2007 ISUZU KB P190 torque

Engine Mechanical – V6 Page 6A1–208

5 Install the crankshaft rear oil seal housing attaching
bolts (1) to the cylinder block (2) and tighten to the
correct torque specification.


Crankshaft rear oil seal housing
attaching bolt torque specification .............8.0 – 12.0 Nm
Figure 6A1 – 373
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings
Remove
1 Remove the engine assembly, refer to 4.1 Engine .
2 Remove both cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
3 Remove the oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly.
4 Mark the top of the piston being removed to identify its specific bore.
5 Install Tool No. EN-46111 (1) onto the crankshaft (2).
6 Rotate the crankshaft until the piston being removed is at the bottom of its stroke; bottom dead centre
(BDC).

Figure 6A1 – 374
CAUTION
If the connecting rod bearings have been
used in a running engine, they must be
replaced with new connecting rod bearings
for reassembly.
7 Before removing the connecting rods, check the connecting rod side clearance using the following procedure: a Tap the connecting rod to one end of the crankshaft journal with a dead blow or wooden hammer.
b Using feeler gauges, measure the clearance between the crankshaft counterweight and the connecting rod.
c The connecting rod side clearance should not exceed specifications, refer to 5 Specifications.

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Engine Mechanical – V6 Page 6A1–209

d If the endplay exceeds the specified limits, measure the width of the crankpin end of the connecting rod, refer
to 5 Specifications.
e If the connecting rod width is significantly smaller than specified and severe wear is present on the side of the connecting rod, replace the connecting rod.
f If the connecting rod width is within specification and excessive scoring is present on the crankshaft journals, replace the crankshaft.
CAUTION
Do not use a stamp, punch or any other
method that may distort or stress the
connecting rod and cap. Extensive engine
damage may result from a connecting rod that
is distorted or stressed.
8 Mark the cylinder number on the connecting rod and the connecting rod cap with a paint stick or permanent marker.
CAUTION
Powdered metal connecting rods have rod
bolts which yield when tighten to the
specified torque. If the bolts are loosened or
removed they must be replaced. Rod bolts
that are not replaced will not torque to the
correct clamp load and can lead to serious
engine damage.
9 Remove the connecting rod bolts (1), loosening progressively from side to side.

CAUTION
The connecting rod caps must remain with
the original connecting rod.
10 Remove the connecting rod cap (2).


Figure 6A1 – 375

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Engine Mechanical – V6 Page 6A1–221

7 Remove connecting rod guide pin set, Tool No.
EN-46121 (1) from the connecting rod bolt holes.
Figure 6A1 – 406
Connecting Rod Bearing Clearance Measurement Procedure
NOTE
Before final assembly, check the clearance of the
new connecting rod bearings.
1 Place a length of fresh, room temperature plastic gauging material all the way across the connecting
rod bearing journal.
2 Install the connecting rod bearing into the connecting rod cap.
3 Install the connecting rod end cap (1) on its original connecting rod and ensure the bearing lock tangs are
aligned on the same side of the rod.
Figure 6A1 – 407
NOTE
Reuse the old connecting rod bolts only for
measuring the connecting rod bearing clearance.
4 Install the connecting rod cap bolts into the connecting rod cap and tighten to the correct torque specification using torque angle wrench, Tool No. EN-7115.
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
5 Allow the assembly to sit for at least 2 minutes.
6 Remove the connecting rod cap bolts and discard.
7 Remove the connecting rod cap.

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Engine Mechanical – V6 Page 6A1–222

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 material 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 incorrectly 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 – 408
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 the 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 – 409
5 Install new connecting rod bolts into the connecting rod 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

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Engine Mechanical – V6 Page 6A1–223


