2007 ISUZU KB P190 engine

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

6A – 102 ENGINE MECHANICAL







RTW 46ALF000501

Reassembly Steps-2
19.
Crankshaft timing gear 23.
Injection pump
20.
Idler gear shaft 24.
W ater pump
21.
Idler gear "A" 25.
Timing gear case cover
22.
Idler gear "B" and shaft 26.
Crankshaft damper pulley


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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 103




Reassembly Steps-3
27.
Cylinder head gasket 31.
Thermostat housing with thermo
switch
28.
Cylinder head 32.
W ater by-pass hose
29.
Push rod 33.
Injection nozzle and bracket
30.
Rocker arm shaft and rocker
arm 34.

Cylinder head cover with gasket

011R300002

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ISUZU KB P190 2007

6A – 104 ENGINE MECHANICAL



Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.








2. Tappet
1. Apply a coat of engine oil to the tappet and the cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if the tappet is to be reused).

NOTE:
The tappet must be installed before the camshaft
installation.





3. Crankshaft Upper Bearing
The crankshaft upper bearings have an oil hole and an oil
groove. The lower bearings do not.
1. Carefully wipe any foreign material from the upper bearing.

NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
2. Locate the position mark applied at disassembly if the removed upper bearings are to be reused.




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


015R100004 015R100003
014LX088
015LX125

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 105






5. Crankshaft 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.
















6. Crankshaft Bearing Cap With Lower Bearing
Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. Apply the recommended liquid gasket or its equivalent to the No. 5 crankshaft bearing cap cylinder body fitting
surfaces at the points shown in the illustration.
NOTE:
Be sure that the bearing cap fitting surface is
completely free of oil before applying the liquid
gasket. Three bond 1207B Do not allow the liquid
gasket to obstruct the cylinder thread holes and
bearings.
ThreeBond 1207B is a fast-drying liquid gasket.
Tighten the bearing caps immediately after applying
the gasket.









2. Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.The bearing
cap numbers must be facing up.
3. Apply engine oil to the crankshaft bearing cap bolts.















4. Tighten the crankshaft bearing cap bolts to the
specified torque a little at time in the sequence shown
in the illustration.

Crankshaft Bearing Cap Torque N·m(kg·m/lbft)
167 (17/123)
5. Check to see the crankshaft turns smoothly by rotating it manually.


015LX115
015LX127
015LX128
015LX129

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ISUZU KB P190 2007

6A – 106 ENGINE MECHANICAL


7. Camshaft
1. Apply a coat of engine oil to the camshaft and the camshaft bearings.
2. Install the camshaft to the cylinder body. Take care not to damage the camshaft bearings.











8. Timing Gear Case
Tighten the timing gear case with timing gear case gasket
to the specified torque.

Timing Gear Case Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)











9. Camshaft Thrust Plate
Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.

Thrust Plate Bolt Torque N·m(kg·m/lbft)
19 (1.9/14)




RTW 36ASH000901








10. Camshaft Timing Gear
1. Install the camshaft timing gear to the camshaft. The timing gear mark must be facing outward.
2. Tighten the timing gear to the specified torque.


Timing Gear Bolt Torque N·m(kg·m/lbft)
110 (11.2/82)
014RY00019
020R300003
020RY00032

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ISUZU KB P190 2007