Page 2689 of 6020
Engine Mechanical – V6 Page 6A1–210
11 Install connecting rod guide pin set, Tool No.
EN-46121 (1) to the connecting rod bolt holes.
Figure 6A1 – 376
CAUTION
Do not damage the crankshaft journal,
cylinder wall and piston cooling jets when
removing the connecting rod and piston
assembly.
12 Using connecting rod guide pin set, Tool No. EN-46121 (1), push the connecting rod and piston
assembly (2) through the top of the cylinder.
Figure 6A1 – 377
CAUTION
When dismantled, ensure the connecting
rod, connecting rod cap, piston and
bearings are organised in their original
position and location. This will also aid
engine mechanical diagnosis.
13 Remove connecting rod guide pin set, Tool No. EN-46121 (1) from the connecting rod bolt holes.
14 Remove the upper connecting rod bearing from the connecting rod (2).
Figure 6A1 – 378
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ISUZU KB P190 2007
Page 2690 of 6020
Engine Mechanical – V6 Page 6A1–211
15 Remove the lower connecting rod bearing (1) from
the connecting rod cap (2).
Figure 6A1 – 379
NOTE
The cap and rod are a matched set and must be
kept together.
16 Reattach the connecting rod cap (1) to the connecting rod (2) to prevent damage to their mating surfaces.
17 Repeat steps 4 to 16 for the remaining piston and connecting rod assemblies.
Figure 6A1 – 380
Disassemble
CAUTION
A piston ring expander must be used to
remove and install the piston rings. Only
expand the rings far enough to fit over the
piston lands. If the rings are overexpanded,
the top ring will shatter and the others will
distort.
1 Remove the piston rings (2) using a piston ring expander (1). Place each ring in a clean shop towel
for storage.
Figure 6A1 – 381
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ISUZU KB P190 2007
Page 2691 of 6020
Engine Mechanical – V6 Page 6A1–212
CAUTION
Do not reuse the piston pin retainers.
2 Remove the piston pin retainers by using the removal access notch (1) in the side of the piston. Discard the
piston pin retainers.
Figure 6A1 – 382
3 Slide the piston pin (1) out of the piston (2). The piston will disconnect from the connecting rod.
Figure 6A1 – 383
Clean and Inspect
Piston Cleaning Procedure
CAUTION
Do not use a wire brush to clean any part of
the piston.
1 Clean the piston skirts and the pins with a suitable solvent.
2 Clean the piston ring grooves with a groove cleaner. Ensure the oil ring holes and slots are clean.
Safety glasses must be worn when using
compressed air.
3 Dry the piston with compressed air.
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Page 2692 of 6020

Engine Mechanical – V6 Page 6A1–213
Piston Inspection Procedure
1 Inspect the pistons for the following conditions:
• eroded areas at the top of the piston (1),
• piston pin retainer grooves for burrs (2),
• worn piston pin bores or worn piston pins (3),
• scuffed or damaged skirt coating (4),
• ring grooves for cracks, nicks or burrs that may
cause binding (5), and
• warped or worn ring lands.
2 Replace pistons that show any signs of damage or excessive wear.
Figure 6A1 – 384
Piston Measurement
1 Measure piston width using the following procedure:
a Using an outside micrometer, measure the width of the piston at 30 mm below the crown
top (1), at the thrust surfaces of the piston,
perpendicular to the piston pin centreline.
b Compare the measurement of the piston to its original cylinder by subtracting the piston width
from the cylinder diameter.
c Check your measurements with specifications, refer to 5 Specifications.
d If the clearance obtained through measurement is greater than the provided specifications and
the cylinder bores are within specification,
replace the piston.
Figure 6A1 – 385
2 Measure the piston pin bore to piston pin (2) clearances using the following procedure:
a Piston pin bores and pins must be free of varnish or scuffing.
b Use an outside micrometer (1) to measure the piston pin in the piston contact areas.
Figure 6A1 – 386
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ISUZU KB P190 2007
Page 2693 of 6020

