAL PARTS

RTW36AMF000401

Removal Steps

1. Clutch Assembly or Flex Plate

2. Intake Pipe and Throttle Body

3-1. EGR Pipe

3-2. EGR cooler (EURO III model only)

4. EGR Valve

5. Oil Level Gauge

6. Fuel Filter Assembly (Except EURO III)

7. Fuel Filter Bracket (Except EURO III)

8. Fuel Injection Pipe with Clip

9. Power Steering Oil Pump Bracket

10. Intake Manifold

11. Engine Mounting Bracket and Foot

12. Injection Pump Cover

13. Injection Pump

14. Starter Motor

15. Oil Pressure Warning Switch

16. Fuel Leak Off Pipe

17. Oil Cooler Water Pipe

18. Cooling Fan Pulley

19. Heat Protector

20. Catalytic Converter

21.

Turbocharger

22. Compressor Bracket

23. Vacuum Pump Oil Return Hose

24. Generator and Adjusting Plate

25. Water Inlet Pipe

26. Generator Bracket

27. Oil Cooler with Oil Filter

28. Exhaust Manifold

6A – 44 ENGINE MECHANICAL

Removal

1. Clutch Assembly or Flex Plate

Remove the clutch assembly or the flex plate.

4JA1L

RTW46ASH000801

2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)

1) Loosen hose clamp between turbocharger and intake

duct.

2) Remove the rubber hose.

3) Remove the intake pipe and the throttle body.

(4JA1TC/4JH1TC only)

RTW36ASH000201

4JA1L

025R100008

3-1. EGR Pipe

1) Remove two bolts from the exhaust manifold.

2) Remove two nuts from the EGR valve adapter.

3) Remove the EGR pipe with gaskets.

RTW36ASH000301

3-2. EGR Cooler (EURO III model only)

4JA1TC/4JH1TC

4JH1TC

ENGINE MECHANICAL 6A – 45

4JA1L

RTW46ASH001001

4. EGR

Valve

1) Remove four nuts and remove the EGR valve

assembly from the intake manifold.

2) Remove four bolts and remove the adapter from the

EGR valve assembly.

4JA1TC

RTW46ASH000901

5. Oil Level Gauge

1) Disconnect PCV hose.

2) Remove two bolts and remove the engine oil level

gauge.

6. Fuel Filter Assembly (Except EURO III model)

1) Disconnect fuel hose.

2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)

Remove three bolts and remove the fuel filter bracket with
leak pipe.

4JH1TC

RTW36ASH001201

8. Fuel Injection Pipe with Clip

1) Loosen the injection pipe sleeve nuts at pump side

and nozzle side.
Do not apply excessive force to the injection pipes.

2) Loosen the injection pipe clips.

3) Remove the injection pipe.

NOTE:

Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket

RTW36ASH000701

10. Intake Manifold

1) Disconnect the PCV hose from the cylinder head

cover.

2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot

12. Injection Pump Cover

6A – 46 ENGINE MECHANICAL

13. Injection Pump

Refer to section 6C-19 (Injection Pump)

14. Starter Motor

15. Oil Pressure Warning Switch

16. Fuel Leak Off Pipe

17. Oil Cooler Water Pipe

18. Cooling Fan Pulley

19. Heat Protector

20. Catalytic Converter

21. Turbocharger

1) Disconnect the water hose between thermostat

housing cover and turbocharger.

2) Disconnect the water hose between water inlet pipe

and turbocharger.

3) Remove the oil feed pipe.

4) Remove the oil return pipe.

5) Remove the turbocharger and the gasket.

NOTE:

Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.

22. Compressor Bracket

23. Vacuum Pump Oil Return Hose

24. Generator and Adjusting Plate

25. Water Inlet Pipe

26. Generator Bracket

27. Oil Cooler with Oil Filter

28. Exhaust Manifold

027R100007

037RY00001