2007 ISUZU KB P190 wheel

ENGINE MECHANICAL (C24SE) 6A-47

Starter Ring Gear (Manual Transmission)
Removal
1. Remove flywheel according to the corresponding operation.
2. Drill starter ring gear underneath tooth gap approx. 8mm/0.30in. deep with 8mm/0.25in. diameter drill.




3. Separate starter ring gear with chisel on the drilling point.


Installation
1. Install starter ring gear with inner chamfered edge to flywheel.
2. Heat starter ring gear evenly to 180 °C /356 °F to 230 °C
/446 °F (yellow paint mark)
3. Install flywheel according to the corresponding operation.


Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.


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ISUZU KB P190 2007

6A-48 ENGINE MECHANICAL (C24SE)
Seal Ring, Crankshaft
(Oil Pump Housing)

Removal
1. Remove toothed belt rear cover according to the
corresponding operation.
2. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.


Installation
1 Install the protective sleeve to the crankshaft.
2. Coat the sealing lip with protective grease.
3. Install the sealing ring.
4. Install the sealing ring using 5-8840-0455-0.
5. Install the rear toothed belt cover and toothed belt according to the corresponding operations.
6. Replace the sealing ring with a new one.
7. Tighten the belt to the crankshaft.




Seal Ring, Crankshaft Rear
Removal
1. Remove transmission and clutch.
2. Remove flywheel or flex plate according to the corresponding operations.
3. Make hole in middle of sealing ring, turn in self-tapping screw and edge out.




Installation
1. Install protective sleeve.
2. Coat sealing lip with Protective Grease.
3. Install sealing ring using 5-8840-0459-0 and 5-8840- 2597-0.
4. Install flywheel, clutch and transmission.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-49







Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf xm.




RTW 46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 ×4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.















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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-55
OPERATIONS ON REMOVED ENGINE
Crankshaft






















Removal
1. Mount the engine on an engine overhaul stand with appropriate adapters.
2. Remove the aggregates, flywheel/drive disc, oil pan, bearing bridge and oil pump according to the
corresponding operation.
3. Mark the con-rod bearing cover.
4. Remove the crankshaft bearing cover.
5. Remove the crankshaft from cylinder block.

Inspection
Remove and install all parts if necessary.

Crankshaft pulse pickup sensor rotor inspection and repair.
Inspect the crankshaft pulse pickup sensor rotor for excessive
wear and damage.
Replace the crankshaft pulse pickup rotor if the inspection
results exceed wear and damage limits.

Installation
1. Install the crankshaft pulse pickup sensor. Torque: 13N !
!!
!
m (1.3 kgf !
!!
!
m)
2. Install new bearing shells into the cylinder block and bearing cover.
3. Coat the bearing shafts with engine oil. For oversizes-see “Technical Data”
4. Install a new crankshaft into the cylinder block.








Note
The sealing of the crankshaft can be corrected with light
blows with a rubber hammer on the crank arm (arrowed).


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ISUZU KB P190 2007

6A-56 ENGINE MECHANICAL (C24SE)





5. Apply a bead of sealant (TB-1207C or equivalent) in the grooves of both bearing shells.

Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.


Torque - Angle Method
Bearing cover to cylinder block - 50 N ⋅m (5.1 kgf ⋅m) +40 ° to
50 °
Con-rod bearing cover to con-rod - 35 N ⋅m (3.5 kgf ⋅m) +45 ° to
60 °.
Use new bolts.

6. Install oil pump, oil pan, bearing bridge rear crankshaft
sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.









Inspection
Bearing play - bearing cover removed

Measure
W ith "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.

Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.


Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-87






Crankshaft, Cylinder Block (continued)
Flywheel
Starter ring gear Before fitting, heat ring gear to 180 °C -
230 °C

Lateral run-out Permissible lateral run-out of installed
starter ring gear to flywheel: 0.5mm

Precision turning Permissible removal of material in clutch disc lining surface area: 0.3mm

In order to achieve the functional
relationship again after removal of material,
the same removal of material must take
place on the fore part of the flywheel
(contact for clutch assembly)

Dimension A: 2.1 to 2.2mm

Cylinder block
Top deck flatness mm 0.05
Cylinder block height mm 280 ±0.075


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ISUZU KB P190 2007

6A-88 ENGINE MECHANICAL (C24SE)
Recommended Torque Values
N⋅m (kgf ⋅m)

Bearing cover to cylinder block ........................................................................................ 60
1) 6.1 +40 ° to 50 °
Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission .......................................................... 60
2) 6.1
Bracket for engine damping block to engine block .......................................................... 60 6.1
Bracket for pump/compressor to engine block ................................................................ 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft ................................................................................... 50 5.1
Clamping bracket for alternator to intake manifold .......................................................... 25 2.5
Clamping bracket to alternator ......................................................................................... 25 2.5
Con-rod bearing cap to con-rod ....................................................................................... 35
1) 3.5 +45 ° to 60 °
Crankshaft pulley bolts ..................................................................................................... 2 0 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90 ° +90 °
+90 °
Engine damping block to engine bracket ......................................................................... 85 8.7
Engine damping block to side member ............................................................................ 52
1) 5.3
Exhaust manifold to cylinder head ................................................................................... 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
N⋅m (kgf ⋅m)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30° to 45 °
Front exhaust pipe to exhaust manifold ........................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket .................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block ........................................................................... 6
2) 0.6
Oil intake pipe to oil pump ................................................................................................ 8 0.8
Oil pan to cylinder block ................................................................................................... 8
2)3) 0.8
Bearing bridge to cylinder block ....................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ........................................................................................ 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................. 30 3.2
Spark plugs in cylinder head ............................................................................................ 20 2. 3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side .............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head ............................................................................... 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover ................................................................................................... 4 0.4
Toothed belt rear cover .................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................. 20 2.3 (M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7 (M12) ............................................................................ 60 6.1
W ater pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

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6A-90 ENGINE MECHANICAL (C24SE)
ITEM NO. ILLUSTRATION PART NO. PART NAME
13


5-8840-0446-0


Flywheel Holder
4

5-8840-2598-0

Holding W rench
4

5-8840-2599-0

Reamer Set
17

5-8840-2601-0

Installer


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ISUZU KB P190 2007