2007 ISUZU KB P190 lock

ENGINE MECHANICAL (4JK1/4JJ1) 6A-103
6. Measure the gap between the piston and the inner
diameter of the cylinder block.
Inner diameter of the cylinder block. • Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
• Measurement position (from the upper surface
of the cylinder block) 20 mm (0.79 in)
• Measure the cylinder block inner diamete
r
based on the average value of the actual
measurement values on 6 positions.
Cylinder block inner diameter mm (in)
95.421 – 95.450 (3.75673 – 3.75787)






LNW 61ASH006401
Legend
1. 20 mm (0.79 in)
2. Radial
3. Thrust

Piston outside diameter
• Use a micrometer to measure the outside
diameter of the piston in the right angle to the
piston pin in the designated position.
• Measurement position (from the bottom surface
of the piston) 11.00 mm (0.43 in).






RTW 56ASH023101
Legend
1. 11 mm (0.43 in)

Gap between the piston and the inner
diameter of the cylinder block mm (in)
Standard 0.082 – 0.100 (0.0032 – 0.0039)
NOTE:
If the gap exceeds the standard value, replace the
piston or rebore the cylinder block.
7. Piston replacement • The head of piston has a marking of grade A, B
or C.
• Refer to “Cylinder Block” if over size piston is
installed.

Piston Grade (Service Part) mm (in)
A 95.330 – 95.339 (3.75314 – 3.75350)
B 95.340 – 95.349 (3.75354 – 3.75389)
C 95.350 – 95.359 (3.75393 – 3.75428)


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ISUZU KB P190 2007

6A-104 ENGINE MECHANICAL (4JK1/4JJ1)
4JK1





RTW 56ASH025701
Legend
1. Grade
2. Front Mark Cut


4JJ1





LNW 76ASH001401
Legend
1. Grade
2. Front Mark Cut

8. Inspect the piston ring.
• Insert the piston ring horizontally (in the position
it would assume if it were installed to the
piston) into the cylinder block.





LNW 21BSH009301
• Push the piston ring into the cylinder bore until
it reaches the measuring point 1 or 2 where the
cylinder block bore is the smallest.
Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or Measuring Point 2 120 mm (4.7 in).






LNW 61ASH004401











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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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ISUZU KB P190 2007

6A-118 ENGINE MECHANICAL (4JK1/4JJ1)
Installation
1. Install the packing of the timing gear case.
• Apply liquid gasket (ThreeBond 1207B o
r
equivalent) on the joint (1) of the cylinder block
and the crank case.




RTW 56ASH016301
2. Install the timing gear case.
• Install the timing gear case to match with the
dowel pins, install bolts in the order shown in
the illustration.



RTW 56ASH022601

Legend
1. Gear Case Assembly
2. Bolt L = 25 mm (0.98 in)
3. Bolt L = 60 mm (2.36 in)
4. Bolt L = 45 mm (1.77 in)
5. Bolt L = 35 mm (1.38 in)
6. Bolt L = 16 mm (0.63 in)
7. Bolt L = 20 mm (0.79 in)
8. Bolt L = 50 mm (1.97 in)
9. UP

• Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Tighten them in the order shown in the
illustration.
3. Install the oil pump.
Refer to installation procedure for “Oil Pump” in this manual.
4. Install the idle gear C shaft and idle gear C, idle gear A shaft and idle gear A.
Refer to installation procedure for “Timing Gea
r
Train” in this manual.
5. Install the gear case cover.
Refer to removal procedure for “Gear Case Cover” in this manual.
6. Install the crankshaft pulley.
Refer to removal procedure for “Crankshaft Front Oil Seal” in this manual.
7. Install the fuel supply pump.
Refer to installation procedure for “Fuel Suppl
y
Pump” in this manual.
8. Install the water pump.
Refer to installation procedure for “W ater Pump” in this manual.
9. Install the power steering pump.
Refer to removal procedure for “Power Steering” in this manual.
10. Install the vacuum pump and pipe.
Refer to removal procedure for “Brake” in this manual.
11. Install the adjustment bracket of generator.
Tighten the bolts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
12. Install the cylinder head.
Refer to installation procedure for “Cylinder Head” in this manual.
13. Install the engine assembly.
Refer to installation procedure for “Engine Assembly” in this manual.


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ISUZU KB P190 2007

6A-128 ENGINE MECHANICAL (4JK1/4JJ1)
Reassembly
1. Install the crank angle sensor rotor.
• Attach by making a rotor tooth’s running out
side into a front side.
•
Apply Loctite #262 or the equivalent to the bolt
threads (if a new bolt is used, Loctite
application is not required).
Tightening torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kg ⋅
⋅⋅
⋅
m / 104 lb in)



RTW 76ASH001601
Legend
1. Crank Angle Sensor Rotor
2. Pin

Inspection
1. Thrust clearance
• Measure the crankshaft end play at the cente
r
journal of the crankshaft.
• Do this before removing the crankshaft bearing
caps. If the measured value exceeds the
specified limit, the crankshaft thrust bearing
must be replaced.
Axial play of the crankshaft mm (in)
Standard 0.10 (0.004)
Limit 0.30 (0.012)
Note:
Measure the thrust clearance before dismounting.






