torque ISUZU KB P190 2007 Workshop Repair Manual

6A-90 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Head Gasket Combination mm (in)






RTW 76ASH000301




RTW 56ASH009501
Note:
Difference of each piston projection must be equal o
r
within 0.05 mm (0.002 in).
7. Select the gear case gasket. • This should be of the same grade as the
cylinder gasket.

8. Apply liquid gasket (ThreeBond 1207B o
r
equivalent) at the two locations.



RTW 56ASH020901
Legend
1. 2 - 3 mm (0.079 - 0.118 in)
2. 3 - 4 mm (0.118 - 0.157 in)


9. Install the cylinder head within 5 minutes application of the liquid gasket.
10. Install the cylinder head. • W ipe the cylinder head lower face.
• Install the cylinder head, adjusting the dowel o
f
the cylinder block.
11. Install the cylinder head bolt. • Please use new cylinder head bolt.
• Use a torque wrench and angle gauge to
tighten the head bolts in the order described in
the drawing.
Tightening torque: 1st step = 70 N ⋅
⋅⋅
⋅
m (7.1 kg ⋅
⋅⋅
⋅
m / 51 lb ft)
2nd step = 70 N ⋅
⋅⋅
⋅
m (7.1 kg ⋅
⋅⋅
⋅
m / 51 lb ft)
3rd step = 60° (degrees)
4th step = 60° (degrees)


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-91




RTW 56ASH009701
Special tool
Angle gauge: 5-8840-0266-0


12. Install the cylinder head gear case bolt and nut.
• Tighten the nuts (1) and bolts (2) to the
specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)




RTW 56ASH020801
13. Install the water by pass pipe.
Apply soapy water to the O-ring.
Tighten the bolt to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)

14. Install the vacuum hose (1).






RTW 66ASH003101
15. Install the rocker arm shaft assembly.
• Apply the engine oil.
• Attach the rocker arm shaft assembly in
sequence from No.1 to No.4.
Tightening torque: 21 N ⋅
⋅⋅
⋅
m (2.1 kg ⋅
⋅⋅
⋅
m / 15 lb ft)



RTW 56ASH012201
Legend
1. Exhaust Rocker Arm Shaft Assembly
2. Bolt (Long)
3. Bolt (Short)
4. Intake Rocker Arm Shaft Assembly
5. Front



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ISUZU KB P190 2007

6A-92 ENGINE MECHANICAL (4JK1/4JJ1)
16. Install the chain guide bolt from cylinder head.
Tighten the bolt to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)



RTW 56ASH019501
17. Install the tension lever.
18. Rotate the crankshaft to make the No.1 cylinde
r
meet the compression top dead center (TDC).





RTW 76ASH001301
Legend
1. TDC



19. Install the timing chain with idle gear D.
• Apply the engine oil bolt thread and seat.
Tightening torque : 59 N ⋅
⋅⋅
⋅
m (6.0 kg ⋅
⋅⋅
⋅
m/43 lb ft)





RTW 56ASH021801
• Align the timing marks at two locations as
shown.


RTW 56ASH020301
Legend
1. Timing Chain
2. Timing Mark
3. Blue Link
4. Yellow Link




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-93
20. Install the timing chain tension lever pivot.
Tighten the bolt to the specified torque.
Tightening torque: 27 N ⋅
⋅⋅
⋅
m (2.8 kg ⋅
⋅⋅
⋅
m / 20 lb ft)





RTW 56ASH019401
21. Attach the hook of the timing chain tensioner.
• Hold the latch (3) depressed. Insert the plunge
r
(2). Attach the hook (5) to the pin (1) to hold the
plunger in place.



RTW 56CSH004401
22. Install the timing chain tensioner (1) and the
gasket (2).
Tighten the nuts (3) to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)




RTW 56CSH001701
23. Unlock the tensioner hook.
• Press the place of the arrow in the figure.
• The hook is opened. The plunger pushes the
tension lever.




RTW 56ASH020401

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ISUZU KB P190 2007

6A-94 ENGINE MECHANICAL (4JK1/4JJ1)
24. Install the camshaft assembly.
• Align timing mark on intake camshaft and
exhaust camshaft to idle gear D.




RTW 56ASH007001
Legend
1. Exhaust Camshaft Gear
2. Intake Camshaft Gear
3. Idle Gear D


25. Install the camshaft bearing cap.
•
Apply engine oil to all of the cylinder head
journals.






RTW 56ASH013801
Tightening torque: 18 N ⋅
⋅⋅
⋅
m (1.8 kg ⋅
⋅⋅
⋅
m / 13 lb ft)

26. Align mark on camshaft to mark on camshaft
bearing cap.
• Align mark (1) on intake camshaft and exhaust
camshaft to mark of bearing cap.





RTW 56ASH006901
27. Remove the lock bolt from the camshaft gear.
28. Turn the crank pulley two rotation (720 °CA).
• Align mark on camshaft to mark on camshaft
bearing cap.




