ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-131
4JK1









RTW 56ASH023901
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5


NOTE:
The crankshaft journal mark No. 4 is stamped on
crankshaft No. 4 journal web front side or rear side. 4JJ1









RTW 56ASH017201
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5

Note:
Be careful about difference in the shape of the bearings
when installing them.







RTW 56ASH017301
Legend
1. Lot No.
2. Size Code



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6A-132 ENGINE MECHANICAL (4JK1/4JJ1)
Bearing Selection Table
mm (in)
Crankshaft
Bearing Housing Crankshaft Journal
Grade
Mark Diamaeter
Grade
Mark Diamaeter Crankshaft
Bearing
Size Code
1 or - 69.927-69.932
(2.7530-2.7532)
2 or - - 69.922-69.927
(2.7528-2.7530) 4 1
73.992-
74.000
(2.9131-
2.9134) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 5
1 or
- 69.927-69.932
(2.7530-2.7532) 2
2 or
- - 69.922-69.927
(2.7528-2.7530) 3 2 73.983-
73.991
(2.9127-
2.9130) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 4
1 or
- 69.927-69.932
(2.7530-2.7532) 1
2 or
- - 69.922-69.927
(2.7528-2.7530) 3 73.975-
73.982
(2.9124-
2.9127) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 2
Installation
1. Install the crankshaft upper bearing.
• The crankshaft upper bearings have an oil hole
and an oil groove. The lower bearings do not.
• Carefully wipe any foreign material from the
upper bearing.
• Locate the position mark applied at
disassembly if the removed upper bearings are
to be reused.
Note:
Do not apply engine oil to the bearing back faces and
the cylinder block bearing fitting surfaces.








015LX125
2. Install the crankshaft assembly.

Apply an ample coat of engine oil to the crankshaft
journals and the crankshaft bearing surfaces
before installing the crankshaft.






015R100004
3. Install the thrust bearing.
•
Apply an ample coat of engine oil to the thrust
bearings before installation. Install the thrust
bearings to the crankshaft center journal.
• The thrust bearing oil grooves must be facing
the sliding faces.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-133






015LX115
4. Install the lower crankshaft bearing.
• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
• Apply the recommended liquid gasket or its
equivalent to the No. 5 crankshaft bearing cap
cylinder body fitting surfaces at the points
shown in the illustration.
Note:
Be sure that the bearing cap fitting surface is completel
y
free of oil before applying the liquid gasket. ThreeBond
1207B Do not allow the liquid gasket to obstruct the
cylinder thread holes and bearings.
ThreeBond 1207B is a fast-drying liquid gasket. Tighten
the bearing caps immediately after applying the gasket.







015LX127

5. Install the bearing cap.
• Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.








015LX128
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence
shown in the illustration.
Crankshaft Bearing Cap Torque N ⋅m (kg ⋅m / lb ft)
166 (16.9 / 122)
Check to see the crankshaft turns smoothly by
rotating it manually.
Note:
Confirm that the crankshaft turns smoothly.








015LX129
6. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".

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6A-134 ENGINE MECHANICAL (4JK1/4JJ1)
7. Install the crank case.
Refer to "Crank Case and Oil Pan".
8. Install the crankshaft gear.





RTW 56ASH017001
9. Install the gear case assembly.
Refer to "Gear Case Assembly".
10.Install the oil pump.
Refer to "Oil Pump".
11.Install the timing gear train.
Refer to "Timing Gear Train".
12.Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
13.Install the front cover.
Refer to "Timing Gear Train".
14.Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
15.Install the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail".
16.Install the cylinder head.
Refer to "Cylinder Head".
17.Install the camshaft assembly.
Refer to "Camshaft Assembly".
18.Install the cylinder head cover.
Refer to "Cylinder Head Cover".
19.Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-135
Torque Specifications




RTW 76AMF000301

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6A-136 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Block
Components




RTW 76ASF000101
Legend
1. Cylinder Block



Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft assembly.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly" in FUEL SYSTEM Section.
6. Remove the oil filter assembly and oil cooler.
Refer to “Oil Filter Assembly and Oil Cooler”.
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
8. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
9. Remove the oil pan.
Refer to "Oil Pan".
10. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
11. Remove the front cover.
Refer to "Front Cover".
12. Remove the timing gear train.
Refer to "Timing Gear Train".
13. Remove the oil pump.
Refer to "Oil Pump".
14. Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the crankshaft.
Refer to "Crankshaft".


