2007 ISUZU KB P190 engine

6A-102 ENGINE MECHANICAL (4JK1/4JJ1)
Note:
Sort the removed bearings according to cylinders b
y
using tags.



LNW 21BSH004901
8. Remove the piston and connecting rod.
• Remove carbon on the upper side of the
cylinder block with a scraper.
• Pull out the piston and connecting rod towards
the cylinder head.
Note:
Be sure not to damage the oil jet and cylinder block
when pushing out the connecting rod.
9. Remove the connecting rod bearing.
Note:
Sort the bearings in the order of cylinders when reusing
them so that they are not confused with the bearings o
f
other cylinders.
Disassembly
1. Remove the piston ring.
• Use ring pliers to remove the piston ring.
Note:
Sort the piston rings in the same order as the cylinders
when reusing them so that they are not confused with
the pistons and piston rings of other cylinders.




LNW 21BSH005101
2. Remove the snap ring.
3. Remove the piston pin.
Note:
Sort the disassembled piston pins, pistons and
connecting rods together in the same order as the
cylinders.







LNW 21BSH005201
4. Remove the connecting rods from the piston.
5. Clean the piston. • Carefully clean carbon that is adhered to the
head of the piston and the groove of the piston
ring.
Note:
Do not use a wire brush to clean the piston because it
scratches the piston.
Visually inspect the piston for cracks, burns and othe
r
excessive wear, and replace it if there is an
y
abnormality.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-103
6. Measure the gap between the piston and the inner
diameter of the cylinder block.
Inner diameter of the cylinder block. • Use a cylinder bore dial indicator to measure
the cylinder block inner diameter both in the
thrust and radial directions in the designated
position.
• Measurement position (from the upper surface
of the cylinder block) 20 mm (0.79 in)
• Measure the cylinder block inner diamete
r
based on the average value of the actual
measurement values on 6 positions.
Cylinder block inner diameter mm (in)
95.421 – 95.450 (3.75673 – 3.75787)






LNW 61ASH006401
Legend
1. 20 mm (0.79 in)
2. Radial
3. Thrust

Piston outside diameter
• Use a micrometer to measure the outside
diameter of the piston in the right angle to the
piston pin in the designated position.
• Measurement position (from the bottom surface
of the piston) 11.00 mm (0.43 in).






RTW 56ASH023101
Legend
1. 11 mm (0.43 in)

Gap between the piston and the inner
diameter of the cylinder block mm (in)
Standard 0.082 – 0.100 (0.0032 – 0.0039)
NOTE:
If the gap exceeds the standard value, replace the
piston or rebore the cylinder block.
7. Piston replacement • The head of piston has a marking of grade A, B
or C.
• Refer to “Cylinder Block” if over size piston is
installed.

Piston Grade (Service Part) mm (in)
A 95.330 – 95.339 (3.75314 – 3.75350)
B 95.340 – 95.349 (3.75354 – 3.75389)
C 95.350 – 95.359 (3.75393 – 3.75428)


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ISUZU KB P190 2007

6A-104 ENGINE MECHANICAL (4JK1/4JJ1)
4JK1





RTW 56ASH025701
Legend
1. Grade
2. Front Mark Cut


4JJ1





LNW 76ASH001401
Legend
1. Grade
2. Front Mark Cut

8. Inspect the piston ring.
• Insert the piston ring horizontally (in the position
it would assume if it were installed to the
piston) into the cylinder block.





LNW 21BSH009301
• Push the piston ring into the cylinder bore until
it reaches the measuring point 1 or 2 where the
cylinder block bore is the smallest.
Do not allow the piston ring to slant to one side or the other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or Measuring Point 2 120 mm (4.7 in).






LNW 61ASH004401











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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-105




LNW 61ASH004501
• Use a thickness gauge to measure the piston
ring gap.
If the measured value exceeds the specified limit, the piston ring must be replaced.
Piston ring gap mm (in)
Standard Limit
1st compression ring 0.3 - 0.5
(0.0118 - 0.0197) 1.50
(0.059)
2nd compression ring 0.3 - 0.5 (0.0118 - 0.0197) 1.50
(0.059)
Oil ring 0.25 - 0.45
(0.0098- 0.0177) 1.50
(0.059)
Measure the clearance between the piston ring
groove and the piston.
• Remove carbon in the piston ring groove.
• Put the piston ring in the piston ring groove, use
a thickness gauge to measure the gap between
them.
• If the clearance between the piston ring groove
and the piston exceeds the limit, replace the
piston and the piston ring.

Piston ring and piston ring groove clearance mm (in)
Standard Limit
1st compression ring — ∗ — ∗
2nd compression ring 0.05 - 0.09
(0.0020 - 0.0035)1.50
(0.059)
Oil ring 0.03 - 0.07
(0.0012- 0.0028) 1.50
(0.059)
∗ Measurement is impossible







LNW 21BSH009501
9. Inspect the piston pin.
• Visually inspect the piston pin for cracks,
scratches and other damage, and replace it i
f
necessary.
• Use a micrometer to measure the oute
r
diameter of the piston pin. If the measured
value exceeds the limit, replace the piston pin.
Piston pin outer diameter mm (in)
Standard 33.995 – 34.000 (1.33838 – 1.33858)
Limit 33.970 (1.33740)




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ISUZU KB P190 2007

6A-106 ENGINE MECHANICAL (4JK1/4JJ1)



LNW 21BSH009601
• Inspect to make sure that there is a resistance
to the extent which the piston can push the
piston pin lightly in normal temperatures.
• If it feels a large looseness or instability in
normal temperatures, replace the piston o
r
piston pin.