Engine Mechanical – V6 Page 6A1–214
3 Using an inside micrometer, measure the piston pin
bore (1). Compare the result with the piston pin
diameter and piston pin to piston pin bore clearance
listed in the specifications, refer to 5 Specifications.
4 If the clearance is excessive, determine which piece is out of specification and replace as required.
5 Replace the piston if any of its dimensions are out of specification.
6 If the new piston does not meet clearance specifications, the cylinder block may need to be
oversized to 0.25 mm. There is only one size of
oversized pistons and rings available for service.
Figure 6A1 – 387
Piston Ring Measurement
1 Measure the piston ring end gap using the following procedure:
a Place the piston ring (1) in the area of the bore where the piston ring will travel, approximately 25 mm below
the deck surface. Ensure the ring is square with the
cylinder bore by positioning the ring with the piston
head.
b Measure the end gap of the piston ring with feeler gauges (2), refer to 5 Specifications.
c If the clearance exceeds the provided specifications, the piston rings must be replaced.
d Repeat the procedure for all piston rings.
Figure 6A1 – 388
2 Measure the piston ring side clearance using the following procedure:
a Roll the piston ring (1) entirely around the piston ring groove. If any binding is caused by the ring groove,
dress the groove with a fine file. If any binding is
caused by a distorted piston ring, replace the ring.
b W ith the piston ring on the piston, use feeler gauges (2) to check clearance at multiple locations.
c Compare the measurements with piston ring side clearance listed in the specifications, refer to 5
Specifications.
d If the clearance is greater than specifications, replace the piston rings.
Figure 6A1 – 389
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Page 2694 of 6020

Engine Mechanical – V6 Page 6A1–215
3 There is a locating dimple (1) on the compression
rings. Install the compression rings with the dimple
facing up.
4 If the new ring does not reduce the clearance to the correct specification, install a new piston.
5 If the new piston does not meet clearance specifications, the cylinder block may need to be
oversized to 0.25 mm. There is only one size of
oversized pistons and rings available for service.
Figure 6A1 – 390
Connecting Rod Cleaning Procedure
1 Clean the connecting rods in solvent.
Safety glasses must be worn when using
compressed air.
2 Dry the connecting rod using compressed air.
3 Remove the connecting rod cap and clean the threads.
4 Remove the connecting rod bearing and discard. Never reuse a connecting rod bearing that has been used in a running engine.
Connecting Rod Visual Inspection Procedure
1 Inspect the piston pin bushing (4) for scoring or
damage.
2 Inspect the connecting rod beam (1) for twisting or bending.
3 Inspect the rod cap (2) for any nicks or damage caused by possible interference.
4 Inspect for scratches or abrasion on the rod bearing seating surface.
5 If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with
a light emery paper.
6 Retain the original bolts (3) for preliminary assembly. They must be replaced for final assembly.
Figure 6A1 – 391
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ISUZU KB P190 2007
Page 2695 of 6020

Engine Mechanical – V6 Page 6A1–216
Connecting Rod Measurement Procedure
Piston Pin End
NOTE
Measurements of all components should be
taken with the components at normal room
temperature.
1 Using an outside micrometer (1), take two measurements of the piston pin (2) in the area of the
connecting rod contact.
Figure 6A1 – 392
2 Using an inside micrometer, measure the connecting rod piston pin bore (1).
3 Subtract the piston pin diameter from the piston pin bore.
4 Compare the clearance measurements listed in the specifications, refer to 5 Specifications.
5 If the clearance is excessive, replace the piston pin. If a new pin does not resolve the clearance problem,
replace the connecting rod.
Figure 6A1 – 393
Crankshaft Bearing End
NOTE
Measurements of all components should be
taken with the components at normal room
temperature.
1 Using an inside micrometer, measure the connecting rod crankshaft bearing bore (1).
2 Compare the bore measurements listed in the specifications, refer to 5 Specifications.
3 Replace the connecting rod if the bore is out of specification. Do not recondition the connecting rod.
Figure 6A1 – 394
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Page 2696 of 6020
Engine Mechanical – V6 Page 6A1–217
Reassemble
Piston and Piston Pin
CAUTION
The arrow located on top of the piston must
point toward the front of the engine.
NOTE
The connecting rod is non-directional and may
be assembled/reassembled to the piston in
either direction.
1 Lubricate the piston pin (1) bores in the piston (2) and the connecting rod with clean engine oil.
2 Assemble the piston and piston pin to the connecting rod. Correctly orient the piston when reusing a
marked connecting rod.
3 Align the piston pin bore with the connecting rod pin bore.
4 Slide the piston pin into the piston and the connecting rod.
Figure 6A1 – 395
CAUTION
New piston pin retainers must be used.
Never reuse the piston pin retainers.
5 Install new piston pin retainers (1).
6 Ensure the piston pin retainers are fully seated in their grooves.
7 Repeat steps 1 to 6 for the remaining pistons.
Figure 6A1 – 396
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ISUZU KB P190 2007