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-137
16. Remove the piston cooling pipe.



RTW 76ASH001101
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block. • Conduct color check and hydraulic (o
r
pneumatic) test and if you find a crack or other
damage, replace the cylinder block.





RTW 76ASH000801

5. Cylinder block wear measurement.
• Use a cylinder indicator to measure the cylinde
r
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft.
• Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder block must be replaced o
r
rebored.





012RY00010

Cylinder block bore diameter mm (in)
Standard 95.421 − 95.450 (3.7567 − 3.7579)
Limit 95.48 (3.7590)




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6A-138 ENGINE MECHANICAL (4JK1/4JJ1)
6. Cylinder Reboring.
• Select oversize pistons to fit the largest cylinde
r
bore (previously measured).
• At a point 11 mm (0.43 in) above the lowe
r
edge of the piston skirt, measure the piston
diameter at a right angle to the piston pin.
Calculate the additional cylinder boring required
for each cylinder.





RTW 56ASH023101
Legend
1. 11mm (0.43in)

• Formula
Boring inside diameter = D + C - H ± E
D = Piston outside diameter (Measured Oversize Piston)
C = Piston and cylinder bore clearance 0.082 - 0.100 mm (0.0032 - 0.0039 in)
H = Honing allowance 0.03 mm (0.0012 in) or less
E = Boring machine error

Piston size mm (in)
Standard 95.330 - 95.359 (3.7531 - 3.7543)
Oversize (0.25) 95.580 - 95.609 (3.7629 - 3.7641)
(0.50) 95.830 - 95.859 (3.7728 - 3.7739)
(0.75) 96.080 - 96.109 (3.7826 - 3.7838)


• Bore and hone the individual cylinders as
required.
• Once again, measure the individual cylinde
r
bores.
Each cylinder bore remainder mm (in)
0.02 (0.0008) or less.

7. Cylinder block upper face warpage.
• Use a straight edge (1) and a thickness gauge
(2) to measure the four sides and the two
diagonals of the cylinder block upper face.
• If the measured values exceeds the limit, the
cylinder block must be replaced.
Cylinder block upper face warpage mm (in)
Standard 0.05 or less (0.002 or less)
Limit 0.20 (0.0080)







012R100001


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-139

Cylinder block height (H) (Reference) mm (in)
Standard 259.945 – 260.055 (10.2340 – 10.2384)







012R100009
Installation
1. Install the piston cooling pipe.
• Align the dowel pin of the piston cooling pipe
with the pin hole on the cylinder block and
tighten with the relief valve.
Tightening torque: Relief valve 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
bolts M8 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
bolts M6 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
Note:
Be careful not to deform or damage the piston cooling
pipe nozzle.



RTW 76ASH001101
2. Install the crankshaft.
Refer to "Crankshaft".
3. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".
4. Install the oil pump.
Refer to "Oil Pump".
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
Refer to "Front Cover".
7. Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
8. Install the oil pan.
Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
10. Install the crankshaft front oil seal. Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
12. Install the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly " in Fuel System Section.
13. Install the cylinder head.
Refer to "Cylinder Head".
14. Install the camshaft assembly.
Refer to "Camshaft Assembly".
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover".
16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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6A-140 ENGINE MECHANICAL (4JK1/4JJ1)
Lubrication System
Service Precautions
• During each disassembly, remove the old gasket
adhering to each part and mating part completel
y
using a scraper at the location, where the fluid
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton
and apply the specified new fluid gasket at each
location.
•
Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
• Always, the start and end of the application should
be overlapped.
Explanations on functions and operation
The lubrication system uses the filter element combined
with a full flow bypass, water-cooled oil cooler, and oil
jet for piston cooling.
Lubricating system diagram






LNW 76ALF000201
1. Oil Pump Relief Valve Operating Pressure: 490 – 686 kPa (5.0 – 7.0 kg/cm2 / 71 – 100 psi)
2. Oil Cooler Relief Valve Opening Pressure: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)
3. Oil Filter Relief Valve Opening Pressure: 80 – 120 kPa (0.8 – 1.2 kg/cm2 / 11 – 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 – 49.0 kPa (0.3 – 0.5 kg/cm2 / 4.3 – 7.1 psi)
5. Regulating Valve: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)


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