2007 ISUZU KB P190 engine

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

ENGINE MECHANICAL (4JK1/4JJ1) 6A-135
Torque Specifications




RTW 76AMF000301

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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-137
16. Remove the piston cooling pipe.



RTW 76ASH001101
Inspection
1. Carefully remove water stains or other foreign
matters on the surface of the cylinder block.
• Be careful not to damage the cylinder block.
2. Carefully remove the liquid gasket on the crankcase mounting surface.
3. Clean up the cylinder block.
4. Visually inspect the cylinder block. • Conduct color check and hydraulic (o
r
pneumatic) test and if you find a crack or other
damage, replace the cylinder block.





RTW 76ASH000801

5. Cylinder block wear measurement.
• Use a cylinder indicator to measure the cylinde
r
bore at measuring point (1) in the thrust (2-2)
and axial (3-3) directions of the crankshaft.
• Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder block must be replaced o
r
rebored.





012RY00010

Cylinder block bore diameter mm (in)
Standard 95.421 − 95.450 (3.7567 − 3.7579)
Limit 95.48 (3.7590)




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ISUZU KB P190 2007

6A-138 ENGINE MECHANICAL (4JK1/4JJ1)
6. Cylinder Reboring.
• Select oversize pistons to fit the largest cylinde
r
bore (previously measured).
• At a point 11 mm (0.43 in) above the lowe
r
edge of the piston skirt, measure the piston
diameter at a right angle to the piston pin.
Calculate the additional cylinder boring required
for each cylinder.





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

• Formula
Boring inside diameter = D + C - H ± E
D = Piston outside diameter (Measured Oversize Piston)
C = Piston and cylinder bore clearance 0.082 - 0.100 mm (0.0032 - 0.0039 in)
H = Honing allowance 0.03 mm (0.0012 in) or less
E = Boring machine error

Piston size mm (in)
Standard 95.330 - 95.359 (3.7531 - 3.7543)
Oversize (0.25) 95.580 - 95.609 (3.7629 - 3.7641)
(0.50) 95.830 - 95.859 (3.7728 - 3.7739)
(0.75) 96.080 - 96.109 (3.7826 - 3.7838)


• Bore and hone the individual cylinders as
required.
• Once again, measure the individual cylinde
r
bores.
Each cylinder bore remainder mm (in)
0.02 (0.0008) or less.

7. Cylinder block upper face warpage.
• Use a straight edge (1) and a thickness gauge
(2) to measure the four sides and the two
diagonals of the cylinder block upper face.
• If the measured values exceeds the limit, the
cylinder block must be replaced.
Cylinder block upper face warpage mm (in)
Standard 0.05 or less (0.002 or less)
Limit 0.20 (0.0080)







012R100001


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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

6A-140 ENGINE MECHANICAL (4JK1/4JJ1)
Lubrication System
Service Precautions
• During each disassembly, remove the old gasket
adhering to each part and mating part completel
y
using a scraper at the location, where the fluid
gasket is to be used, clean the traces of oil,
moisture, and dirt completely using waste cotton
and apply the specified new fluid gasket at each
location.
•
Avoid excessive or insufficient coating volume.
Note that seizure may occur in case of excessive
coating due to clogging of the oil gallery and oil jet,
and oil and water leakage may occur if the coating
is insufficient.
• Always, the start and end of the application should
be overlapped.
Explanations on functions and operation
The lubrication system uses the filter element combined
with a full flow bypass, water-cooled oil cooler, and oil
jet for piston cooling.
Lubricating system diagram






LNW 76ALF000201
1. Oil Pump Relief Valve Operating Pressure: 490 – 686 kPa (5.0 – 7.0 kg/cm2 / 71 – 100 psi)
2. Oil Cooler Relief Valve Opening Pressure: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)
3. Oil Filter Relief Valve Opening Pressure: 80 – 120 kPa (0.8 – 1.2 kg/cm2 / 11 – 17 psi)
4. Oil Pressure Switch Operating Pressure: 29.4 – 49.0 kPa (0.3 – 0.5 kg/cm2 / 4.3 – 7.1 psi)
5. Regulating Valve: 176 – 216 kPa (1.8 – 2.2 kg/cm2 / 26 – 31 psi)


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-141
Functional Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil o
r
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.






RTW 56ASH015501
Legend
1. Oil Pressure Switch

5. W arm the engine.
6. Measure the oil pressure, to check whether it is more than 400 kPa (4 kg/cm
2 / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.
Engine oil
•
Ensure the car is on level ground. Before starting
the engine or when 30 minutes or more have
elapsed after stopping the engine, check the
engine oil volume using the level gauge. The
volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lowe
r
limit. Also, check for contamination of the engine
oil.




RTW 56ASH015601







RTW 56ASH015701
Legend
1. Lower Limit
2. Upper Limit



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