2007 ISUZU KB P190 check engine

ENGINE MECHANICAL 6A – 69
3. Check that the rocker arm oil port is free of obstructions. If necessary, use compressed air to clean the rocker arm
oil port.




Rocker Arm Correction
Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.



CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner. Refer to "Cylinder Liner Replacement".
















3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.

Cylinder Body Upper Face Warpage mm (in)
Standard Limit
0.05 (0.002) or less 0.20 (0.008)


Cylinder Body Height (H) (Reference) mm (in)
Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)
4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner. Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.


014RY00024
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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 73






Cylinder Liner Installation
1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and bore surfaces.

NOTE:
All foreign material must be carefully removed from
the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2) from the top of the cylinder body.










4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).

NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
6. Use the bench press to apply a seating force of 4,900 N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder liner projection.
Refer to "Cylinder Liner Projection Inspection".

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 85
CRANKSHAFT PILOT BEARING
Check the crankshaft pilot bearing for excessive wear and
damage and replace it if necessary.















Crankshaft Pilot Bearing Replacement
Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the crankshaft pilot
bearing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
















Crankshaft Pilot Bearing Installation
1. Place the crankshaft pilot bearing right angle across the crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing outer races with a brass hammer to drive the bearing into the
crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0

NOTE:
Strike only the crankshaft pilot bearing outer race with
the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.







































FLYWHEEL AND RING GEAR
Flywheel
1. Inspect the flywheel friction surface for excessive wear and
heat cracks.
2. Measure the flywheel friction surface depth. If the measured value is within the specified limit, the
flywheel may be reground.
If the measured value exceeds the specified limit, the
flywheel must be replaced.

Flywheel Friction Surface Depth (1) mm (in)
Standard Limit
4JA1T (L),
4JA1TC 20 (0.7874) 21 (0.8267)
4JH1TC 18 (0.7087) 19 (0.7480)

Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
015RY00010
015RY00019 015RY00018

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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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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

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
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ISUZU KB P190 2007

6A – 108 ENGINE MECHANICAL











10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of anglar tigthen method.

Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft) 4JA1T (L), 4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step; 29.0–29.2 (3.00/22.0–3.01/22.2) 4JH1TC
2nd step; 45°-60 °






13. Piston Cooling Oil Jet
1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified torque.

Oil Jet Bolt Torque N·m(kg·m/lb ft)
M8 × 1.25 19 (1.9/14)
M6
× 1.00 8 (0.8/6)


Relief Valve Torque N·m(kg·m/lb ft)
29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.
















14. Oil Pump with Oil Pipe Apply a coat of the molybdenum disul fide and engine oil
enough on the pinion gear.
Install the oil pump with the oil pipe and tighten the bolts to
the specified torque.

Oil Pump Bolt Torque N·m(kg·m/lb ft)
19 (19/14)
NOTE:
Take care not to damage the O-rings when tightening
the oil pipe bolts.







15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer: 5-8840-2359-0


015LX130
015LX112
052LX010
051R100004

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ISUZU KB P190 2007

ENGINE MECHANICAL 6A – 117


RTW 46ASH001201
33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder bracket to the cylinder head.










3. Tighten the nozzle holder bracket bolt to the specified
torque.


Injection Nozzle Holder Bracket Bolt
Torque N·m(kg·m/lbft)
37 (3.8/28)













Note on Valve Clearance Adjustment
Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.

Valve Clearance (At Cold) mm(in)
0.4 (0.0157)


RTW 46ASH001101















34. Cylinder Head Cover
1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical order shown in the illustration.


Cylinder Head Cover Bolt Torque N·m(kg·m/lbft)
13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose to the cylinder head cover.




014RY00015

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