height ISUZU KB P190 2007 Workshop Owner's Manual

FRONT WHEEL DRIVE 4C1-11

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front W heel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in this section.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-13


NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kgf·m/73 lb·ft)
9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque.
Torque : 93 N·m (9.5kgf·m/69 lb·ft)
10. Install lower nuts of the stabilizer link, tighten it to the specified torque.
Torque : 50 N·m (5.1kgf·m/37 lb·ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake system.
16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque.
Torque : 226 N·m (23.0kgf·m/166 lb·ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Front Alignment section.
20. Tighten the bolts and nuts of the lower control arm to the specified torque.
Refer to Lower Control Arm in Suspension section.


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ISUZU KB P190 2007

BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW 35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal. mm (in)
Pedal free play (L1) 6 - 10 (0.24 - 0.39)
M/T 174 - 186 (6.85 - 7.32) Height (L2)
A/T 176 - 188 (6.93 - 7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque
N⋅m (kgf ⋅m/lb ⋅
⋅⋅
⋅
ft)
15 - 25 (1.5 – 2.5 / 11 - 18)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 57 mm (2.24 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005

How to connect the CLEVICE of the BOOSTER ROD with the
PEDAL ARM and how to adjust the PEDAL SW .
After connecting the CLEVIS of the BOOSTER ROD to the
PEDAL ARM, adjust the PEDAL SW mounted (PDA) to the
PEDAL BRACKET using the procedure explained below.
1. Set the hole of the CLEVIS of the BOOSTER & M/CYL
ROD with the hole in the PEDAL ARM.
2. Enter the PIN; PUSH ROD to the PEDAL to the holes from the left side of the PEDAL.
3. Enter and fix the PIN; SNAP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SW ITCH counter- clock-wise.

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 61

INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.





CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the limit, it should be replaced.


Cylinder Head Lower Face Warpage mm (in)
Standard Limit
0.05
(0.002) or less 0.20
(0.0079)




NOTE:
The cylinder head lower face cannot be reground.

Cylinder Head Height (
H) (Reference) mm (in)
Standard
91.95 – 92.05
(3.620 – 3.624)






Positive Crankcase Ventilation (PCV) Valve
1. Remove PCV valve assembly from cylinder head cover.
2. Inspect the diaphragm for broken.
3. Inspect the spring for broken or weaken.
4. If find any abnormal condition, replace the PCV valve assembly.

011RY00012
011RY00013011RY00014

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 63


Measuring Method-II
1. Measure the valve stem outside diameter. Refer to the Item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to measure the valve guide inside diameter.













Valve Guide Replacement
Valve Guide Removal
Use a hammer and the valve guide replacer to drive out the
valve guide from the cylinder head lower face.
Valve Guide Replacer: 9-8523-1212-0













Valve Guide Installation
1. Apply engine oil to the valve guide outer circumference.
2. Attach the valve guide installer to the valve guide.
3. Use a hammer to drive the valve guide into position from the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0











4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.


Valve Guide Upper End Height (H) (Reference) mm (in)
12.8-13.2 (0.50-0.52)
NOTE:
If the valve guide has been removed, both the valve
and the valve guide must be replaced as a set.

011LX029
011RY00024
011RY000025 011RY00023

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ENGINE MECHANICAL 6A – 67













Valve Spring Free Height
Use a vernier caliper to measure the valve spring free height.
If the measured value is less than the specified limit, the valve
spring must be replaced.


Spring Free Height mm (in)
Standard Limit
4JA1T (L) 4JA1TC, 4JH1TC Single spring 48.0 (1.89) 47.1 (1.85)
















Valve Spring Squareness
Use a surface plate and a square to measure the valve spring
squareness.
If the measured value exceeds the specified limit, the valve
spring must be replaced.


Spring Squareness mm (in)
Limit
4JA1T (L) 4JA1TC, 4JH1TC Single spring 1.7 (0.070)

















Valve Spring Tension
Use a spring tester to measure the valve spring tension.
If the measured value is less than the specified limit, the valve
spring must be replaced.

Valve Spring Tension N (kg/lb)
Compressed
Height Standard Limit
4JA1T (L)
4JA1TC, 4JH1TC Single
spring 38.9mm
(1.53in) 296.0
(30.2/66.4) 257.7
(26.3/57.9)

011LX024
014RY00025
011LX026

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ENGINE MECHANICAL 6A – 69
3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm
oil port.




