2007 ISUZU KB P190 engine mount

Engine Mechanical – V6 Page 6A1–254
Page 6A1–254
4.2 Oil Pan and Oil Pump Suction Pipe
Assembly
Remove
1 Remove the engine assembly from the vehicle, refer to 4.1 Engine .
2 Separate the engine and transmission assemblies, refer to Section 7C1 Automatic – 4L60E – General Information.
3 Mount the engine assembly on a suitable engine stand.
4 Remove the engine front cover, refer to 3.15 Front Cover Assembly.
5 Remove the two long bolts (1) attaching the rear of the oil pan to the crankshaft rear oil seal housing.
6 Remove the remaining eleven bolts attaching the oil pan to the cylinder block.
7 Using the shear points loca ted at the edge of the oil
pan shear the RTV sealant.
8 Remove the oil pan from the cylinder block.


Figure 6A1 – 443

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–256
Page 6A1–256
Inspect
1 Inspect the exterior of the oil pan for the following
conditions:
• Damage to the drain plug or drain plug hole,
• Damage to the transmission mounting bosses,
• Damage to the oil level sensor threads, and
• Dents or damage to the exterior.
2 Inspect the interior of the oil pan for the following conditions:
• Gouges or damage to the oil pan sealing
surfaces,
• Damage to the crankshaft oil deflector,
• Damage to the bolt holes,
• Damage to the oil suction tube mounting
bosses, and
• Damage to the crankshaft oil deflector mounting
bosses.

Figure 6A1 – 445
3 Inspect the oil pan deflector for damage.
4 Repair or replace the o il pan deflector and/or oil pan
as required.


Figure 6A1 – 446
5 Inspect the following:
6 The mounting face (1) of the oil pump suction pipe for possible leakage paths.
7 The oil pump pipe support bracket (2) for cracks or damage.
8 The oil pump suction pipe tube (3) for cracks, imperfections and/or damage.
9 The oil pump screen (4) for blockage, foreign material, tears, cracks and/or damage.
10 Repair or replace the oil pan and/or oil pan components as required.


Figure 6A1 – 447

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–259
Page 6A1–259
4.3 Flexplate Assembly
Remove
1 Remove the transmission, refer to Section 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing .
2 Remove the starter motor, refer to Section 6D1-2 Starting System – V6.
3 Install the flexplate holding tool, Tool No. EN-46106 (1) into the starter motor mounting location.

Figure 6A1 – 452
4 Loosen the eight flexplate attaching bolts (1).
5 Remove the flexplate holding tool.
6 Using a suitable permanent ma rker or paint pen, mark
the flexplate assembly (2) to crankshaft relationship.
7 Remove the eight flexplate attaching bolts and discard.
8 Remove the flexplate assembly.

Figure 6A1 – 453
Clean
1 Clean the flexplate assembly in a suitable solvent.

Safety glasses must be worn when using
compressed air.
2 Dry the flexplate assembly with compressed air.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–260
Page 6A1–260
Inspect
1 Inspect the flexplate assembly for the following
conditions:
• Stress cracks around the flexplate to torque
converter mounting bolt hole locations (1).
• Stress cracks around the flexplate to crankshaft
mounting bolt hole locations (2 and 4).
• Cracks at welded areas that retain the ring gear
onto the flexplate (3).
• Damaged or missing ring gear teeth (5).
2 Replace the flexplate assembly as required.
NOTE
The flexplate ring gear is not serviced
separately and cannot be repaired. If found to
be faulty or damaged, the flexplate assembly
must be replaced.
CAUTION
Do not repair the welded areas that retain
the ring gear to the fl explate. The flexplate
must be replaced.

Figure 6A1 – 454
Reinstall
NOTE
The bolt holes are unevenly spaced to enable
flexplate fitment in the one position only.
1 Place the flexplate assembly (2) in position on the crankshaft.
2 Install new flexplate attaching bolts (1) and hand tighten.

Figure 6A1 – 455

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–261
Page 6A1–261
3 Install the flexplate holding tool, Tool No. EN-46106
(1) into the starter motor mounting location.
4 Tighten the eight flexplate attaching bolts to the correct torque specification.

„ Flexplate attaching bolt
torque specification:
Stage 1.............. 26.0 – 34.0 Nm
Stage 2................................. 45°

5 Remove the flexplate holding tool.
6 Install the starter motor, refer to Section 6D1-2
Starting System – V6 .
7 Install the transmission, refer to Section 7E4
Automatic Transmission – 4L60E – On-vehicle
Servicing .

