Page 1465 of 6020

ENGINE MECHANICAL (4JK1/4JJ1) 6A-105
LNW 61ASH004501
• Use a thickness gauge to measure the piston
ring gap.
If the measured value exceeds the specified limit, the piston ring must be replaced.
Piston ring gap mm (in)
Standard Limit
1st compression ring 0.3 - 0.5
(0.0118 - 0.0197) 1.50
(0.059)
2nd compression ring 0.3 - 0.5 (0.0118 - 0.0197) 1.50
(0.059)
Oil ring 0.25 - 0.45
(0.0098- 0.0177) 1.50
(0.059)
Measure the clearance between the piston ring
groove and the piston.
• Remove carbon in the piston ring groove.
• Put the piston ring in the piston ring groove, use
a thickness gauge to measure the gap between
them.
• If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and the piston ring.
Piston ring and piston ring groove clearance mm (in)
Standard Limit
1st compression ring — ∗ — ∗
2nd compression ring 0.05 - 0.09
(0.0020 - 0.0035)1.50
(0.059)
Oil ring 0.03 - 0.07
(0.0012- 0.0028) 1.50
(0.059)
∗ Measurement is impossible
LNW 21BSH009501
9. Inspect the piston pin.
• Visually inspect the piston pin for cracks,
scratches and other damage, and replace it i
f
necessary.
• Use a micrometer to measure the oute
r
diameter of the piston pin. If the measured
value exceeds the limit, replace the piston pin.
Piston pin outer diameter mm (in)
Standard 33.995 – 34.000 (1.33838 – 1.33858)
Limit 33.970 (1.33740)
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Page 1466 of 6020

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)
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Page 1467 of 6020

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.
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ISUZU KB P190 2007
Page 1468 of 6020

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.
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Page 1469 of 6020
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”.
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Page 1470 of 6020
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
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ISUZU KB P190 2007
Page 1471 of 6020
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.
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Page 1472 of 6020

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
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ISUZU KB P190 2007