2007 ISUZU KB P190 oil

ENGINE MECHANICAL 6A – 93
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
ROCKER ARM SHAFT AND ROCKER ARM


020RY00029

Reassembly Steps
1.
Rocker arm shaft 5.
Rocker arm
2.
Rocker arm shaft snap ring 6.
Rocker arm shaft spring
3.
Rocker arm 7.
Rocker arm shaft snap ring
4.
Rocker arm shaft bracket








Reassembly
1. Rocker Arm Shaft
1. Position the rocker arm shaft with the large oil hole (4φ) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker arm, the rocker arm shaft bracket, and the spring.
2. Rocker Arm Shaft Snap Ring
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
7. Rocker Arm Shaft Snap Ring

014RY00037

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ISUZU KB P190 2007

6A – 94 ENGINE MECHANICAL
CYLINDER HEAD




RTW 46ALF001301

Reassembly Steps
1.
Cylinder head 6.
Valve spring upper seat
2.
Valve spring lower seat 7.
Split collar
3.
Valve stem oil seal 8.
Intake manifold gasket
4. Intake and exhaust valve 9. Intake manifold
5.
Valve spring



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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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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 97


Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to the piston.





RTW 36ASH001801
Install the piston to the connecting rod so that the piston
head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
3. Piston Pin Snap Ring




RTW 36ASH001901


4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the piston pin hole.
2. Use your fingers to force the piston pin into the piston until it makes contact with the snap ring.



5. Piston Pin Snap Ring 1. Use your fingers to force the piston pin snap ring into the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the piston pin.



F06MV015
015R100001

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ISUZU KB P190 2007

6A – 98 ENGINE MECHANICAL


RTW 36ASH002001



































6. Piston Ring
1. Use a piston ring replacer to install the three piston rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring

NOTE:
Install the compression rings with the stamped side
facing up.
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.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the piston ring grooves





7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.




015R100006

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 99

POSITIVE CRANKCASE VENTILATION (PCV) VALVE


RTW 46AMF000101


Reassembly Steps
1.
Positive Crankcase Ventilation
(PCV) Valve 5.

Fixing bolt
2.
Rubber space 6.
Oil filler cap
3.
Cylinder head insulator cover
4.
Breather pipe


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ISUZU KB P190 2007

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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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 101
MAJOR COMPONENT



Reassembly Steps-1
1.
Cylinder body 10.
Camshaft timing gear
2.
Tappet 11.
Piston and connecting rod with
upper bearing
3.
Crankshaft upper bearing 12.
Connecting rod bearing cap with
lower bearing
4.
Crankshaft 13.
Piston cooling oil pipe
5.
Crankshaft thrust bearing 14.
Oil pump with oil pipe
6.
Crankshaft bearing cap with
lower bearing 15.

Crankshaft rear oil seal
7.
Camshaft 16.
Crank case
8.
Timing gear case 17.
Cylinder body rear plate
9.
Camshaft thrust plate 18.
Flywheel


014R300004

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ISUZU KB P190 2007