lock ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (C24SE) 6A-23
Toothed Belt Tension, Adjust
(Engines with toothed belt tension
roller)
Removal
Refer to 6A-21. Toothed Belt and Timing check and removal
steps.


Adjust
1. Loosen the fastening bolt of the toothed belt tension roller.
2. Turn the toothed belt tension roller at adjustment eccentric (1) in the direction of arrow (counterclockwise),
until pointer (2) comes to the right stop.
3. If necessary tighten the fastening bolt of toothed belt tension roller.


4. Rotate the crankshaft twice (720
°) in the engine
rotational direction until marks (2) and (1) align again.


5. Turn the eccentric in the direction of arrow (clockwise)
until pointer (1) and notch (2) are positioned to suit age of
toothed belt.
6. Rotate the crankshaft twice (720 °) in the engine
rotational direction again and correct adjustment if
necessary.

Installation
Refer to 6A-21. Toothed Belt and Timing check and installation
steps.


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ENGINE MECHANICAL (C24SE) 6A-25









Adjust
Loosen the fastening bolt of the toothed belt tension roller and
turn the adjustment eccentric in the direction of arrow
(clockwise) until pointer (1) comes to the left stop.
Remove the toothed belt.

Installation
1. Install a new toothed belt while keeping tension side taut.

Adjust
Toothed belt tension - see operation " Toothed Belt Tension".


2. Install the toothed belt to the cover.
3. Install the crankshaft pulley while counterholding on the fastening bolt of toothed belt drive gear.
4. Install the fan shroud.
5. Install the fan belt.
6. Install the V-belt for A/C.
7. Install the V-belt for power steering.
8. Install the fan.
9. Install the belts to the bracket for alternator.



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ENGINE MECHANICAL (C24SE) 6A-31






Installation
1. Install toothed belt rear cover.
2. Install camshaft pulley while counterholding at camshaft hex head.
3. Install camshaft housing cover.

Tighten (Torque)
Toothed belt rear cover to oil pump and camshaft housing - 6
N ⋅m/4 lbf ft.
Camshaft housing cover to housing - 6 N ⋅m (0.6 kgf ⋅m).
Camshaft pulley to camshaft - 45 N ⋅m (4.6 kgf ⋅m).




4. Install toothed belt drive gear to crankshaft - 130 N
⋅m
(13.3 kgf ⋅m).
5. Install toothed belt according to the operation "Toothed Belt".


Toothed Belt Tension Roller
Removal
1. Mark operating direction of toothed belt.
2. Remove toothed belt according to the operation "Toothed Belt”.
3. Remove toothed belt tension roller (1) from oil pump.










Installation
1. Install toothed belt tension roller and make sure that the locking lever (1) engages in the guide lugs (arrowed) on
the oil pump housing.
2. Install toothed belt according to the operation "Toothed Belt" with paying attention to the operating direction of
toothed belt.

Tighten (Torque)
Toothed belt tension roller to oil pump - 25 N ⋅m (2.5 kgf ⋅m)


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6A-36 ENGINE MECHANICAL (C24SE)



















Clean
All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface
according to the corresponding operations.

Installation
1. Install cylinder head sealing with marking "OBEN/TOP"
facing upwards and to right side of engine.
2. Install cylinder head on cylinder block.
3. Install hydraulic valve lash adjuster, pressure parts and rocker arm - molybdenum disulphate paste.
4. Install camshaft housing-Sealing Compound TB-1207C or equivalent.

Important!
Use new cylinder head bolts.
Screw in bolts until they rest on cover.




Torque - Angle Method
Cylinder head to cylinder block - 25 N ⋅m (2.5 kgf ⋅m)
Further turn angle 90 °+90 °+ 90 °.
Tighten cylinder head bolts from inside outwards. In four
stages in a spiral pattern.








5. Install rear toothed belt cover onto camshaft housing.
6. Install toothed belt and apply tension according to the corresponding operation.

Tighten (Torque)
Camshaft timing gear to camshaft - 45 N ⋅m (4.6 kgf ⋅m)




7. Install camshaft housing cover and front toothed belt
cover.
8. Install cable connections, all hoses and lines onto cylinder head.
9. Adjust accelerator cable for free of play.
10. Install V-belt according to the corresponding operation.
11. Install air intake hose.
12. Install front exhaust pipe.
13. Install ground cable onto battery.
14. Fill up cooling system and bleed according to the corresponding operation.

