torque ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (4JK1/4JJ1) 6A-133






015LX115
4. Install the lower crankshaft bearing.
• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
• Apply the recommended liquid gasket or its
equivalent to the No. 5 crankshaft bearing cap
cylinder body fitting surfaces at the points
shown in the illustration.
Note:
Be sure that the bearing cap fitting surface is completel
y
free of oil before applying the liquid gasket. ThreeBond
1207B Do not allow the liquid gasket to obstruct the
cylinder thread holes and bearings.
ThreeBond 1207B is a fast-drying liquid gasket. Tighten
the bearing caps immediately after applying the gasket.







015LX127

5. Install the bearing cap.
• Install the bearing caps with the bearing cap
head arrow mark facing the front of the engine.
The bearing cap numbers must be facing up.








015LX128
• Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence
shown in the illustration.
Crankshaft Bearing Cap Torque N ⋅m (kg ⋅m / lb ft)
166 (16.9 / 122)
Check to see the crankshaft turns smoothly by
rotating it manually.
Note:
Confirm that the crankshaft turns smoothly.








015LX129
6. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-135
Torque Specifications




RTW 76AMF000301

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-139

Cylinder block height (H) (Reference) mm (in)
Standard 259.945 – 260.055 (10.2340 – 10.2384)







012R100009
Installation
1. Install the piston cooling pipe.
• Align the dowel pin of the piston cooling pipe
with the pin hole on the cylinder block and
tighten with the relief valve.
Tightening torque: Relief valve 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
bolts M8 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
bolts M6 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
Note:
Be careful not to deform or damage the piston cooling
pipe nozzle.



RTW 76ASH001101
2. Install the crankshaft.
Refer to "Crankshaft".
3. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".
4. Install the oil pump.
Refer to "Oil Pump".
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
Refer to "Front Cover".
7. Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
8. Install the oil pan.
Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
10. Install the crankshaft front oil seal. Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
12. Install the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly " in Fuel System Section.
13. Install the cylinder head.
Refer to "Cylinder Head".
14. Install the camshaft assembly.
Refer to "Camshaft Assembly".
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover".
16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-143
Oil Filter Cartridge
Components






RTW 56ASF000101
Legend 1. Oil Filter Cartridge

Removal
1. Place a tray under the oil filter cartridge.
2. Remove the oil filter cartridge using the oil filte
r
wrench.

Special tool
Oil filter wrench: 5-8840-0203-0 (1)







RTW 56ASH012501

Installation
1. Install the oil filter cartridge.
•
Apply grease or engine oil to the seal in the
cartridge and install it using the oil filter wrench.
• Tighten the cartridge using the specified torque.
Tightening torque: 20 N·m (2.0 kg·m / 14 lb ft) Or
After it comes in contact with the oil seal,
tighten it through an additional turn of 1 and
1/4.
Special tool
Oil filter wrench: 5-8840-0203-0

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-147
Reassembly
1. Install the gasket on the element.
2. Install the element.
3. Tighten the element fixing nut using the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)

Installation
1. Install the oil filter and cooler.
• Install the O-ring on the oil filter and cooler,
apply grease.
•
Apply the liquid gasket and mount within 5
minutes. Apply liquid gasket (ThreeBond TB-
1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.079 and 0.118 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).






RTW 56ASH013101
Legend
1. Liquid Gasket
2. O-ring

• Align the oil filter and cooler holes with the
cylinder block studs. Install the oil cooler to the
cylinder clock.


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6A-148 ENGINE MECHANICAL (4JK1/4JJ1)







RTW 56ASH013201
Legend
1. Bolt 45 mm (1.77 in)
2. Bolt 110 mm (4.33 in)
3. Bolt 70 mm (2.76 in)
4. Nut

• Tighten the bolts to the specified torque in the
order shown in the illustration.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)








RTW 56ASH013301

2. Install the water intake pipe.
a. Temporarily tighten the bolt (6).
b. Install the O-ring (2) to the water intake pipe (7).
c. Apply soapy water to the O-ring (2) and install the water intake pipe (7). • Take care not to twist the O-ring.
d. Temporarily tighten the bolts.
Temporary tightening order: 1 →3→ 4→ 5
e. Tighten the bolts to the specified torque.
Fully tightening order: 3 →4→ 1→ 5→ 6
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)




RTW 76ASH001701
3. Install the water bypass pipe (1).
• After applying soapy water to O-ring, set it on
bypass pipe and insert into the cylinder head.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-149


RTW 56ASH008401
4. Install the bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 51 N ⋅
⋅⋅
⋅
m (5.2 kg ⋅
⋅⋅
⋅
m / 38 lb ft)
5. 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)
6. Install the generator.
Refer to Installation procedure for generator in this manual.
7. Install the exhaust manifold.
Refer to Installation procedure for turbocharge
r
and exhaust manifold in this manual.




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6A-152 ENGINE MECHANICAL (4JK1/4JJ1)
7. Remove the cylinder head.
Refer to “Cylinder Head”.
8. Remove the timing gear case.
Refer to “Timing Gear Case”.
9. Remove the retainer.



RTW 76ASH002001
Legend
1. Retainer
2. Bolt

10. Remove the crank case.






RTW 56ASH021901
Legend
1. O-ring
2. Crank Case

Note:
Take care not to damage the O-ring.

Disassembly
1. Remove the oil strainer.



RTW 66ASH009201
Legend
1. Gasket
2. Oil Strainer
3. Bolt
4. Crank Case

Reassembly
Install the oil strainer.
• Install the gasket on the strainer.
• Tighten the bolts to the specified torque.
Tightening torque: 22 N ⋅
⋅⋅
⋅
m (2.2 kg ⋅
⋅⋅
⋅
m / 16 lb ft)


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-153
Installation
1. Install the crank case.
• Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)




RTW 56ASH015301
Legend
1. 2.0 - 3.0 mm (0.079 - 0.118 in)
2. 4.0 - 5.0 mm (0.157 - 0.197 in)

2. Install the oil pan.
• Apply the liquid gasket (ThreeBond TB-1207B
or equivalent)and mount within 5 minutes.
Tightening torque: 22 N ⋅
⋅⋅
⋅
m (2.2 kg ⋅
⋅⋅
⋅
m / 16 lb ft)








RTW 56ASH015201
Legend
1. 2.0 mm (0.079 in)
2. 3.0 mm (0.118 in)


3. Install the retainer.
• Apply the liquid gasket (ThreeBond TB-1207C
or equivalent) and mount within 5 minutes.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)







RTW 56ASH017701
Legend
1. 2 - 2.5 mm (0.079 - 0.098 in)
2. 2 - 2.5 mm (0.079 - 0.098 in)



RTW 76ASH002001
Legend
1. Retainer
2. Bolt

4. Install the timing gear case.
Refer to “Gear Case Assembly”.
5. Install the cylinder head.
Refer to “Cylinder Head”.

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6A-154 ENGINE MECHANICAL (4JK1/4JJ1)
6. Install the rear plate.
• Tighten the bolts to the specified torque.
Tightening torque: 82 N ⋅
⋅⋅
⋅
m (8.4 kg ⋅
⋅⋅
⋅
m / 61 lb ft)
7. Install the flywheel.
Refer to “Flywheel”.
8. Connect the earth terminal of crank case side.
Note:
Do not allow the caulked portion of the terminal to
interfere with nearby parts.
9. Install the oil level gage guide tube. • Apply the engine oil to the O-ring.
• Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
10. Install the engine assembly.
Refer to “Engine Assembly”.



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