LNW 21BSH009701
• Measure the bush of the small edge of the
connecting rod. If the clearance of the bush inne
r
diameter and the pin diameter exceeds the limit,
replace the bush or connecting rod assembly, and
the pin.
Piston pin and connecting rod small end bushing
clearance mm (in)
Standard 0.008 - 0.020 (0.0003 - 0.0008)
Limit 0.05 (0.0020)







LNW 21BSH009801
10. Measure the clearance between the piston and
the piston pin.
•
Apply engine oil on the piston pin. Use your
finger to push it in the piston hole and rotate it.
If the pin smoothly rotates without instability,
the clearance is normal. If there is instability,
measure the clearance. If the clearance
exceeds the limit, replace the piston and the
piston pin.
Piston pin and piston pin hole clearance mm (in)
Standard 0.004 - 0.017 (0.0002 - 0.0007)
Limit 0.04 (0.0016)
11. Measure the connecting rod alignment.
• Use a connecting rod aligner to measure the
torsion and parallel level of the big end hole
and the small end hole. If the measured value
exceeds the limit, replace it.
Connecting rod alignment
(par length of 100 mm (3.94 in)) mm (in)
Standard Limit
Distortion 0.08 (0.003) or less 0.20 (0.008)
Parallelism 0.05 (0.002) or less 1.50 (0.060)


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-107





LNW 21BSH010401
12. Measure the bearing oil clearance.
• Install the bearing to the connecting rod big
end.
• Tighten the bearing cap to the two step o
f
angular tightening method.
• Use an inside dial indicator to measure the
connecting rod bearing inside diameter.
Connecting rod bearing cap bolt torque:
N ⋅m (kg ⋅m / lb ft)
1st step 29.4 (3.0 / 22)
2nd step 45 deg
If the clearance between the measured bearing
inside diameter and the crankpin exceeds the
specified limit, the bearing and/or the crankshaft
must be replaced.
Crankpin and bearing clearance mm (in)
Standard 0.029 - 0.083 (0.0011 - 0.0033)
Limit 0.10 (0.0039)
Reassembly
1. Install the piston.
2. Install the connecting rod. • Install it so that the front mark of the head o
f
the piston, and the connecting rod forging mark
(projecting) on the connecting rod, both face in
the same direction.
• Install the snap ring of one side.







LNW 46ASH004601
Legend
1. Front Mark
2. Forging Mark (Projecting)

4. Apply enough engine oil on the piston pin, push it
in the piston and the connecting rod small edge.
5. Use snap ring pliers to install the snap ring.
Note:
Make sure that the snap ring is installed in the ring
groove properly. Make sure that the connecting rod
moves smoothly.






015R100001
6. Use ring pliers to install the piston ring.
• Install the piston rings in the order shown in the
illustration.
• Install 2nd and 1st compression rings in this
order so that the marks “2N” and “N” face
upward.

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ISUZU KB P190 2007

6A-108 ENGINE MECHANICAL (4JK1/4JJ1)
• 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.






RTW 56ASH023201
Legend
1. Compression Ring 1st
2. Compression Ring 2nd
3. Oil Ring
4. Expander

Installation
1. Install the connecting rod bearing.
• Install the bearing on the connecting rod, and
apply engine oil on the bearing.
2. Install the piston and connecting rod assembly. • Apply enough engine oil on the piston ring, ring
groove and piston side surface.
• W ith the piston front mark cut facing forward,
use the piston ring compressor to insert the
piston in the cylinder block.
Note: • Be sure not to make the connecting rod touch
the oil jet when pushing in the piston.
• Be sure not to harm the inside of the cylinde
r
block when pushing in the piston.
Special tool
Piston ring compressor: 5-8840-9018-0







015LX096
3. Install the connecting rod cap.
• Install the bearing on the connecting rod cap
and apply engine oil.
• Install the cap, matching the numbers (1, 2, 3,
and 4) of the caps and connecting rods.





015R100007
• Apply engine oil disulfide on the screw part and
the setting face of the tightening bolt and
tighten it with the designated torque.
Tightening torque: 1st step = 29 N ⋅
⋅⋅
⋅
m (3.0 kg ⋅
⋅⋅
⋅
m / 22 lb ft)
2nd step = 45° (degrees)
Special tool
Angle gauge: 5-8840-0266-0
Note:
Make sure that the crankshaft smoothly rotates.


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ISUZU KB P190 2007

ENGINE MECHANICAL (4JK1/4JJ1) 6A-109






015LX130
4. Install the oil pan.
Refer to “Oil Pan”.
5. Install the gear case assembly.
Refer to “Gear Case Assembly”.
6. Install the cylinder head.
Refer to “Cylinder Head”.
7. Install the camshaft assembly.
Refer to “Camshaft Assembly”.
8. Install the cylinder head cover.
Refer to “Cylinder Head Cover”.



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ISUZU KB P190 2007