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6A-40 ENGINE MECHANICAL (C24SE)




Removal
6. Remove the camshaft housing cover and camshaft pulley by counter-holding at the hex head of camshaft.




Removal
7. Remove the fastening bolts from camshaft housing.



Removal
8. Remove the exhaust pipe from exhaust manifold.
9. Loosen the cylinder head bolts spirally from the outside inwards (first 1/4, then 1/2 revolution).



Removal
1. Remove the camshaft housing from cylinder head.
2. Remove the cam followers, thrust pieces and hydraulic valve lifters.
Note the allocation.
3. Remove the cylinder head.




Clean
Sealing surfaces, bores and threads of cylinder head bolts.

Inspection
Check cylinder head and cylinder block for plane surfface-see
operations “Cylinder Head, Check for Plane Surface” and
“Cylinder Block, Check for Plane Surface.”


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-41


Installation
1. Install the cylinder head gasket.
Mark "OBEN/TOP" on top and turn it towards timing side of engine.
2. Place cylinder head on cylinder block.

1
2
3


Installation
1. Insert the hydraulic valve lifters (3), thrust pieces (2) and
cam followers (1) with MoS2 paste.
Note allocation.
2. Apply a bead of Sealing Compound TB1207C to sealing surface of cylinder head.
3. Install the camshaft housing on cylinder head.



Torque-Angle Method
Cylinder head and camshaft housing with new cylinder head
bolts to cylinder block.

Cylinder head bolts in sequence shown.



Installation
1. Install the rear toothed belt cover to camshaft housing.
2. Install the camshaft pulley to camshaft.
3. Install the camshaft housing cover to housing.




Installation
1. Install the toothed belt on camshaft pulley.
See operation "Timing Adjust".
2. Install the front toothed belt cover.


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ENGINE MECHANICAL (C24SE) 6A-45




Valve Seating, Mill
Place cylinder head on block of wood.
Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-8840-
2593-0.
Valve seat-45 °, side face, upper correction-30 °, side face
(arrows on cutter).
Valve seat width:

Inlet-1.0 to 1.5 mm/0.04 to 0.06 in.
Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.




Inspection
Valve stem projection-use 5-8840-2596-0.

Important!
If dimension “A” is exceeded, use new valves.
Check valve stem projection again. If dimension “A” is
exceeded, replace cylinder head.








Cylinder Head, Overhaul
Cylinder head disassembled.

Valve, Grind
Important!
Ensure that there are no crater-like burns on the valve cone.

Regrinding possible once or twice.
Grinding of valve stem end is not permitted.

Angle at valve head-44 °




Inspection
Check valve stem projection as shown 5-8840-2596-0.


Valve, Grind in
Lubricate valve stem, use fine-graining grinding paste.

Lift up valve from seat rythmically using valve grinding tool (1)
for distribution of grinding paste.




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6A-46 ENGINE MECHANICAL (C24SE)





Inspection
Check contact pattern ( I) on valve seat and in cylinder head.

Clean
Valves, valve guides, cylinder head.

Flywheel

Removal
1. Remove transmission and clutch.
2. Remove flywheel while locking with 5-88400-446-0.







Torque - Angle Method
Flywheel to crankshaft - 65 Nm/6.5 kgf ⋅m.+30 ° to 45 °

Important!
Use new bolts.
Do not apply grease to the thread.

Installation
1. Install clutch and transmission.


Component Parts
Flywheel and Ring gear. (Manual Transmission)


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ENGINE MECHANICAL (C24SE) 6A-49







Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf xm.




RTW 46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 ×4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.















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ISUZU KB P190 2007

6A-50 ENGINE MECHANICAL (C24SE)

Clean
Sealing surfaces.





013RW 004










Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.

Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4 ×4 model
only]).
8. Install the crossmember.

Tighten (Torque)
Oil intake pipe to oil pump -8N ⋅m (0.8 kgf ⋅m)
Oil intake pipe bracket to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil pan to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
Bearing bridge to cylinder block – 8 N ⋅m (0.8 kgf ⋅m)



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