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 remaining piston/connecting rod assemblies.
7 Reinstall the oil pan and oil pump pick up assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly.
8 Reinstall the cylinder heads, refer to 3.22 Cylinder Head Assembly.
9 Reinstall the engine assembly, refer to 4.1 Engine .
4.6 Crankshaft and Main Bearings
1 Remove the engine assembly, refer to 4.1 Engine .
2 Remove both cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
3 Remove the oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly.
4 Remove the piston and connecting rod assemblies, refer to 4.5 Pistons, Pins, Rings, Connecting Rods and Big- end Bearings.
5 Remove the oil pump assembly, refer to 3.17 Oil Pump Assembly.
6 Remove the crankshaft rear oil seal and plate assembly, refer to 4.4 Crankshaft Rear Seal and Plate Assembly.
7 Remove the crankshaft position sensor, refer to 6C1-3 Engine Management – V6 – Service Operations.
Crankshaft End Play Measurement
1 Place a dial indicator at the end of the crankshaft nose.
2 Gently force the crankshaft towards the front and rear of the cylinder block with a lever while monitoring the movement of the dial indicator.
3 The crankshaft endplay should not exceed specifications, refer to 5 Specifications.
4 If the specifications are exceeded, inspect the thrust bearing thrust outer diameter and the crankshaft thrust wall for wear and/or excessive runout. Compare the values with the specifications, refer to 5 Specifications.
5 Replace the thrust bearing or crankshaft as required.
Remove
1 Remove the crankshaft bearing cap side bolts (3).
CAUTION
The crankshaft bearing cap outer bolts are
yield tightened during assembly and must
be replaced prior to reassembly. Crankshaft
bearing cap outer bolts that are not replaced
will not torque to the correct clamp load and
can lead to serious engine damage.
2 Remove the crankshaft bearing cap outer bolts (1).
3 Remove the crankshaft bearing cap inner bolts (2).
Figure 6A1 – 410

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Engine Mechanical – V6 Page 6A1–224

4 Loosen the nuts (1) of the crankshaft main bearing
cap remover, Tool No. J-41818 (2) to separate the
chamfered collets. Install the collets into the inner bolt
holes of the front main bearing cap (3).
5 Tighten the remover nuts to the correct torque specification.

Crankshaft bearing cap remover nut .................11.0 Nm.

6 Install a slide hammer, Tool No. J-6125-1B (4) onto the crankshaft bearing cap remover and remove the
crankshaft bearing cap.
7 Repeat steps 9 to 14 for the remaining crankshaft bearing caps.
Figure 6A1 – 411
8 Remove the crankshaft (1) from the engine block (2), lifting evenly to avoid jamming against the main thrust
bearing.
9 Place the crankshaft in a secure place.
Figure 6A1 – 412
10 If required, remove the crankshaft sprocket drive pin (1) from the crankshaft (2),
Figure 6A1 – 413

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Engine Mechanical – V6 Page 6A1–231

4 Install the new lower crankshaft bearings (2) into
position in the main bearing caps (1). The lower
crankshaft bearings are identified by no grooves or
holes. The bearings must fit flush with the crankshaft
bearing caps.

Figure 6A1 – 427
Crankshaft Main Bearing Clearance Measurement
1 Place a length of fresh, room temperature plastic gauging material all the way across all the crankshaft
bearing journals.
2 Install the crankshaft main bearing caps.
3 Loosely install the original inner main cap bolts (1).
4 Loosely install the original outer main cap bolts (2).
Figure 6A1 – 428
5 Loosely install the original short/inner side main cap bolts.
6 Loosely install the original long/outer side main cap bolts (3).
7 Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.
8 Tighten the main caps bolts to the correct torque specification, and in the following sequence.
Crankshaft main bearing cap inboard
attaching bolt torque specification:
Stage 1 .........................20.0 Nm
Stage 2 ................................. 80°
Crankshaft main bearing cap outboard
attaching bolt torque specification:
Stage 1 .........................15.0 Nm
Stage 2 ............................... 110°
Crankshaft main bearing cap side
attaching bolt torque specification:
Stage 1 .........................30.0 Nm
Stage 2 ................................. 60°
Figure 6A1 – 429

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Engine Mechanical – V6 Page 6A1–233

Crankshaft Final Installation Procedure
1 If removed, install the crankshaft sprocket drive
pin (1). Lightly tap the pin in place with a small soft
face, bronze/plastic, hammer until it bottoms in the
hole.
Figure 6A1 – 432
CAUTION
Ensure the crankshaft position sensor has
been removed from the cylinder block prior
to loading the crankshaft, as damage to the
sensor may occur.
2
Apply a liberal amount of clean engine oil to the upper
and lower bearing surfaces.
3 Gently lower the crankshaft (1) into position in the cylinder block (2).
Figure 6A1 – 433
4 Install the crankshaft main bearing caps.
5 Loosely install the original inner main cap bolts (1).
CAUTION
The outer crankshaft bearing cap bolts (2)
are yield tightened during assembly and
must be replaced prior to reassembly. Outer
crankshaft bearing cap bolts that are not
replaced will not torque to the correct clamp
load and can lead to serious engine damage.
6 Loosely install the new outer main bearing cap bolts (2).
7 Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.
Figure 6A1 – 434

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