Figure 6A1 – 456

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–279
Page 6A1–279
8 Determine the connecting rod bearing clearance by
comparing the width of the flattened plastic
gauging (1) material at its widest point with the
graduation on the gauging mate rial container (2).
9 Compare the measurements with the specifications,
refer to 5 Specifications .
10 If the new bearings do not provide the correct crankshaft to connecting rod bearing clearance,
inspect the following:
11 Measure the crankshaft connecting rod journals for the correct specified size and ensure the correct new
bearings are being installed. If the crankshaft
connecting rod journals are in correctly sized, replace
or regrind the crankshaft. Crankshaft machining is
permitted and undersized bearings are available.
12 Measure the connecting rod bearing bore diameter to
ensure correct size. The connecting rod is not
machineable and the connecting rod must be
replaced if out of specification.
13 Clean the plastic gauging material from the connecting rod bearing journals using a soft lint-free
cloth.

Figure 6A1 – 498
Connecting Rod Final Assembly Procedure
1 Carefully guide the connecting rod away from the crankshaft connecting rod journal slightly to lubricate
the crankshaft connecting rod bearing journal.
2 Apply a liberal amount of clean engine oil to the crankshaft connecting rod bearing journal.
3 Guide the connecting rod to the crankshaft connecting rod journal.
4 Install the connecting rod end cap (1) on its original
connecting rod and ensure t he bearing lock tangs are
aligned on the same side of the rod.
CAUTION
• Do not lubricate the new connecting rod
bolts. The new bolts have a pre-applied
graphite lubricant. Applying lubricant to
the connecting rod bolts will effect the
clamp load when the connecting rod
bolts are tightened to the specified
torque. Incorrect clamp load can lead to
component failure and extensive engine
damage.
• Do not reuse the old connecting rod
bolts.

Figure 6A1 – 499
5 Install new connecting rod bolts into the connecting r od cap and tighten to the correct torque specification.
„ Connecting rod cap attaching bolt
torque specification:
Stage 1 .........................30.0 Nm
Stage 2 ........Loosen completely
Stage 3 .........................25.0 Nm
Stage 4 ..................110 degrees
NOTE
During and after installation, ensure each piston
is positioned correctly in the correct cylinder. The
locating arrow on the top of each piston must be
pointing toward the front of the engine.
6 Repeat these procedures for the rema ining piston/connecting rod assemblies.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–284
Page 6A1–284
Crankshaft and Main Bearing Visual Inspection
1 Perform the following visual inspections:
• Inspect the crankshaft balancer bolt hole (1) for
thread damage.
• Inspect the crankshaft balancer mounting
area (2) for damage.
• Inspect the crankshaft sprocket pin hole (3) for
damage.
• Inspect the oil pump drive flats (4) for damage.
• Inspect the crankshaft main journals (5) for
damage.
• Inspect the crankshaft connecting rod
journals (6) for damage.
• Inspect the crankshaft oil passages (7) for
obstructions.
• Inspect the crankshaft main bearing thrust wall
surfaces (8) for damage.
• Inspect the crankshaft counterweights (9) for
damage.
• Inspect the crankshaft reluctor ring teeth (10) for
damage.
• Inspect the crankshaft rear main oil seal surface
(11) for damage.
• Inspect the crankshaft engine flexplate
mounting surface (12) for damage.
• Inspect the crankshaft pilot hole (13) for
damage.
• Inspect the crankshaft engine flywheel bolt
holes (14) for thread damage.
2 Repair or replace the crankshaft as required.

Figure 6A1 – 506


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–287
Page 6A1–287
3 Measure the crankshaft thrust wall width (1) for wear
using an inside micrometer and compare with the
engine specifications, refer to 5 Specifications.
4 Measure the crankshaft thrust wall surface (2) for runout using a dial indica tor, mounted to a magnetic
stand and compare with t he engine specifications,
refer to 5 Specifications .
5 If the crankshaft journals are damaged or worn beyond specifications, t he crankshaft may be ground
0.25 mm. There is only one size of oversized main
bearings available for service.


Figure 6A1 – 512
6 Inspect the crankshaft main journals (1) for undersize, using an outside micrometer (2).


Figure 6A1 – 513
7 Inspect the crankpins (1) for undersize using an outside micrometer (2).
8 Compare your measurements with those listed in the
engine specifications, refer to 5 Specifications. If the
crankpin journals are worn beyond the specifications,
the crankshaft may be ground 0.25 mm. Only one
size of oversized connecting rod bearings available
for service.


Figure 6A1 – 514

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ISUZU KB P190 2007