2007 ISUZU KB P190 torque

6A-46 ENGINE MECHANICAL (C24SE)





Inspection
Check contact pattern ( I) on valve seat and in cylinder head.

Clean
Valves, valve guides, cylinder head.

Flywheel

Removal
1. Remove transmission and clutch.
2. Remove flywheel while locking with 5-88400-446-0.







Torque - Angle Method
Flywheel to crankshaft - 65 Nm/6.5 kgf ⋅m.+30 ° to 45 °

Important!
Use new bolts.
Do not apply grease to the thread.

Installation
1. Install clutch and transmission.


Component Parts
Flywheel and Ring gear. (Manual 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

6A-50 ENGINE MECHANICAL (C24SE)

Clean
Sealing surfaces.





013RW 004










Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.

Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4 ×4 model
only]).
8. Install the crossmember.

Tighten (Torque)
Oil intake pipe to oil pump -8N ⋅m (0.8 kgf ⋅m)
Oil intake pipe bracket to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil pan to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
Bearing bridge to cylinder block – 8 N ⋅m (0.8 kgf ⋅m)



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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-51
OPERATIONS ON CRANK DRIVE
Con-Rod Bearing









Removal
1. Remove oil pan and bearing bridge according to the corresponding operation.
2. Remove con-rod bearing cap and con-rod bearing after marking both sides.

Clean
Con-rod journal, con-rod bearing cap










Installation
1. Install new bearing shafts lightly coated with engine oil.
2. Install con-rod bearing cap.

Torque-Angle Method
Con-rod bearing cap to con-rod - 35N ⋅m (3.5 kgf ⋅m) +45 ° to
60 °

Important!
Use new bolts.

3. Install oil pan and bearing bridge according to the corresponding operation.




Piston with Con-Rod
Removal
1. Remove cylinder head and oil pan according to the corresponding operations.
2. Remove piston with con-rod after marking con-rod bearing cap.





Inspection
Remove and install all parts, if applicable.

Important!
Ring gap offset:
Piston rings - 180 °.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.


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ISUZU KB P190 2007

6A-52 ENGINE MECHANICAL (C24SE)






Installation
1. Install piston with con-rod by inserting with engine oil.
2. Coat piston rings with engine oil and compress with piston ring compressor.

Important!
Installation position:
Arrow / notch on piston head on timing side of engine
Beads on con-rod on clutch side






Torque-Angle Method
Piston to cylinder block.
Con-rod bearing cap to con-rod-35N ⋅m (3.5 kgf ⋅m) +45 ° to 60 °

Important!
Use new bolts.


Installation
1. Install oil pan and cylinder head according to the corresponding operations.
2. Install sealing Gasket or replace if damaged.
3. Install camshaft housing to cylinder head.
4. Install cylinder head according to the corresponding operation.




Con-Rod
Removal
1. Remove piston with con-rod according to the corresponding operation.
2. Disassemble con-rod piston assembly by pressing out piston pin, using 5-8840-0468-0.


Installation
1. Slide guide drift (5-8840-0468-0) in horizontal position through piston and con-rod as far as side plate stops.
2. Tighten bolts evenly so that the piston rests flush on the rear plate.
3. Remove centre piece from guide drift and insert piston bolts (lubricated) into guide drift.


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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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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-57



Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"


Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.











1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.

Installation
1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.

Important!
Do not allow crankshaft to rotate.

Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° + to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.6 kgf ⋅m) +45 °.



Removal
1. Remove bearing cap and shell.

Measure
W idth of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"

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ISUZU KB P190 2007