Isuzu KB P190. Service manual — part 368

6A-112 ENGINE MECHANICAL (4JK1/4JJ1)

RTW56ASH014201

3. Remove the driven plate.

• Remove the driven plate from the flywheel

along with the clutch aligner.

• Install the crankshaft stopper in the starter

installation part of the rear plate.

Note:
Make sure that the stopper is applied with the ring gear
and installed properly.

Special

tool

Crankshaft stopper: 5-8840-0214-0

4. Remove the pilot bearing.

• Remove the pilot bearing from the flywheel.

015RY00018

Special

tool

Pilot Bearing Remover: 5-8840-2000-0

Sliding Hammer: 5-8840-0019-0

5. Remove the flywheel.

• Gradually loosen the flywheel installation bolts

in the order shown in the drawing so that the

flywheel does not rotate.

• After loosening the bolts, remove the stopper

and remove the flywheel.

• In the case of A/T car, after loosening the

flywheel installation bolts, remove the washer,

flexible plate, flywheel and sleeve in this order.

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6. Remove the ring gear.

• Put a bar on the ring gear and hit it with a

hammer to remove it.

LNW21BSH012001

ENGINE MECHANICAL (4JK1/4JJ1) 6A-113

Inspection

1. Visual inspection

• Inspect the flywheel friction surface for cracks

and damages, and replace it if it has

abnormality.

• Inspect the tooth part of the ring gear, replace

the ring gear if it has damage or serious wear.

2. Measurement of the friction surface

• Measure the depth of the friction surface of the

flywheel.

• Adjust it if the measured value is within the

standard value and the limit.

• If the measured value exceeds the limit,

replace the flywheel.

Depth of the friction surface of the flywheel

mm (in)

Standard 18

(0.7087)

Limit 19

(0.7480)

Depth = From the pressure installation surface

to the friction surface.

LNW21BSH011901

3. Flywheel installation bolts.

• There is no damage in appearance.
• Exchange for a new part if damage is

extensive.

Installation

1. Install the ring gear.

• Heat the ring gear evenly with a gas burner to

invite thermal expansion. Do not allow the

temperature of the gas burner to exceed 200°C

(392°F).

• Install the ring gear when it is sufficiently

heated. The ring gear must be installed with the

chamfer facing the clutch.

Note:

• Install the ring gear so that the side with a

pattern faces forward.

• Shrink fit the ring gear to the flywheel.

Make sure that flywheel and ring gear adhesion

is complete.

LNW21BSH01201

2. Install the pilot bearing.

• Place the crankshaft pilot bearing right angle

across the crankshaft bearing installation hole.

• 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.

Special

tool

Pilot Bearing Installer: 5-8522-0024-0

6A-114 ENGINE MECHANICAL (4JK1/4JJ1)

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3. Install the flywheel.

• Install the flywheel of the crankshaft, tighten

them in the order shown in the illustration.

• Apply molybdenum disulfide on the screw part

and setting face of the bolt.

• Install the crankshaft stopper on the starter

installation part of the rear plate.

Tightening torque:

1st step = 59 N

⋅⋅⋅⋅m (6.0 kg⋅⋅⋅⋅m / 43 lb ft)

2nd step = 60° - 90° (degrees)

Special

tool

Crankshaft stopper: 5-8840-0214-0

015RY00001

4. Install the driven plate.

• Use a clutch aligner to install the driven plate

on the flywheel.

LNW21BSH002601

Legend

1. Clutch

Aligner

5. Install the clutch pressure plate.

• Install the pressure plate on the flywheel so that

the installation hole of the pressure plate

matches with the dowel pins of the flywheel.

• Tighten the pressure plate in the order shown

in the illustration.

Tightening torque: 18 N

⋅⋅⋅⋅m (1.8 kg⋅⋅⋅⋅m / 13 lb ft)

RTW56ASH023301

6. Install the transmission assembly.

Refer to removal procedure for “TRANSMISSION”.

ENGINE MECHANICAL (4JK1/4JJ1) 6A-115

Torque Specifications

Special Tools

ILLUSTRATION

PART NO.

PART NAME

ILLUSTRATION

PART NO.

PART NAME

5-8840-0214-0

Crankshaft stopper

5-8522-0024-0

Pilot Bearing Installer

5-8840-2000-0

Pilot Bearing Remover

5-8840-0019-0

Sliding Hammer