engine ISUZU KB P190 2007 Workshop Repair Manual

6A-86 ENGINE MECHANICAL (4JK1/4JJ1)






014RY00027
Repair of the seat surface
• Remove carbon from the surface of the valve
insert seat.
• Use a seat cutter to minimize the scratch and
other roughness (15/45/75 degree-blade), thereb
y
returning the contact width to the standard value.







LNW 21BSH018201
Note:
Remove only scratches and roughness, and do not cut
the surface too much.
Use the free adjustment valve cutter pilot.
Do not let the valve cutter pilot waver inside the valve
guide.

Valve Seat Angle Degree
45










LNW 21BSH056101
• Attach compound in the valve insert seat.
• Insert the valve into the valve guide.
•
Attach compound on the valve seat surface, rotate
the valve and hit it lightly to grind it, and confirm
that it has even contact all round.
Note:
Remove compound completely after grinding.





LNW 21BSH031801


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-87
Remove the valve seat insert
• Arc-weld the entire inner diameter of the valve seat
insert.
• Cool the valve seat insert for two to three minutes.
Contraction due to cooling makes it easier to
remove the valve seat insert.
• Remove the valve seat insert, using a scre
w
driver . Be sure not to harm the cylinder head.


LNW 21BSH056001
Legend
1. Arc-W eld
2. Valve Seat Insert
3. Screw Driver

Install the valve seat insert
• Carefully place a washer (the outer diameter is
smaller than the valve seat insert) on the valve
seat insert.
• Use the press to apply pressure gradually on the
washer, thereby pushing the valve seat insert.
Note:
Do not apply too much pressure with the press. Attach
compound on the valve seat surface, rotate the valve
and hit it lightly to grind it, and confirm that it has even
contact all round.






LNW 21BSH018601
Legend
1. Attach Compound
2. Valve Seat
3. Press

Reassembly
1. Install the oil seal.
• Install on the surface of the injection pipe insert.
• Hammer it in so that the seal does not incline.
Note:
Be sure not to harm the lip.
Special tool
Injection pipe oil seal installer: 5-8840-2820-0




RTW 56ASH008801


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6A-88 ENGINE MECHANICAL (4JK1/4JJ1)





RTW 56ASH009101
Legend
1. Cylinder Head
2. Oil Seal Installer

2. Install the valve guide.
• Hammer in the valve guide from the uppe
r
surface of the cylinder head, using the valve
guide installer.
Special tool
Valve guide remover and installer:
5-8840-2816-0
Note:
W hen replacing the valve guide, it must be replaced
together with the valve.



RTW 56ASH009001
• Height from the upper surface of the cylinder
head to the edge surface of the valve guide









RTW 56ASH023001
Legend
1. 12.6 ± 0.1 mm (0.50 ± 0.0039 in)
2. Cylinder Head

3. Install the valve spring lower seat.
4. Install the valve stem oil seal. • Refer to procedure for valve stem and valve in
this manual.
5. Install the intake and exhaust valve. • Apply engine oil on the valve stem part and
install the valve.
6. Install the valve spring, the valve spring upper seat and the split collar.
• Refer to procedure for valve stem and valve in
this manual.
7. Install the rocker arm and shaft assembly. • Refer to procedure for valve stem and valve in
this manual.
8. Install the exhaust manifold assembly. • Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
9. Install the turbocharger. • Refer to procedure for Turbocharger and
Exhaust Manifold in this manual.
10. Install the intake manifold assembly. • Refer to procedure for Intake Manifold in this
manual.
11. Install the throttle assembly. • Refer to procedure for Intake Manifold in this
manual.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-89
Installation
1. Select the cylinder head gasket.
Cylinder Head Gasket Selection
Cylinder head gasket is determined by the piston head
projection from the cylinder body upper surface, in orde
r
to improve engine performance.
Three types of gasket are provided with difference o
f
thickness. Select the appropriate one out of three
grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston
head and cylinder body surface and also clean the
place where the gasket was installed.




011LX011
1. Use a dial indicator to measure the piston
projection amount.
2. Refer to the illustration for the piston head projection measuring positions. All measuring
positions should be as close as possible to the
cylinder block.








RTW 36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two
differences 1-2 and 3-4 on each cylinder. Calculate
the average value of the piston head projection on
each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum value described above in accordance
with the following table.






011RY00027



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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 â‹…
â‹…â‹…
â‹…
m (7.1 kg â‹…
â‹…â‹…
â‹…
m / 51 lb ft)
2nd step = 70 N â‹…
â‹…â‹…
â‹…
m (7.1 kg â‹…
â‹…â‹…
â‹…
m / 51 lb ft)
3rd step = 60° (degrees)
4th step = 60° (degrees)


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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 â‹…
â‹…â‹…
â‹…
m (2.5 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (2.5 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (2.1 kg â‹…
â‹…â‹…
â‹…
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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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 â‹…
â‹…â‹…
â‹…
m (2.5 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (6.0 kg â‹…
â‹…â‹…
â‹…
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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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 â‹…
â‹…â‹…
â‹…
m (2.8 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (1.0 kg â‹…
â‹…â‹…
â‹…
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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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 â‹…
â‹…â‹…
â‹…
m (1.8 kg â‹…
â‹…â‹…
â‹…
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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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 â‹…
â‹…â‹…
â‹…
m (2.5 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (1.0 kg â‹…
â‹…â‹…
â‹…
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 â‹…
â‹…â‹…
â‹…
m (1.0 kg â‹…
â‹…â‹…
â‹…
m / 87 lb in)


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