RTW 56ASH020701
Legend
1. Exhaust Camshaft Gear
2. Intake Camshaft Gear
3. Idle Gear D




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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-95


RTW 56ASH020301
Legend
1. Timing Chain
2. Timing Mark
3. Blue Link
4. Yellow Link


29. Apply liquid gasket (ThreeBond TB-1207C or
equivalent) to timing chain cover upper (1).
• Attach cover within 5minutes after the
application of gasket.







RTW 56CSH002101

30. Install the timing chain cover upper (1).
Tighten the bolt to the specified torque. •
Apply loctite #262 or equivalent to the bolt and
stud threads of cylinder side head side (2).
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)





RTW 76CSH001201
31. Apply liquid gasket (ThreeBond TB-1207C or
equivalent) to the timing chain cover lower (1).
• Attach the cover within 5 minutes of applying
the liquid gasket.






RTW 56CSH002301
32. Install the timing chain cover lower.
Tighten the bolts and nuts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
33. Install the noise cover to the timing chain cove
r
lower.
Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)


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ISUZU KB P190 2007

6A-96 ENGINE MECHANICAL (4JK1/4JJ1)
34. Inspection / adjustment of valve clearance.
• Refer to procedure for Service Precautions in
this manual.
35. Install the fuel injector. • Refer to procedure for Fuel System in this
manual.
36. Install the baffle cover. • Refer to procedure for Camshaft Assembly in
this manual.
37. Install the cam end gasket. • Apply the liquid gasket (ThreeBond TB-1207B
or equivalent).



RTW 56ASH020601
Legend
1. Cam End Gasket
2. 2.0 - 3.0 mm (0.078 - 0.118 in)


38. Install the cylinder head cover.
Refer to procedure for Cylinder Head Cover in this manual.

39. Install the glow plug .
Tighten the glow plug to the specified torque.
Tightening torque: 18 N ⋅
⋅⋅
⋅
m (1.8 kg ⋅
⋅⋅
⋅
m / 13 lb ft)
40. Install the glow plug connector.
Tighten the nut to the specified torque.
Tightening torque: 2 N ⋅
⋅⋅
⋅
m (0.2 kg ⋅
⋅⋅
⋅
m / 17 lb in)





RTW 56ASH010201
Legend
1. Glow Plug Connector
2. Nut




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ENGINE MECHANICAL (4JK1/4JJ1) 6A-97
47. Install the A/C compressor adjust pulley.
Tighten the bolt and nut to the specified torque.
Tightening torque: bolt 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
Tightening torque: nut 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)






RTW 56ASH010601
Legend
1. Bolt
2. Nut


48. Install the A/C compressor and connector.
Tighten the bolt to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
49. Connect each connector. • Barometric Sensor
• EGR Valve
• Glow plug
• W ater temperature sensor
• Camshaft Position sensor
• Throttle Assembly

50. Install the turbocharger engine oil return pipe (1).
Tighten the bolt and nut to the specified torque.
Tightening torque: nut: 25 N ⋅
⋅⋅
⋅
m (2.6 kg ⋅
⋅⋅
⋅
m/19 lb ft)
bolt: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m/87 lb in)





RTW 56ASH010701
51. Install the turbocharger engine oil feed pipe (1).
Tighten the bolt to the specified torque.
Tightening torque: bolt 23 N ⋅
⋅⋅
⋅
m (2.3 kg ⋅
⋅⋅
⋅
m/17 lb ft)




RTW 56ASH010801


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6A-100 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 76AMF000201

Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME
5-8840-2820-0
Injection pipe oil seal installer
5-8840-0266-0
Angle gauge
5-8840-2816-0
Valve guide remover and installer



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ENGINE MECHANICAL (4JK1/4JJ1) 6A-107





LNW 21BSH010401
12. Measure the bearing oil clearance.
• Install the bearing to the connecting rod big
end.
• Tighten the bearing cap to the two step o
f
angular tightening method.
• Use an inside dial indicator to measure the
connecting rod bearing inside diameter.
Connecting rod bearing cap bolt torque:
N ⋅m (kg ⋅m / lb ft)
1st step 29.4 (3.0 / 22)
2nd step 45 deg
If the clearance between the measured bearing
inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replaced.
Crankpin and bearing clearance mm (in)
Standard 0.029 - 0.083 (0.0011 - 0.0033)
Limit 0.10 (0.0039)
Reassembly
1. Install the piston.
2. Install the connecting rod. • Install it so that the front mark of the head o
f
the piston, and the connecting rod forging mark
(projecting) on the connecting rod, both face in
the same direction.
• Install the snap ring of one side.







LNW 46ASH004601
Legend
1. Front Mark
2. Forging Mark (Projecting)

4. Apply enough engine oil on the piston pin, push it
in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
Note:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.






015R100001
6. Use ring pliers to install the piston ring.
• Install the piston rings in the order shown in the
illustration.
• Install 2nd and 1st compression rings in this
order so that the marks “2N” and “N” face
upward.

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