2007 ISUZU KB P190 engine

6A – 90 ENGINE MECHANICAL






CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.

Connecting Rod Alignment Per 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 0.15 (0.006)


Connecting Rod Side Face Clearance
1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance between the connecting rod big end side face and the crankpin side
face.
If the measured value exceeds the specified limit, the
connecting rod must be replaced.


Connecting Rod Big End and Crankpin Side Face Clearance
mm (in)
Standard Limit
0.23 (0.009) 0.35 (0.014)


Piston Pin and Connecting Rod Small End
Bushing Clearance
Use a caliper calibrator and a dial indicator to measure the
piston pin and connecting rod small end bushing clearance.
If the clearance between the piston pin and the connecting rod
small end bushing exceeds the specified limit, replace the
piston pin and/or the connecting rod.

Piston Pin and Connecting Rod Small End
Bushing Clearance mm (in)
Standard Limit
4JA1T (L) 0.008-0.020
(0.003-0.0008) 0.050 (0.002)
4JA1TC,
4JH1TC 0.005-0.018
(0.0002-0.0007) 0.050 (0.002)

015LX034
011RY00029 015LX028

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 91




IDLER GEAR SHAFT AND IDLER GEAR
Idler Gear "A" Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside
diameter.
If the measured value is less than the specified limit, the idler
gear shaft must be replaced.

Idler Gear "A" Shaft Outside Diameter mm (in)
Standard Limit
44.945-44.975
(1.7695-1.7707) 44.845 (1.755)




Idler Gear "A" Shaft inside Diameter
1. Use an inside dial indicator or an inside micrometer to measure the idler gear inside diameter.

Idler Gear Inside Diameter mm (in)
Standard Limit
45.0-45.03
(1.7717-1.7718) 45.10 (1.7756)
If the clearance between the idler gear shaft outside diameter
and the idler gear inside diameter exceeds the limit, the idler
gear must be replaced.

Idler Gear Shaft and Idler Gear Clearance mm (in)
Standard Limit
0.025-0.085
(0.0010-0.0033) 0.200 (0.0079)















TIMING GEAR CASE COVER
Replace the crankshaft front oil seal if it is excessively worn or
damaged.

Crankshaft Front Oil Seal Replacement
Oil Seal Removal
Use a plastic hammer and a screwdriver to tap around the oil
seal to free it from the gear case cover.
Take care not to damage the oil seal lip surfaces.


020RY00025
014LX022
020R300004

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ISUZU KB P190 2007

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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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

6A – 96 ENGINE MECHANICAL
PISTON AND CONNECTING ROD




RTW 46ALF000301


Reassembly Steps
1.
Piston 5.
Piston pin snap ring
2.
Connecting rod 6.
Piston ring
3.
Piston pin snap ring 7.
Connecting rod bearing
4.
Piston pin



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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