015RY00002
2. Main bearing clearance
• Remove the crank case.
Set out disassembled main bearings in the order of the numbers.
• Remove the crankshaft. Remove the main
bearings.
• Clean the crankshaft journal and upper and
lower bearings.
• Check the bearings for damage or excessive
wear.

If you find damage or excessive wear, replace the bearings in pairs.

• Place the upper bearings and the crankshaft on
the cylinder block. Install the crankshaft so that
it is horizontal.
Note:
Turn the crankshaft about 30 degrees to allow the
bearings to settle in.
• Place plastigage on the crankshaft journal as
shown.
• Place the lower bearings at original positions on
the bearing cap.

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ENGINE MECHANICAL (4JK1/4JJ1) 6A-129




015RY00012
• Install the bearing cap and tighten bolts to the
specified tightening torque.
• Tighten the bearing cap in the sequence shown
using a torque wrench and an angle gauge.








015LX129
Tightening torque: 166 N ⋅
⋅⋅
⋅
m (16.9 kg ⋅
⋅⋅
⋅
m / 122 lb ft)
Note:
Do not turn the crankshaft after you have tightened the
bearing cap.
• Loosen the bolts and gently remove the bearing
cap.
• Measure the widest part of the Plastigage
flattened by tightening the bearing cap to
determine the clearance.
Journal oil clearance mm (in)
Standard 0.032 - 0.077 (0.0013 - 0.0030)
Limit 0.11 (0.0043)




LNW 21BSH024401
•
If the journal oil clearance exceeds the limit,
replace the main bearings altogether or the
crankshaft.
• Remove the Plastigage from the bearings and
the crankshaft.

Inspection of the crankshaft
• Check the crankshaft journal and crank pin
surfaces for wear and damage. Check the oil
seal contact surface for excessive wear and
damage.
• Check the oil port for clogging.
3. Crankshaft run-out
Carefully set the crankshaft on the V block. Slowl
y
turn the crankshaft to measure the run-out. If the
crankshaft run-out exceeds the limit, replace the
crankshaft.
Crankshaft run-out mm (in)
Standard 0.05 or less (0.0020 or less)
Limit 0.08 (0.003)


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ISUZU KB P190 2007

6A-130 ENGINE MECHANICAL (4JK1/4JJ1)






015LX061
4. Measure the journal and the crankpin diameters
and uneven wear.
• Measure outer diameters of the journal and the
pin and calculate differences between the
maximum and the minimum values. Take
measurements at four positions for both the
journal and the pin.





LNW 21BSH024601

Crankshaft outside diameter mm (in)
Standard Limit
Journal 69.917 – 69.932
(2.7526 – 2.7532) 69.91
(2.7524)
Pin 52.915 – 52.930
(2.0833 – 2.0839) 52.9
(2.083)



Note:
Tufftriding (soft nitriding treatment) is applied to
enhance strength of the crankshaft. Therefore, you
should not polish the surface of the crankshaft.
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 marks 1, 2
or 3 are stamped on the rear right hand side o
f
the cylinder block.






RTW 56ASH017101
Legend
1. No.1
2. No.2
3. No.3
4. No.4
5. No.5

• 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 afte
r
installation of the crankshaft and the crankshaft
bearings.





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6A-132 ENGINE MECHANICAL (4JK1/4JJ1)
Bearing Selection Table
mm (in)
Crankshaft
Bearing Housing Crankshaft Journal
Grade
Mark Diamaeter
Grade
Mark Diamaeter Crankshaft
Bearing
Size Code
1 or - 69.927-69.932
(2.7530-2.7532)
2 or - - 69.922-69.927
(2.7528-2.7530) 4 1
73.992-
74.000
(2.9131-
2.9134) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 5
1 or
- 69.927-69.932
(2.7530-2.7532) 2
2 or
- - 69.922-69.927
(2.7528-2.7530) 3 2 73.983-
73.991
(2.9127-
2.9130) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 4
1 or
- 69.927-69.932
(2.7530-2.7532) 1
2 or
- - 69.922-69.927
(2.7528-2.7530) 3 73.975-
73.982
(2.9124-
2.9127) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 2
Installation
1. Install the crankshaft upper bearing.
• The crankshaft upper bearings have an oil hole
and an oil groove. The lower bearings do not.
• Carefully wipe any foreign material from the
upper bearing.
• Locate the position mark applied at
disassembly if the removed upper bearings are
to be reused.
Note:
Do not apply engine oil to the bearing back faces and
the cylinder block bearing fitting surfaces.








015LX125
2. Install the crankshaft assembly.

Apply an ample coat of engine oil to the crankshaft
journals and the crankshaft bearing surfaces
before installing the crankshaft.






015R100004
3. Install the thrust bearing.
•
Apply an ample coat of engine oil to the thrust
bearings before installation. Install the thrust
bearings to the crankshaft center journal.
• The thrust bearing oil grooves must be facing
the sliding faces.


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ISUZU KB P190 2007