torque ISUZU KB P190 2007 Workshop Repair Manual

6A-108 ENGINE MECHANICAL (4JK1/4JJ1)
• Insert the expander coil into the oil ring groove
so that there is no gap on either side of the
expander coil before installing the oil ring.






RTW 56ASH023201
Legend
1. Compression Ring 1st
2. Compression Ring 2nd
3. Oil Ring
4. Expander

Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, and
apply engine oil on the bearing.
2. Install the piston and connecting rod assembly. • Apply enough engine oil on the piston ring, ring
groove and piston side surface.
• W ith the piston front mark cut facing forward,
use the piston ring compressor to insert the
piston in the cylinder block.
Note: • Be sure not to make the connecting rod touch
the oil jet when pushing in the piston.
• Be sure not to harm the inside of the cylinde
r
block when pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0







015LX096
3. Install the connecting rod cap.
• Install the bearing on the connecting rod cap
and apply engine oil.
• Install the cap, matching the numbers (1, 2, 3,
and 4) of the caps and connecting rods.





015R100007
• Apply engine oil disulfide on the screw part and
the setting face of the tightening bolt and
tighten it with the designated torque.
Tightening torque: 1st step = 29 N ⋅
⋅⋅
⋅
m (3.0 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
2nd step = 45° (degrees)
Special tool
Angle gauge: 5-8840-0266-0
Note:
Make sure that the crankshaft smoothly rotates.


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ISUZU KB P190 2007

6A-110 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 56AMF001801

Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-9018-0
Piston ring compressor

5-8840-0266-0
Angle gauge



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6A-114 ENGINE MECHANICAL (4JK1/4JJ1)





015RY00010
3. Install the flywheel.
• Install the flywheel of the crankshaft, tighten
them in the order shown in the illustration.
•
Apply molybdenum disulfide on the screw part
and setting face of the bolt.
• Install the crankshaft stopper on the starte
r
installation part of the rear plate.
Tightening torque: 1st step = 59 N ⋅
⋅⋅
⋅
m (6.0 kg ⋅
⋅⋅
⋅
m / 43 lb ft)
2nd step = 60° - 90° (degrees)
Special tool
Crankshaft stopper: 5-8840-0214-0





015RY00001
4. Install the driven plate.
• Use a clutch aligner to install the driven plate
on the flywheel.









LNW 21BSH002601
Legend
1. Clutch Aligner

5. Install the clutch pressure plate.
• Install the pressure plate on the flywheel so that
the installation hole of the pressure plate
matches with the dowel pins of the flywheel.
• Tighten the pressure plate in the order shown
in the illustration.
Tightening torque: 18 N ⋅
⋅⋅
⋅
m (1.8 kg ⋅
⋅⋅
⋅
m / 13 lb ft)





RTW 56ASH023301
6. Install the transmission assembly.
Refer to removal procedure for “TRANSMISSION”.

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-115
Torque Specifications






Special Tools
ILLUSTRATION PART NO.
PART NAME
ILLUSTRATION PART NO.
PART NAME
5-8840-0214-0
Crankshaft stopper
5-8522-0024-0
Pilot Bearing Installer
5-8840-2000-0
Pilot Bearing Remover

5-8840-0019-0
Sliding Hammer


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ISUZU KB P190 2007

6A-118 ENGINE MECHANICAL (4JK1/4JJ1)
Installation
1. Install the packing of the timing gear case.
• Apply liquid gasket (ThreeBond 1207B o
r
equivalent) on the joint (1) of the cylinder block
and the crank case.




RTW 56ASH016301
2. Install the timing gear case.
• Install the timing gear case to match with the
dowel pins, install bolts in the order shown in
the illustration.



RTW 56ASH022601

Legend
1. Gear Case Assembly
2. Bolt L = 25 mm (0.98 in)
3. Bolt L = 60 mm (2.36 in)
4. Bolt L = 45 mm (1.77 in)
5. Bolt L = 35 mm (1.38 in)
6. Bolt L = 16 mm (0.63 in)
7. Bolt L = 20 mm (0.79 in)
8. Bolt L = 50 mm (1.97 in)
9. UP

• Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Tighten them in the order shown in the
illustration.
3. Install the oil pump.
Refer to installation procedure for “Oil Pump” in this manual.
4. Install the idle gear C shaft and idle gear C, idle gear A shaft and idle gear A.
Refer to installation procedure for “Timing Gea
r
Train” in this manual.
5. Install the gear case cover.
Refer to removal procedure for “Gear Case Cover” in this manual.
6. Install the crankshaft pulley.
Refer to removal procedure for “Crankshaft Front Oil Seal” in this manual.
7. Install the fuel supply pump.
Refer to installation procedure for “Fuel Suppl
y
Pump” in this manual.
8. Install the water pump.
Refer to installation procedure for “W ater Pump” in this manual.
9. Install the power steering pump.
Refer to removal procedure for “Power Steering” in this manual.
10. Install the vacuum pump and pipe.
Refer to removal procedure for “Brake” in this manual.
11. Install the adjustment bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
12. Install the cylinder head.
Refer to installation procedure for “Cylinder Head” in this manual.
13. Install the engine assembly.
Refer to installation procedure for “Engine Assembly” in this manual.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-119
Torque Specifications





RTW 76ALF000701


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-121
3. Remove the crankshaft pulley.
Note:
Do not reuse the bolt and the washer.








LNW 61ASH005301
4. Remove the crankshaft front oil seal.
• Remove only the oil seal with a screwdriver o
r
the like, avoiding damage to the oil seal contact
surface on the front cover and the shaft.
Installation
1. Install the crankshaft front oil seal. • Use the special tool to install the front oil seal.
Front Oil Seal
Installer: 5-8840-2821-0 (1)




RTW 56ASH016501


• Apply engine oil to the lip of the oil seal.
• W ith the seal pressed in check the dimension
of the oil seal section.
Standard Dimension = 1.5 mm (0.06 in)







RTW 56ASH016601
2. Install the crankshaft damper pulley.
• Install the crankshaft pulley aligning with the
key on the crankshaft.
• Hold the flywheel ring gear stationary to prevent
the crankshaft from turning when tightening the
damper pulley bolt.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30 kg ⋅
⋅⋅
⋅
m/217 lb ft)
• Take care not to damage the crankshaft
damper pulley boss.







014R100014
3. Install the fan belt.
• Refer to “Engine Cooling”


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ISUZU KB P190 2007

6A-122 ENGINE MECHANICAL (4JK1/4JJ1)
Torque Specifications



RTW 76AMF000601
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2821-0
Oil seal installer


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ISUZU KB P190 2007

6A-128 ENGINE MECHANICAL (4JK1/4JJ1)
Reassembly
1. Install the crank angle sensor rotor.
• Attach by making a rotor tooth’s running out
side into a front side.
•
Apply Loctite #262 or the equivalent to the bolt
threads (if a new bolt is used, Loctite
application is not required).
Tightening torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kg ⋅
⋅⋅
⋅
m / 104 lb in)



RTW 76ASH001601
Legend
1. Crank Angle Sensor Rotor
2. Pin

Inspection
1. Thrust clearance
• Measure the crankshaft end play at the cente
r
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.
Axial play of the crankshaft mm (in)
Standard 0.10 (0.004)
Limit 0.30 (0.012)
Note:
Measure the thrust clearance before dismounting.






015RY00002
2. Main bearing clearance
• Remove the crank case.
Set out disassembled main bearings in the order of the numbers.
• Remove the crankshaft. Remove the main
bearings.
• Clean the crankshaft journal and upper and
lower bearings.
• Check the bearings for damage or excessive
wear.

If you find damage or excessive wear, replace the bearings in pairs.

• Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it is horizontal.
Note:
Turn the crankshaft about 30 degrees to allow the
bearings to settle in.
• Place plastigage on the crankshaft journal as
shown.
• Place the lower bearings at original positions on
the bearing cap.

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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-129




015RY00012
• Install the bearing cap and tighten bolts to the
specified tightening torque.
• Tighten the bearing cap in the sequence shown
using a torque wrench and an angle gauge.








015LX129
Tightening torque: 166 N ⋅
⋅⋅
⋅
m (16.9 kg ⋅
⋅⋅
⋅
m / 122 lb ft)
Note:
Do not turn the crankshaft after you have tightened the
bearing cap.
• Loosen the bolts and gently remove the bearing
cap.
• Measure the widest part of the Plastigage
flattened by tightening the bearing cap to
determine the clearance.
Journal oil clearance mm (in)
Standard 0.032 - 0.077 (0.0013 - 0.0030)
Limit 0.11 (0.0043)




LNW 21BSH024401
•
If the journal oil clearance exceeds the limit,
replace the main bearings altogether or the
crankshaft.
• Remove the Plastigage from the bearings and
the crankshaft.

Inspection of the crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil
seal contact surface for excessive wear and
damage.
• Check the oil port for clogging.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowl
y
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
Crankshaft run-out mm (in)
Standard 0.05 or less (0.0020 or less)
Limit 0.08 (0.003)


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