2007 ISUZU KB P190 Workshop Repair Manual

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Page 3073 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–296
Page 6A1–296
10 Remove the cylinder block-to-transmission alignment
dowels (1).

Figure 6A1 – 535
11 Remove the front oil gallery expansion plug

Page 3074 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–297
Page 6A1–297
Clean
1 Remove all thread sealant, gasket material or sealant using a commercially available plastic or wood scraper.
2 Clean all the fol

Engine Mechanical – V6 Page 6A1–297
Page 6A1–297
Clean
1 Remove all thread sealant, gasket material or sealant using a commercially available plastic or wood scraper.
2 Clean all the following areas with a suitable solvent:
• sealing surfaces,
• cooling passages,
• oil passages, and
• bearing journals.
3 Clean all threaded and through holes with a suitable solvent.

Safety glasses must be worn when using
compressed air.
4 Dry the engine block with compressed air.
Inspect
Visual Inspection
NOTE
The following procedure assumes the engine has
been disassembled and cleaned, as described
above.
1 Inspect the crankshaft bearing journals for damage or spun bearings. The crankshaft bearing journals are not
repairable and if damage is f ound, the cylinder block assembly must be replaced.
2 Inspect the primary camshaft chain t ensioner mounting surface on the engine block for burrs or any defects that
would affect the sealing of the new primary camshaft chain tensioner gasket.
3 Inspect all sealing and mating surfaces for damage, repair or replace the cylinder block assembly if required.
4 Inspect all threaded and through holes for damage or excessive debris.
5 Inspect all bolts for damage, if damaged replace with new bolts only.
6 Inspect the cylinder walls for cracks or damage. The cyli nder sleeves are not serviced separately, if the cylinders
are damaged the cylinder block assembly must be replaced.
7 Inspect the engine block for cracks. Do not repair any cra cks. If cracks are found, the cylinder block assembly must
be replaced. Repair any damaged threaded holes, refer to 4.9 Thread Repair Specifications.
Measuring Cylinder Bore Diameter
1 Measure the cylinder bore diameter 37 mm from the
deck face (1) using a commercially available bore
gauge or Tool No. J-8087 (2).
2 Record the results and compare with the dimensions listed in the specifications, refer to 5 Specifications.

NOTE
If the cylinder diameter exceeds the
specifications, the cylinder block may be
oversized to 0.25 mm. Only one size of
oversized pistons and rings are available for
service. If the cylinder bore diameter exceeds
specification by mo re than 0.25 mm, the
cylinder block must be replaced.

Figure 6A1 – 538

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TO MODEL INDEX
ISUZU KB P190 2007

Page 3075 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–298
Page 6A1–298
Measuring Cylinder Bore Taper
1 Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centreline, at 10 mm be

Engine Mechanical – V6 Page 6A1–298
Page 6A1–298
Measuring Cylinder Bore Taper
1 Measure the cylinder bore along the thrust surfaces, perpendicular to the crankshaft centreline, at 10 mm below the
deck surface and record the measurement.
2 Measure the cylinder bore along the th rust surfaces, perpendicular to the crankshaft centreline, at 100 mm below
the deck surface and record the measurement.
3 Calculate the difference betw een the two measurements. The re sult will be the cylinder taper.
4 Compare the results with the dimensions listed in the specifications, refer to 5 Specifications.
NOTE
If the cylinder diameter exceeds the
specifications, the cylinder block may be
oversized to 0.25 mm. Only one size of oversized
pistons and rings are available for service. If the
cylinder bore diameter ex ceeds specification by
more than 0.25 mm, the cylinder block must be
replaced.
Measuring Cylinder Bore Out-of-Round
1 Measure both the thrust and non-thrust cylinder diameter at 10 mm below the deck. Record your measurements.
2 Calculate the difference bet ween the two measurements. The result will indicate out-of-r ound at the upper end of
the cylinder.
3 Measure both the thrust and non-thru st cylinder diameter at 100 mm below the deck surface. Record your
measurements.
4 Calculate the difference between the tw o measurements. The result will indicate out-of-round at the lower end of
the cylinder.
5 Compare your results with the dimensions listed in the specifications, refer to 5 Specifications.
NOTE
If the cylinder diameter exceeds the
specifications, the cylinder block may be
oversized to 0.25 mm. Only one size of oversized
pistons and rings are available for service. If the
cylinder bore diameter ex ceeds specification by
more than 0.25 mm, the cylinder block must be
replaced.
Deck Flatness Inspection
1 Ensure the engine block decks are clean and free of gasket material.
2 Inspect the surface for any imperfections or scratches
that could inhibit correct cylinder head gasket sealing.
3 Place a straight-edge diagonally across the cylinder block deck face surface.
4 Measure the clearance between the straight-edge
and the cylinder block deck face using a feeler gauge
at 4 points along the straight-edge.
5 If the warpage is less t han 0.05 mm, the cylinder
block deck surface does not require resurfacing.
6 If the warpage is between 0.05 ±0.20 mm or any imperfections or scratches that could inhibit correct
cylinder head gasket sealing are present, the cylinder
block deck surface requires resurfacing.
7 If resurfacing is requir ed the maximum amount that
can be removed is 0.25 mm.
8 If the cylinder block deck surface requires more than 0.25 mm material removal the block must be
replaced.

Figure 6A1 – 539

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TO MODEL INDEX
ISUZU KB P190 2007

Page 3076 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–299
Page 6A1–299
Reassemble
1 Install the cylinder block-to-cylinder head alignment
dowels (1).

Figure 6A1 – 540
2 Install a new front oil gallery ex

Page 3077 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–300
Page 6A1–300
4 Place RTV sealant on new coolant expansion plugs
(1) and install the new coolant expansion plugs.

Figure 6A1 – 543
5 Install the le

Page 3078 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–301
Page 6A1–301
7 Install the M14 rear oil gallery threaded plug (1) and
tighten to the correct torque specification.

M14 cylinder block rear o

Page 3079 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–302
Page 6A1–302
10 Install the cylinder block-to-oil pan alignment
dowels (1).

Figure 6A1 – 549
11 Install the new right-hand front oil pan rail oi

Page 3080 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–303
Page 6A1–303
4.8 Thread Repairs
General Information
The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type ins

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