check engine ISUZU KB P190 2007 Workshop Manual PDF

ENGINE MECHANICAL 6A – 41

















































Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5 minutes and stop the engine.
6. W hen the engine has been cooled, check filler neck for water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity lit (US/UK gal)

4JA1 / TC 9.4 (2.5 / 2.1)
4JH1TC M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
























Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system. Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.



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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 51

10. Timing Gear Case Cover The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.

11. Water Pump



12. Idle Gear B and shaft Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.



13. Idler Gear "A" 1. Measure the camshaft timing gear backlash and the crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the idler gear.

NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.



Timing Gear Backlash Measurement
1. Set a dial indicator to the timing gear to measured. Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.

Timing Gear Backlash mm (in)
Standard Limit
0.10 - 0.17 (0.0039 - 0.0067) 0.30 (0.012)
020L200006
020L200020
020RY00019
020RY00020

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 65
















Valve Contact Width
1. Check the valve contact faces for roughness and unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width. If the measured value exceeds the specified limit, the valve
seat insert must be replaced.

Valve Contact Width mm (in)
Standard Limit
Intake 1.7 (0.067) 2.2 (0.087)
Exhaust 2.0 (0.079) 2.5 (0.078)
























Valve Seat Insert Replacement
Valve Seat Insert Removal
1. Arc weld the entire inside circumference (1) of the valve seat insert (2).
2. Allow the valve seat insert to cool for a few minutes. This will invite contraction and make removal of the valve
seat insert easier.
3. Use a screwdriver (3) to pry the valve seat insert free. Take care not to damage the cylinder head (4).
4. Carefully remove carbon and other foreign material from the cylinder head insert bore.


014RY00027
011LX039

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ISUZU KB P190 2007

6A – 66 ENGINE MECHANICAL


Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller outside diameter than the valve seat insert) on the valve
seat insert (2).
NOTE:
The smooth side of the attachment must contact the
valve seat insert.

2. Use a bench press (3) to gradually apply pressure to the attachment and press the valve seat insert into place.

NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.








Valve Seat Insert Correction
1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15 °, 45 °, and 75 ° blades) to minimize
scratches and other rough areas. This will bring the
contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away unblemished
areas of the valve seat surface.









Valve Seat Angle Degree
45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.











3. Apply abrasive compound to the valve seat insert surface.
4. Insert the valve into the valve guide.
5. Turn the valve while tapping it to fit the valve seat insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.



011LX063
014RY00026
011LX037011LX038

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ISUZU KB P190 2007

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

ENGINE MECHANICAL 6A – 73






Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and bore surfaces.

NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2) from the top of the cylinder body.










4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).

NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
6. Use the bench press to apply a seating force of 4,900 N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder liner projection.
Refer to "Cylinder Liner Projection Inspection".

012RY00017
012RY00018

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ENGINE MECHANICAL 6A – 85
CRANKSHAFT PILOT BEARING
Check the crankshaft pilot bearing for excessive wear and
damage and replace it if necessary.















Crankshaft Pilot Bearing Replacement
Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the crankshaft pilot
bearing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
















Crankshaft Pilot Bearing Installation
1. Place the crankshaft pilot bearing right angle across the crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing outer races with a brass hammer to drive the bearing into the
crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0

NOTE:
Strike only the crankshaft pilot bearing outer race with
the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.







































FLYWHEEL AND RING GEAR
Flywheel
1. Inspect the flywheel friction surface for excessive wear and
heat cracks.
2. Measure the flywheel friction surface depth. If the measured value is within the specified limit, the
flywheel may be reground.
If the measured value exceeds the specified limit, the
flywheel must be replaced.

Flywheel Friction Surface Depth (1) mm (in)
Standard Limit
4JA1T (L),
4JA1TC 20 (0.7874) 21 (0.8267)
4JH1TC 18 (0.7087) 19 (0.7480)

Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
015RY00010
015RY00019 015RY00018

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ENGINE MECHANICAL 6A – 97


Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to the piston.





RTW 36ASH001801
Install the piston to the connecting rod so that the piston
head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
3. Piston Pin Snap Ring




RTW 36ASH001901


4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the piston pin hole.
2. Use your fingers to force the piston pin into the piston until it makes contact with the snap ring.



5. Piston Pin Snap Ring 1. Use your fingers to force the piston pin snap ring into the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the piston pin.



F06MV015
015R100001

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6A – 98 ENGINE MECHANICAL


RTW 36ASH002001



































6. Piston Ring
1. Use a piston ring replacer to install the three piston rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring

NOTE:
Install the compression rings with the stamped side
facing up.
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.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the piston ring grooves





7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.




015R100006

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ENGINE MECHANICAL 6A – 105






5. Crankshaft Thrust Bearing
Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
















6. Crankshaft Bearing Cap With Lower Bearing
Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. 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
completely free of oil before applying the liquid
gasket. Three bond 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.









2. 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.
3. Apply engine oil to the crankshaft bearing cap bolts.















4. 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/lbft)
167 (17/123)
5. Check to see the crankshaft turns smoothly by rotating it manually.


015LX115
015LX127
015LX128
015LX129

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