2007 ISUZU KB P190 Engine

6A-46 ENGINE MECHANICAL (C24SE)





Inspection
Check contact pattern ( I) on valve seat and in cylinder head.

Clean
Valves, valve guides, cylinder head.

Flywheel

Removal
1. Remove transmission and clutch.
2. Remove flywheel while locking with 5-88400-446-0.







Torque - Angle Method
Flywheel to crankshaft - 65 Nm/6.5 kgf ⋅m.+30 ° to 45 °

Important!
Use new bolts.
Do not apply grease to the thread.

Installation
1. Install clutch and transmission.


Component Parts
Flywheel and Ring gear. (Manual Transmission)


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-47

Starter Ring Gear (Manual Transmission)
Removal
1. Remove flywheel according to the corresponding operation.
2. Drill starter ring gear underneath tooth gap approx. 8mm/0.30in. deep with 8mm/0.25in. diameter drill.




3. Separate starter ring gear with chisel on the drilling point.


Installation
1. Install starter ring gear with inner chamfered edge to flywheel.
2. Heat starter ring gear evenly to 180 °C /356 °F to 230 °C
/446 °F (yellow paint mark)
3. Install flywheel according to the corresponding operation.


Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.


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ISUZU KB P190 2007

6A-48 ENGINE MECHANICAL (C24SE)
Seal Ring, Crankshaft
(Oil Pump Housing)

Removal
1. Remove toothed belt rear cover according to the
corresponding operation.
2. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.


Installation
1 Install the protective sleeve to the crankshaft.
2. Coat the sealing lip with protective grease.
3. Install the sealing ring.
4. Install the sealing ring using 5-8840-0455-0.
5. Install the rear toothed belt cover and toothed belt according to the corresponding operations.
6. Replace the sealing ring with a new one.
7. Tighten the belt to the crankshaft.




Seal Ring, Crankshaft Rear
Removal
1. Remove transmission and clutch.
2. Remove flywheel or flex plate according to the corresponding operations.
3. Make hole in middle of sealing ring, turn in self-tapping screw and edge out.




Installation
1. Install protective sleeve.
2. Coat sealing lip with Protective Grease.
3. Install sealing ring using 5-8840-0459-0 and 5-8840- 2597-0.
4. Install flywheel, clutch and transmission.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-49







Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf xm.




RTW 46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 ×4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.















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ISUZU KB P190 2007

6A-50 ENGINE MECHANICAL (C24SE)

Clean
Sealing surfaces.





013RW 004










Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.

Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4 ×4 model
only]).
8. Install the crossmember.

Tighten (Torque)
Oil intake pipe to oil pump -8N ⋅m (0.8 kgf ⋅m)
Oil intake pipe bracket to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil pan to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
Bearing bridge to cylinder block – 8 N ⋅m (0.8 kgf ⋅m)



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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-51
OPERATIONS ON CRANK DRIVE
Con-Rod Bearing









Removal
1. Remove oil pan and bearing bridge according to the corresponding operation.
2. Remove con-rod bearing cap and con-rod bearing after marking both sides.

Clean
Con-rod journal, con-rod bearing cap










Installation
1. Install new bearing shafts lightly coated with engine oil.
2. Install con-rod bearing cap.

Torque-Angle Method
Con-rod bearing cap to con-rod - 35N ⋅m (3.5 kgf ⋅m) +45 ° to
60 °

Important!
Use new bolts.

3. Install oil pan and bearing bridge according to the corresponding operation.




Piston with Con-Rod
Removal
1. Remove cylinder head and oil pan according to the corresponding operations.
2. Remove piston with con-rod after marking con-rod bearing cap.





Inspection
Remove and install all parts, if applicable.

Important!
Ring gap offset:
Piston rings - 180 °.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.


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ISUZU KB P190 2007

6A-52 ENGINE MECHANICAL (C24SE)






Installation
1. Install piston with con-rod by inserting with engine oil.
2. Coat piston rings with engine oil and compress with piston ring compressor.

Important!
Installation position:
Arrow / notch on piston head on timing side of engine
Beads on con-rod on clutch side






Torque-Angle Method
Piston to cylinder block.
Con-rod bearing cap to con-rod-35N ⋅m (3.5 kgf ⋅m) +45 ° to 60 °

Important!
Use new bolts.


Installation
1. Install oil pan and cylinder head according to the corresponding operations.
2. Install sealing Gasket or replace if damaged.
3. Install camshaft housing to cylinder head.
4. Install cylinder head according to the corresponding operation.




Con-Rod
Removal
1. Remove piston with con-rod according to the corresponding operation.
2. Disassemble con-rod piston assembly by pressing out piston pin, using 5-8840-0468-0.


Installation
1. Slide guide drift (5-8840-0468-0) in horizontal position through piston and con-rod as far as side plate stops.
2. Tighten bolts evenly so that the piston rests flush on the rear plate.
3. Remove centre piece from guide drift and insert piston bolts (lubricated) into guide drift.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-53

4. Heat a new con-rod to 280
°C in the oil bath.
5. Install the con-rod to the piston and insert the piston pin.


Important!
Since the con-rods have no weight balancing studs, re-working
is not possible.
Exchange con-rods in sets only.
Installation position, beads on con-rod point to the flattening on
the piston pin eye.
Firmly seated piston pin cannot be pushed in. Carry out
installation quickly.








Piston Rings
Removal
1. Remove piston with con-rod according to the corresponding operation.
2. Remove piston rings using commercially available ring installer or piston ring clamp pliers.

Clean
Piston ring grooves - ground piece of old piston ring


Inspection
Piston ring gap
For piston ring sizes, permissible piston ring gaps - see
"Technical Data"


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ISUZU KB P190 2007