engine ISUZU KB P190 2007 Workshop Repair Manual

6A-80 ENGINE MECHANICAL (C24SE)
Cylinder Head (continued)
Valve System

Valve lifter valve play compensator
(hydraulic)

Valve rotators
(inlet or outlet) outlet

Valve play
(warm or cold) inlet mm 0
outlet mm 0

Cylinder head bottom, face parallelism mm 0.05
Valve Dimensions
C24SE
A in mm B in
mm C(diameter in mm) and identification mark D
1) 2) Normal K Oversize K1
0.075 Oversize K2
0.150 Oversize A
0.250
Inlet valve
104.2 103.8 41.8 7.012
6.998 7.087
7.073 7.162
7.148 7.262
7.248 44
°
Outlet valve 104.0 103.6 36.5 6.992
6.978 7.087
7.053 7.142
7.128 7.242
7.228 44
°
Valve stem
bore - 7.050
7.030 7.125
7.105 7.200
7.180 7.300
7.280 -
1) Production
2) Customer service
The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)
only



Camshaft
2.4L
Identification letter K

Colour code Normal size -
0.1mm undersize violet

Radial runout mm 0.03

End play mm 0.09 to 0.21

Cam lift Inlet and outlet valve mm 6.67




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ENGINE MECHANICAL (C24SE) 6A-81
Grinding Dimension for Camshaft Bearing Position Bearing Bearing journal
diameter in mm Diameter
in housing
normal -0.1mm normal -0.1mm
1 42.470 42.455 42.370
42.355 42.525
42.425 42.500
42.400

2 42.720 42.705 42.620
42.605 42.775
42.750 42.675
42.650

3 42.970 42.955 42.870
42.855 43.025
43.000 42.925
42.900

4 43.220 43.205 43.120
43.105 43.275
43.250 43.175
43.150

5 43.470 43.455 43.370
43.355 43.525
43.500 43.425
43.400

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6A-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block
Cylinder Grinding and Piston Dimensions
Size Cylinder bore dia. in mm Cylinder to Related piston dia. in mm Piston head
Crankshaft co- efficient
housing
co-efficient
over to over to
Production
(2.4L) 1 87.48
87.49 87.49
87.50 99
00 87.46
87.47 87.47
87.48 99
00
Customer service (2.4L) - 87.99 88.00 0+0.5 87.97 87.98 7+0.5
Piston diameter must be measured at the position "D".
*inclusive


Cylinder Bore
Rebore cylinder Permissible oversize to 0.5mm (see parts
microfiche)

After reboring, invalidate original crankcase
housing coefficient and drive in new oversize
coefficient

Permissible out-of-round: 0.013mm
Permissible taper: 0.013mm
Measure out-of-round in bore at 4 different
heights
Piston projection above upper edge of cylinder block 0.40mm

Piston
Type Recessed pistons

Clearance For short-blocks and cylinder blocks with complete pistons, the clearance is 0.02 to
0.04mm

For replacement (oversize), depending on
available pistons, a clearance of 0.02 to
0.04mm is permissible

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ENGINE MECHANICAL (C24SE) 6A-83
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180 °

Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation W hen installing piston pins,
heat con-rods to approx.
280 °C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.


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6A-84 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)

Crankshaft jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
Normal size
Bearing journal and colour code from 57.9820 green
to 57.9885
> 57.9885 brown
to 57.9950
25.900
25.850
48.988
48.970
26.580
26.460
26.390
26.338

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown-662N
green-663N brown-655N
green-658N

Crankshaft
jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.25mm Undersize for Production and Customer Service
Bearing journal and colour code from 57.7320 green/
to 57.7385 blue
> 57.7385 brown/
to 57.7450 blue
26.100
26.050
48.738
48.720
26.580
26.460

Bearing shell identification mark Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown/blue-664 A
green/blue-655 A brown/blue-657 A
green/blue-658 A

Crankshaft jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.50mm Undersize Customer Service
Bearing journal and colour code from 57.4820 green/
to 57.4885 blue
> 57.4885 brown/
to 57.4950 blue
26.300
26.250
48.488
48.470
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown/white-666 B
green/white-667 B brown/blue-659 B
green/blue-660 B








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ENGINE MECHANICAL (C24SE) 6A-85
Piston Pins
Dimensions
Length mm
Diameter mm
61.5 21
Type Shank-fit in con-rod
Clearance
In piston mm
In con-rod mm 2.4L
0.010 to 0.015 0
Installation See operation “Con-rod, Replace”


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6A-86 ENGINE MECHANICAL (C24SE)
Con-rod
Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g.
As the con-rods have no counterweights, re-working is not possible.
Con-rods must be replaced only as a set.

