2007 ISUZU KB P190 torque

ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


014RY00015
8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end.

014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360 °.
14. Realign the crankshaft damper pulley TDC notched line with the timing pointer.
15. Adjust the clearances for the remaining valves as shown in the illustration.



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6A – 32 ENGINE MECHANICAL









































COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 °C (158 – 176 °F).
2. Remove the following parts.
• Leak off pipe
• Injection nozzle holder bracket
• Injection nozzle holder
3. Install the following parts.
• Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
• Injection nozzle holder bracket

Injection nozzle holder bracket Bolt Torque
N·m (kg·m /lb·ft)
37 (3.8/27)

Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0


4. Turn the engine over with the starter motor and take the compression gauge reading.

Compression Pressure MPa (kg/cm
2 /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)




5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
F06XL056
901R100003

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ISUZU KB P190 2007

6A – 34 ENGINE MECHANICAL



RTW 46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8 °)
is aligned with the pointer.

Injection Timing : BTDC 8 ° ± 2 °

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket bolts.
11. Adjust the injection pump setting angle.
W hen large than standard value W hen smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.
12. Install the distributor head bolt.
Distributor head bolt torque N·m (kg·m /lb·ft)
29 (3.0/22)



ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant temperature reaches 70 - 80 °C (158 - 176 °F).


4. Disconnect the engine control cable from the control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 ± 25 rpm



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ISUZU KB P190 2007

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model) Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor.

14. Transmission member 1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing.
2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts.
16. Transmission coupling bolt 1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer) Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007
P1010025


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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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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 95
















Reassembly
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve springs.Take care not to allow the installed valves to
fall free.







5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.

6. Valve Spring Upper Seat









7. Split Collar
1. Use the spring compressor to compress the valve spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the collar with a rubber hammer.





RTW 46ASH002301








8. Intake manifold gasket
9. Intake manifold
1. Install the manifold gasket with the end having the sharp corners facing the rear of the engine.
2. Install the intake manifold to the cylinder head.
3. Tighten the manifold bolt/nuts to the specified torque.

Manifold Bolt/Nut Torque N·m(kg·m/lbft)
Bolt 19 (1.9/14)
Nut 24 (2.4/17)

011RW 027
011LX055
014RY00039

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6A – 100 ENGINE MECHANICAL














Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.


PCV Valve Bolts Torque N·m(kg·m/lb in)
2 (0.2/17)
2. Rubber Spacer
3. Cylinder Head Insulator Cover







RTW 36ASH001401












4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt

Fixing Bolt Torque N·m(kg·m/lb in)
19 (1.9/14)

6. Oil Filler Cap


010R100014

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