engine ISUZU KB P190 2007 Workshop Repair Manual

6A-106 ENGINE MECHANICAL (4JK1/4JJ1)



LNW 21BSH009601
• Inspect to make sure that there is a resistance
to the extent which the piston can push the
piston pin lightly in normal temperatures.
• If it feels a large looseness or instability in
normal temperatures, replace the piston o
r
piston pin.






LNW 21BSH009701
• Measure the bush of the small edge of the
connecting rod. If the clearance of the bush inne
r
diameter and the pin diameter exceeds the limit,
replace the bush or connecting rod assembly, and
the pin.
Piston pin and connecting rod small end bushing
clearance mm (in)
Standard 0.008 - 0.020 (0.0003 - 0.0008)
Limit 0.05 (0.0020)







LNW 21BSH009801
10. Measure the clearance between the piston and
the piston pin.
•
Apply engine oil on the piston pin. Use your
finger to push it in the piston hole and rotate it.
If the pin smoothly rotates without instability,
the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
Piston pin and piston pin hole clearance mm (in)
Standard 0.004 - 0.017 (0.0002 - 0.0007)
Limit 0.04 (0.0016)
11. Measure the connecting rod alignment.
• Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole
and the small end hole. If the measured value
exceeds the limit, replace it.
Connecting rod alignment
(par length of 100 mm (3.94 in)) mm (in)
Standard Limit
Distortion 0.08 (0.003) or less 0.20 (0.008)
Parallelism 0.05 (0.002) or less 1.50 (0.060)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-107





LNW 21BSH010401
12. Measure the bearing oil clearance.
• Install the bearing to the connecting rod big
end.
• Tighten the bearing cap to the two step o
f
angular tightening method.
• Use an inside dial indicator to measure the
connecting rod bearing inside diameter.
Connecting rod bearing cap bolt torque:
N ⋅m (kg ⋅m / lb ft)
1st step 29.4 (3.0 / 22)
2nd step 45 deg
If the clearance between the measured bearing
inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replaced.
Crankpin and bearing clearance mm (in)
Standard 0.029 - 0.083 (0.0011 - 0.0033)
Limit 0.10 (0.0039)
Reassembly
1. Install the piston.
2. Install the connecting rod. • Install it so that the front mark of the head o
f
the piston, and the connecting rod forging mark
(projecting) on the connecting rod, both face in
the same direction.
• Install the snap ring of one side.







LNW 46ASH004601
Legend
1. Front Mark
2. Forging Mark (Projecting)

4. Apply enough engine oil on the piston pin, push it
in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
Note:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.






015R100001
6. Use ring pliers to install the piston ring.
• Install the piston rings in the order shown in the
illustration.
• Install 2nd and 1st compression rings in this
order so that the marks “2N” and “N” face
upward.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-109






015LX130
4. Install the oil pan.
Refer to “Oil Pan”.
5. Install the gear case assembly.
Refer to “Gear Case Assembly”.
6. Install the cylinder head.
Refer to “Cylinder Head”.
7. Install the camshaft assembly.
Refer to “Camshaft Assembly”.
8. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.



BACK TO CHAPTER INDEX
TO MODEL INDEX
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



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-111
Flywheel
Components











RTW 56ALF001701
Legend 1. Flywheel Assembly and Pilot Bearing
2. Driven Plate
3. Pressure Plate Assembly 4. Release Bearing
5. Shift Fork
6. Transmission Assembly

Removal
1. Remove the transmission assembly.
Refer to "transmission assembly removal and installation".
2. Remove the clutch pressure plate.
• Remove the pressure plate installation bolts in
the order shown in the drawing.
• Remove the pressure plate from the flywheel.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6A-112 ENGINE MECHANICAL (4JK1/4JJ1)





RTW 56ASH014201
3. Remove the driven plate.
• Remove the driven plate from the flywheel
along with the clutch aligner.
• Install the crankshaft stopper in the starte
r
installation part of the rear plate.
Note:
Make sure that the stopper is applied with the ring gea
r
and installed properly.
Special tool
Crankshaft stopper: 5-8840-0214-0
4. Remove the pilot bearing. • Remove the pilot bearing from the flywheel.







015RY00018
Special tool
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0

5. Remove the flywheel.
• Gradually loosen the flywheel installation bolts
in the order shown in the drawing so that the
flywheel does not rotate.
•
After loosening the bolts, remove the stopper
and remove the flywheel.
• In the case of A/T car, after loosening the
flywheel installation bolts, remove the washer,
flexible plate, flywheel and sleeve in this order.





015RY00001
6. Remove the ring gear.
• Put a bar on the ring gear and hit it with a
hammer to remove it.






LNW 21BSH012001


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-113
Inspection
1. Visual inspection
• Inspect the flywheel friction surface for cracks
and damages, and replace it if it has
abnormality.
• Inspect the tooth part of the ring gear, replace
the ring gear if it has damage or serious wear.
2. Measurement of the friction surface • Measure the depth of the friction surface of the
flywheel.
•
Adjust it if the measured value is within the
standard value and the limit.
• If the measured value exceeds the limit,
replace the flywheel.
Depth of the friction surface of the flywheel mm (in)
Standard 18 (0.7087)
Limit 19 (0.7480)
Depth = From the pressure installation surface
to the friction surface.



LNW 21BSH011901
3. Flywheel installation bolts.
• There is no damage in appearance.
• Exchange for a new part if damage is
extensive.
Installation
1. Install the ring gear.
• Heat the ring gear evenly with a gas burner to
invite thermal expansion. Do not allow the
temperature of the gas burner to exceed 200°C
(392°F).
• Install the ring gear when it is sufficientl
y
heated. The ring gear must be installed with the
chamfer facing the clutch.
Note: • Install the ring gear so that the side with a
pattern faces forward.
• Shrink fit the ring gear to the flywheel.
Make sure that flywheel and ring gear adhesion is complete.




LNW 21BSH01201
2. Install the pilot bearing.
• Place the crankshaft pilot bearing right angle
across the crankshaft bearing installation hole.
• 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.
Special tool
Pilot Bearing Installer: 5-8522-0024-0


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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”.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007