ISUZU KB P190 2007 Workshop Repair Manual

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 47
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS








Disassembly Steps-1
1.
W ater bypass hose 5.
Rocker arm shaft and rocker
2.
Thermostat housing with thermo arm
switch 6. Push rod
3.
Cylinder head cover 7.
Cylinder head
4.
Injection nozzle and bracket 8.
Cylinder head gasket

011R300001

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 48 ENGINE MECHANICAL







RTW 46ALF000101

Disassembly Steps-2
9. Crankshaft damper pulley
10. Timing gear case cove
11. W ater pump
12. Idle gear "B" and shaft
13. Idle gear "A"
14. Idle gear shaft
15. Crankshaft timing gear
16. Injection pump

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 49

014R300005

Disassembly Steps-3
17. Flywheel 27. Piston and connecting rod with
18. Crank case upper bearing
19. Oil pump with oil pipe 28. Crankshaft bearing cap with
20. Camshaft timing gear lower bearing
21. Camshaft thrust plate 29. Crankshaft thrust bearing
22. Camshaft 30. Crankshaft
23. Timing gear case 31. Crankshaft upper bearing
24. Cylinder body rear plate 32. Tappet
25. Piston cooling oil jet 33. Crankshaft rear oil seal
26. Connecting rod bearing cap with 34. Cylinder body
lower bearing


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 50 ENGINE MECHANICAL
Disassembly
1. Water Bypass Hose
2. Thermostat Housing with Thermo Switch
3. Cylinder Head Cover
4. Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.







2. Use the injection nozzle remover and the sliding
hammer to remove the injection nozzle together.
Injection Nozzle Remover: 5-8840-2723-0
Sliding Hammer: 5-8840-0019-0



5. Rocker Arm Shaft and Rocker Arm Loosen the rocker arm shaft bracket bolts in numerical
order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bolts in
numerical order a little at a time will adversely affect the
rocker arm shaft.

6. Push Rod



7. Cylinder Head Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.

8. Cylinder Head Gasket
9. Crankshaft Damper Pulley


011R100002
011RY00005
011RY00006
011RY00007

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 51

10. Timing Gear Case Cover The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.

11. Water Pump



12. Idle Gear B and shaft Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.



13. Idler Gear "A" 1. Measure the camshaft timing gear backlash and the crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the idler gear.

NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.



Timing Gear Backlash Measurement
1. Set a dial indicator to the timing gear to measured. Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.

Timing Gear Backlash mm (in)
Standard Limit
0.10 - 0.17 (0.0039 - 0.0067) 0.30 (0.012)
020L200006
020L200020
020RY00019
020RY00020

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 52 ENGINE MECHANICAL


RTW 36ASH000801
Idler Gear "A" End Play Measurement
Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
If the measured value exceeds the specified limit, the
thrust collar must be replaced.

Idler Gear End Play mm (in)
Standard Limit
0.07 (0.0028) 0.2 (0.0079)






4JA1T(L)
040R300009
14. Idle Gear Shaft
15. Crankshaft Timing Gear




4JA1TC/4JH1TC RTW 36ASH001301
16. Injection Pump
1. Remove the injection pump cover (4JA1TC/4JH1TC only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump timing gear free toward the rear of the engine.

NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.









17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0

18. Crank Case

19. Oil Pump With Oil Pipe

015RY00001

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 53
















20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.

Camshaft End Play mm (in)
Standard Limit
0.050 - 0.114
(0.002 - 0.0044) 0.20
(0.008)
















2. Remove the camshaft timing gear bolt from the
camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.


21. Camshaft Thrust Plate


22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.



23. Timing Gear Case

24. Cylinder Body Rear Plate



25. Piston Cooling Oil Jet The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.





014RT0001
901R100008
014RY00019
052RY00001

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A – 54 ENGINE MECHANICAL
26. Connecting Rod Bearing Cap with Lower Bearing
If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.






27. Piston and Connecting Rod with Upper Bearing
1. Remove carbon deposits from the upper portion of the cylinder wall with a scraper before removing the piston
and connecting rod.
2. Move the piston to the top of the cylinder and tap it with a hammer grip or a similar object from the
connecting rod lower side to drive it out.





RTW 36ASH001501
If the connecting rod upper bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.


















28. Crankshaft Bearing Cap with Lower Bearing
1. Measure the crankshaft end play at the center journal of the crankshaft.
Do this before removing the crankshaft bearing caps.
If the measured value exceeds the specified limit, the
crankshaft thrust bearing must be replaced.

Crankshaft End Play mm (in)
Standard Limit
0.10 (0.004) 0.30 (0.012)

014LX056
015LX018
015RY00002

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 55
2. Loosen the crankshaft bearing cap bolts in numerical order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.

29. Crankshaft Thrust Bearing

30.Crankshaft



31. Crankshaft Upper Bearing If the crankshaft upper bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
cylinder number from which it was removed.



32. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.












33. Crankshaft Rear Oil Seal
• W ith the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover: 5-8840-2360-0


34. Cylinder Body
015RY00003
015RY00004
015RY00005
015LV002

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007