Rocker Arm Correction
Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.



CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner. Refer to "Cylinder Liner Replacement".
















3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.

Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)


Cylinder Body Height (H) (Reference) mm (in)
Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)
4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner. Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.


014RY00024
012R100001
012RY00009 014RY00023

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ISUZU KB P190 2007

6A – 70 ENGINE MECHANICAL





















Cylinder Liner Bore Measurement
Use a cylinder indicator to measure the cylinder bore at
measuring point (1) in the thrust (2-2) and axial (3-3) directions
of the crankshaft.
Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder
liner must be replaced.


Cylinder Liner Bore mm (in)
Standard Limit
4JA1T(L), 4JA1TC 93.00 (3.6614) 93.08 (3.6646)
4JH1TC 95.40 (3.7559) 95.48 (3.7590)
NOTE:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.




















Cylinder Liner Projection Inspection
1. Hold a straight edge along the top edge of the cylinder liner
to be measured.
2. Use a feeler gauge to measure each cylinder liner projection.

Cylinder Liner Projection mm (in)
Standard
0-0.1 (0-0.004)
The difference in the cylinder liner projection height
between any two adjacent cylinders must not exceed 0.03
mm (0.0012 in).












Cylinder Liner Replacement
Cylinder Liner Removal
1. Insert the cylinder liner remover (1) into the cylinder body (from the lower side of the cylinder body) until it makes firm
contact with the cylinder liner.
Cylinder Liner Remover : 5-8840-2039-0 (4JA1L/TC)
: 5-8840-2304-0 (4JH1TC)
2. Use a bench press (2) to slowly force the cylinder liner from the cylinder body.


NOTE:
Take care not to damage the cylinder body upper face
during the cylinder liner removal procedure.
3. Measure the cylinder body upper face warpage. Refer to "Cylinder Body Upper Face Warpage".
012RY00010
012LX016
012RY00012

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 77


CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.














Camshaft Journal Diameter
Use a micrometer to measure each camshaft journal diameter
in two directions (1 and 2). If the measured value is less than
the specified limit, the camshaft must be replaced.

Camshaft Journal Diameter mm (in)
Standard Limit
49.945 - 49.975
(1.9663 - 1.9675) 49.60 (1.953)














Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.

Cam Height (H) mm (in)
Standard Limit
42.016 (1.6542) 41.65 (1.640)



















Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator. If the measured value exceeds the specified limit, the
camshaft must be replaced.

Camshaft Run-Out mm (in)
Standard Limit
0.02 (0.0008) 0.10 (0.004)

014RY00032
014RY00033 014LX092

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6A-62 ENGINE MECHANICAL (4JK1/4JJ1)
3. Remove the dowel pin.
4. Inspect the camshaft visually. • Check if the journal and cam parts of the
camshaft are worn or damaged, if so, replace
it.




LNW 21BSH020201
5. Inspect an end clearance of the camshaft.
• Use a thickness gauge to measure an end
clearance of the camshaft gear and the
camshaft bracket.
• If the measurement exceeds the limit, replace
the camshaft gear or the camshaft.
End clearance of the camshaft mm (in)
Standard 0.085 − 0.205 (0.003 − 0.008)
Limit 0.25 (0.010)
Note:
Measure an end clearance of the camshaft before
disassembling.





RTW 56ASH013901
6. Check if the cam lobe is worn.
• Use a micrometer to measure the height of the
cam lobe.
• If the height of the cam lobe is at the limit o
r
less, replace the camshaft.
Height of the cam lobe mm (in)
Inlet Exhaust
Standard 40.6 (1.60) 40.6 (1.60)
Limit 39.6 (1.56) 39.6 (1.56)



LNW 21BSH020401
7. Check if the camshaft journal is worn.
• Use a micrometer to measure wear which is
not even with a diameter of the camshaft
journal.
• If the measured uneven wear exceeds the limit,
replace the camshaft.

External diameter of the camshaft journal part
mm (in)
Standard 29.909 − 29.930
(1.1775 − 1.1783)
Limit 29.809 (1.1736)

Partial wear of the camshaft journal part mm (in)
Limit 0.05 (0.0020)


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