Crankshaft Grinding Dimensions
Crankshaft
bearing journals
I, II, III, IV, V Guide bearings
III

Con-Rod bearing journals
1 to 4
Con-rod
diameter
in
mm/colour code width
in mm diameter
in mm width
in mm width
in mm
Standard Size for Production and Service

from 57.974
white
to 57.981
over 57.981 green
to 57.988
over 57.988 brown
to 57.995 26.002

25.950
48.988
48.970
26.580
26.450
26.390
26.338





Crankshaft, Cylinder Block (continued)
Crankshaft and con-rod journal Permissible out-of-round:
0.04mm

Out-of-round Permissible variation of
middle crankshaft bearing
journal when seating shaft into
cylinder block: 0.03mm

Permissible end play 0.05 to 0.152mm

Permissible main bearing play Bearing I to V0.015 to 0.04mm

Permissible con-rod play 0.006 to 0.031mm

Permissible con-rod and play 0.07 to 0.24mm





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ENGINE MECHANICAL (C24SE) 6A-87






Crankshaft, Cylinder Block (continued)
Flywheel
Starter ring gear Before fitting, heat ring gear to 180 °C -
230 °C

Lateral run-out Permissible lateral run-out of installed
starter ring gear to flywheel: 0.5mm

Precision turning Permissible removal of material in clutch disc lining surface area: 0.3mm

In order to achieve the functional
relationship again after removal of material,
the same removal of material must take
place on the fore part of the flywheel
(contact for clutch assembly)

Dimension A: 2.1 to 2.2mm

Cylinder block
Top deck flatness mm 0.05
Cylinder block height mm 280 ±0.075


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6A-88 ENGINE MECHANICAL (C24SE)
Recommended Torque Values
N⋅m (kgf ⋅m)

Bearing cover to cylinder block ........................................................................................ 60
1) 6.1 +40 ° to 50 °
Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission .......................................................... 60
2) 6.1
Bracket for engine damping block to engine block .......................................................... 60 6.1
Bracket for pump/compressor to engine block ................................................................ 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft ................................................................................... 50 5.1
Clamping bracket for alternator to intake manifold .......................................................... 25 2.5
Clamping bracket to alternator ......................................................................................... 25 2.5
Con-rod bearing cap to con-rod ....................................................................................... 35
1) 3.5 +45 ° to 60 °
Crankshaft pulley bolts ..................................................................................................... 2 0 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90 ° +90 °
+90 °
Engine damping block to engine bracket ......................................................................... 85 8.7
Engine damping block to side member ............................................................................ 52
1) 5.3
Exhaust manifold to cylinder head ................................................................................... 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
N⋅m (kgf ⋅m)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30° to 45 °
Front exhaust pipe to exhaust manifold ........................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket .................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block ........................................................................... 6
2) 0.6
Oil intake pipe to oil pump ................................................................................................ 8 0.8
Oil pan to cylinder block ................................................................................................... 8
2)3) 0.8
Bearing bridge to cylinder block ....................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ........................................................................................ 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................. 30 3.2
Spark plugs in cylinder head ............................................................................................ 20 2. 3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side .............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head ............................................................................... 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover ................................................................................................... 4 0.4
Toothed belt rear cover .................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................. 20 2.3 (M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7 (M12) ............................................................................ 60 6.1
W ater pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

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ENGINE MECHANICAL (C24SE) 6A-89
SPECIAL SERVICE TOOLS
ITEM NO. ILLUSTRATION PART NO. PART NAME
4


5-8840-2634-0



Aligner
2


5-8840-2593-0


Cutter set
3


5-8840-2594-0


Spring Compressor
4


5-8840-0451-0


Installer
5


5-8840-2596-0


Distance Gauge
6


5-8840-0455-0


Assembly Sleeves
7

5-8840-2597-0

Installer
8


5-8840-0457-0


Remover / Installer
10


5-8840-0468-0


Remover / Installer
11


5-8840-0459-0


Installer

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