2007 ISUZU KB P190 oil

ENGINE MECHANICAL (4JK1/4JJ1) 6A-125
Special Tools
ILLUSTRATION PART NO.
PART NAME

5-8840-2359-0
Oil seal installer

5-8840-2360-0
Oil seal remover





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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-127
Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail" in the fuel system section.
6. Remove the front cover.
Refer to "Front Cover".
7. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
8. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
9. Remove the timing gear train.
Refer to "Timing Gear Train".
10.Remove the oil pump.
Refer to "Oil Pump".
11. Remove the gear case assembly.
Refer to “Gear Case Assembly”.
12. Remove the crankshaft gear.









901R100008
13. Remove the crank case.
Refer to "Crank Case and Oil Pan".
14.Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the bearing cap. • Loosen the crankshaft bearing cap bolts in
numerical order a little at a time.







015RY00003
16.Remove the lower crankshaft bearings.
17.Remove the crankshaft assembly.
18.Remove the thrust bearing.
19.Remove the upper crankshaft bearings.
Disassembly
1. Remove the crank angle sensor rotor (1). • Confirm that the pin (2) is not removed.




RTW 76ASH001501


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ISUZU KB P190 2007

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-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

ENGINE MECHANICAL (4JK1/4JJ1) 6A-133






015LX115
4. Install the lower crankshaft bearing.
• Before the crankshaft bearing installation,
select the appropriate bearings in accordance
with the description in CRANK BEARING
SELECTION of INSPECTION AND REPAIR.
• 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 completel
y
free of oil before applying the liquid gasket. ThreeBond
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.







015LX127

5. Install the bearing cap.
• 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.








015LX128
• 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 / lb ft)
166 (16.9 / 122)
Check to see the crankshaft turns smoothly by
rotating it manually.
Note:
Confirm that the crankshaft turns smoothly.








015LX129
6. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".

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ISUZU KB P190 2007

6A-134 ENGINE MECHANICAL (4JK1/4JJ1)
7. Install the crank case.
Refer to "Crank Case and Oil Pan".
8. Install the crankshaft gear.





RTW 56ASH017001
9. Install the gear case assembly.
Refer to "Gear Case Assembly".
10.Install the oil pump.
Refer to "Oil Pump".
11.Install the timing gear train.
Refer to "Timing Gear Train".
12.Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
13.Install the front cover.
Refer to "Timing Gear Train".
14.Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
15.Install the fuel supply pump and fuel rail.
Refer to "Fuel Supply Pump" and "Fuel Rail".
16.Install the cylinder head.
Refer to "Cylinder Head".
17.Install the camshaft assembly.
Refer to "Camshaft Assembly".
18.Install the cylinder head cover.
Refer to "Cylinder Head Cover".
19.Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ISUZU KB P190 2007

6A-136 ENGINE MECHANICAL (4JK1/4JJ1)
Cylinder Block
Components




RTW 76ASF000101
Legend
1. Cylinder Block



Removal
1. Demount the engine assembly.
Refer to "Engine Assembly".
2. Remove the cylinder head cover.
Refer to "Cylinder Head Cover".
3. Remove the camshaft assembly.
Refer to "Camshaft Assembly".
4. Remove the cylinder head.
Refer to "Cylinder Head".
5. Remove the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly" in FUEL SYSTEM Section.
6. Remove the oil filter assembly and oil cooler.
Refer to “Oil Filter Assembly and Oil Cooler”.
7. Remove the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal".
8. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
9. Remove the oil pan.
Refer to "Oil Pan".
10. Remove the water pump.
Refer to "W ater Pump" in Cooling System Section.
11. Remove the front cover.
Refer to "Front Cover".
12. Remove the timing gear train.
Refer to "Timing Gear Train".
13. Remove the oil pump.
Refer to "Oil Pump".
14. Remove pistons and connecting rods.
Refer to "Piston and Connecting Rod".
15. Remove the crankshaft.
Refer to "Crankshaft".


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-139

Cylinder block height (H) (Reference) mm (in)
Standard 259.945 – 260.055 (10.2340 – 10.2384)







012R100009
Installation
1. Install the piston cooling pipe.
• Align the dowel pin of the piston cooling pipe
with the pin hole on the cylinder block and
tighten with the relief valve.
Tightening torque: Relief valve 30 N ⋅
⋅⋅
⋅
m (3.1 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
bolts M8 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
bolts M6 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
Note:
Be careful not to deform or damage the piston cooling
pipe nozzle.



RTW 76ASH001101
2. Install the crankshaft.
Refer to "Crankshaft".
3. Install pistons and connecting rods.
Refer to "Piston and Connecting Rod".
4. Install the oil pump.
Refer to "Oil Pump".
5. Install the timing gear train.
Refer to "Timing Gear Train".
6. Install the front cover.
Refer to "Front Cover".
7. Install the water pump.
Refer to "W ater Pump" in Cooling System Section.
8. Install the oil pan.
Refer to "Oil Pan".
9. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal".
10. Install the crankshaft front oil seal. Refer to "Crankshaft Front Oil Seal".
11. Install the oil filter assembly and oil cooler.
Refer to "Oil Filter Assembly and Oil Cooler".
12. Install the fuel supply pump and fuel rail assembly.
Refer to "Fuel Supply Pump" and "Fuel Rail Assembly " in Fuel System Section.
13. Install the cylinder head.
Refer to "Cylinder Head".
14. Install the camshaft assembly.
Refer to "Camshaft Assembly".
15. Install the cylinder head cover.
Refer to "Cylinder Head Cover".
16. Mount the engine assembly on the chassis.
Refer to "Engine Assembly".


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ISUZU KB P190 2007