width ISUZU KB P190 2007 Workshop Repair Manual

POWER-ASSISTED STEERING SYSTEM 3B-15
3. Install tie-rod assembly with tab washer, then tighten
to specified torque. For 4 ×2 except High ride suspension models;
Torque: 83 N ⋅
⋅⋅
⋅
m (8.5 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
ft)
For 4 ×4 and 4 ×2 High ride suspension models;
Torque: 108 N ⋅
⋅⋅
⋅
m (11.0 kgf ⋅
⋅⋅
⋅
m/80 lb ⋅
⋅⋅
⋅
ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply grease to the tie-rod groove. Install bellows on housing assembly.
CAUTION :
Make sure that there are no bulges or dents in the
bellows.
After installation, confirm the small end of the
bellows is inserted into the tie-rod groove.











RUW 53BSH000301

5. Caulk the band using clamp pliers 5-8840-2745-0.
For 4 ×2 except High ride suspension models;
Caulk gap(A): less than 2.0mm(0.08in).
For 4 ×4 and 4 ×2 High ride suspension models;
Caulk gap(A): 2.6 – 3.3mm(0.10 – 0.13in).

CAUTION :
Be sure to use a new band.





RUW 53BSH000601
6. Install clip.
7. Install tie-rod end and tighten lock nut.
Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)


Main Data and Specifications
General Specifications
2W D 4W D
Power steering W ithout W ith
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.23


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3D-2 REAR SUSPENSION
MAIN DATA AND SPECIFICATIONS
General Specifications Models Standard Suspension, Soft ride Suspension Heavy-duty
Suspension
Items 4
× 2
(Except High Ride Suspension)
4 × 2 (High Ride Suspension)
4 × 4 4
× 2
Type
Leaf rigid

Leaf spring

No. of leaves
5
7
Spring eye type Berlin eye type
Up turned eye type
Bushing outside dia mm(in) Front; 40 (1.57), Rear; 30 (1.18)
Length mm(in) 1,200 (47.24)
Width mm(in) 60 (2.36)

Rear shock absorbers

Type
Gas-sealed, Twin tube
Mean stroke
mm(in)
198 (7.80) 199 (7.83) 198 (7.80)
Compressed length mm(in)
323 (12.7) 349 (13.7) 323 (12.7)
Extended length mm(in) 521 (20.5) 549 (21.6) 521 (20.5)

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SHIFT ON THE FLY SYSTEM 4C2-7















412RS026
Inner Shaft Run-Out
W ith both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit) mm (in)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.






RTW 440SH000101
Inner Shaft Bearing
Inspect the state of inner shaft bearing. If any abnormality
such as smooth less is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smooth less, replace the
needle bearing.

Sleeve
Visual Check
Check and see that there is not wear, damage, or checking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.











412RW 011
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smooth less is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.






412RW 022
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit) mm (in)
7.1 (0.28)

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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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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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ENGINE MECHANICAL 6A – 81

Connecting Rod Bearing Inside Diameter
1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening method.

Connecting Rod Bearing Cap Bolt Torque
N·m (kg·m/Ib ft)
4JA1T (L), 4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45°-60 °
3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.



Crankpin and Bearing Clearance
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 Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100(0.0039)
4JH1TC
0.029-0.083
(0.0011-0.033) 0.100 (0.0039)



Clearance Measurements (With Plastigage)
Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting surface, the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30 ° to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal across the full width of the bearing.
6. Install the bearing caps with the bearing.








7. Tighten the bearing caps to the specified torque.

Crankshaft Bearing Cap Bolt Torque mm (in)
167 (17/123)
Do not allow the crankshaft to turn during bearing cap
installation and tightening.
8. Remove the bearing cap.


015RY00012
015RY00013
015RY00011

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6A – 82 ENGINE MECHANICAL




































9. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1. Use a micrometer to measure the crankshaft outside diameter.
2. Use an inside dial indicator to measure the bearing inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the bearing
must be replaced.

Crankshaft Journal and Bearing Clearance mm (in)
Standard Limit
0.032 - 0.077
(0.0013 - 0.0030) 0.110 (0.0043)
































Crankpin and Bearing Clearance
1. Clean the crankshaft, the connecting rod, the bearing cap, and the bearings.
2. Install the bearing to the connecting rod and the bearing cap.
Do not allow the crankshaft to move when installing the
bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin. Apply engine oil to the Plastigage to keep it from falling.
5. Install the bearing cap and tighten it to the two step of anglar tihtening method.
Do not allow the connecting rod to move when installing
and tightening the bearing cap.

Connecting Rod Bearing Cap Bolt Torque
N·m (kg·m/Ib ft)
4JA1T (L), 4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45°-60 °
015LX129
015LX060

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ENGINE MECHANICAL 6A – 83































6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the specified limit, perform
the following additional steps.
1. Use a micrometer to measure the crankpin outside diameter.
2. Use an inside dial indicator to measure the bearing inside diameter.
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing must
be replaced.

Crankpin and Bearing Clearance mm (in)
Standard Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100 (0.0039)
4JH1TC
0.029-0.083
(0.0011-0.0033) 0.100 (0.0039)

CRANKSHAFT BEARING SELECTION
Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing inserts.
Match the crankshaft bearing housing grade marks and the
crankshaft journal grade marks in the table below to determine
the correct crankshaft bearing size.

Crankshaft Bearing Housing Grade Mark
Position
Crankshaft bearing housing grade marks 1, 2 or 3 are stamped
on the rear right hand side of the cylinder body.




Crankshaft Journal Grade Mark Position
The crankshaft journal grade marks (1 or -, 2 or --, 3 or ---) are
stamped on each crankshaft journal web.
The crankshaft journal and bearing clearance must be the
same for each position after installation of the crankshaft and
the crankshaft bearings.

NOTE:
The crankshaft journal mark No. 4 is stamped on
crankshaft No. 4 journal web front side or rear side.
015LX060
015RY00016

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-85




011RY00023
Valve Thickness
Measure the valve thickness.
If the measured value is less than the specified limit, the
valve and the valve guide must be replaced as a set.
Intake and Exhasut Valve Thickness mm (in)
Standard 1.32 (0.052)
Limit 1.1 (0.043)






014RY00020

Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to measure the valve depression from the
cylinder head lower surface.
If the measured value exceeds the specified limit, the valve seat insert must be replaced.
Valve Depression mm (in)
Standard 1.8 (0.07)
Limit 2.5 (0.098)







014RY00021
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 W idth
mm (in)
Intake Exhaust
Standard 1.7 (0.067) 2.0 (0.079)
Limit 2.2 (0.087) 2.5 (0.098)



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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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