2007 ISUZU KB P190 tow

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

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

Engine Mechanical – V6 Page 6A1–218

Piston Ring
NOTE
The ends of the expander must be facing
toward the top of the piston.
1 Correctly orient the oil control ring expander (1) before installation.
Figure 6A1 – 397
2 Using a piston ring expander, install the oil control ring assembly using the following procedure:
3 Install the expander ring (3).
4 Install the two oil scraper rings (4). Expand the rings only enough to clear the piston diameter. Over-
expanding the piston rings will distort or crack the
rings.
5 Install the second (2) and top (1) piston rings as follows.
Figure 6A1 – 398
6 Using the ring expander (1), install the second piston ring (2) onto the piston (3). Do not over-expand the
ring. Repeat for the top ring.
Figure 6A1 – 399

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–220

Reinstall
Piston Connecting Rod and Connecting Rod Bearing Installation
CAUTION
The piston is directional and must be
installed in the engine block in the correct
direction. The locating arrow on the top of
each piston must be pointing toward the
front of the engine.
1 Liberally lubricate the cylinder walls, piston rings and piston skirts with engine oil.
2 Select the correctly numbered piston/connecting rod assembly for the cylinder. A dot (1) showing correct
piston orientation is located on the top of the piston.
Figure 6A1 – 403
3 Install connecting rod guide pin set, Tool No. EN-46121 (1) into the connecting rod bolt holes.
Figure 6A1 – 404
4 Compress the piston rings using a commercially available ring compressor.
CAUTION
Extreme care must be used when installing
the piston and connecting rod to ensure the
rod does not scrape or nick the cylinder
bore, oil jets, or crankshaft surfaces.
5 Using both hands from the top and bottom of the cylinder, slowly guide the piston (2) and connecting
rod assembly into the cylinder. Do not allow the
connecting rod to contact the cylinder wall.
6 W hen the ring compressor contacts the deck surface, gently tap the piston into the cylinder using the handle
end of a dead-blow hammer. Guide the connecting
rod onto the crankshaft bearing journal using
connecting rod guide pin set, Tool No. EN-46121 (1)
while gently tapping the piston into the cylinder with a
soft-blow hammer.
Figure 6A1 – 405

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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 6A1–195
Page 6A1–195
11 Ensure that the feet (2) of the Tool No. EN 48313 are
facing the front of the engine.
CAUTION
DO NOT tighten the Tool No. EN 48313 at
this stage.
12 Partially expand the legs (1) on the Tool No. EN 48313 by turning the T-shaped handle clockwise.
CAUTION
Ensure the feet (2) of the Tool No. EN 48313
are correctly engaged into one of the link
pockets to prevent the chain from slipping
during tightening.
13 Continue expanding the Tool No. EN 48313 until the feet (2) contact the timing chain.

Figure 6A1 – 316
14 Hand tighten the Tool No. EN 48313. DO NOT allow the body of the Tool No. EN 48313 to rotate when tightening
the T-handle.
15 Use an open-end spanner on the hex cast into both the right intake and exhaust camshafts and rotate the
camshafts towards each other in order to creat e slack in the chain between the actuators.
16 The Tool No. EN 48313 is now correctly inst alled to hold the timing chain in position.
NOTE
Ensure the camshaft timing chain and the
camshaft position actuators are marked for
correct reassembly.
17 Mark the timing chain and the respective location on both camshaft position actuators.
18 Remove the bolt (1) attaching the right-hand exhaust camshaft sprocket (2) and remove the sprocket.


Figure 6A1 – 317

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Engine Mechanical – V6 Page 6A1–198
Page 6A1–198
11 Ensure that the feet (2) of the Tool No. EN 48313 are
facing the front of the engine.
CAUTION
DO NOT tighten the Tool No. EN 48313 at
this stage.
12 Partially expand the legs (1) on the Tool No. EN 48313 by turning the T-shaped handle clockwise.
CAUTION
Ensure the feet (2) of the Tool No. EN 48313
are correctly engaged into one of the link
pockets to prevent the chain from slipping
during tightening.

Figure 6A1 – 323
13 Continue expanding the Tool No. EN 48313 until the feet (2) contact the timing chain.
14 Hand tighten the Tool No. EN 48313. DO NOT allow the body of the Tool No. EN 48313 to rotate when tightening
the T-handle.
15 Use an open-end spanner on the hex cast into both the left intake and exhaust camshafts and rotate the camshafts
towards each other in order create sla ck in the chain between the actuators.
16 The Tool No. EN 48313 is now correctly inst alled to hold the timing chain in position.
NOTE
Ensure the camshaft timing chain and the
camshaft position actuators are marked for
correct reassembly.
17 Mark the timing chain and the respective location on both camshaft position actuators.
18 Remove the bolt (1) attaching the left-hand exhaust camshaft sprocket (2) and remove the sprocket.

Figure 6A1 – 324

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Engine Mechanical – V6 Page 6A1–201
Page 6A1–201
3.20 Camshaft
Remove
Right-hand Side
1 Remove the right-hand cylinder head camshaft sprockets, refer to 3.18 Camshaft Sprocket.
NOTE
Tool No. EN-46105–1 was installed as part of the
right-hand cylinder head camshaft sprocket
removal procedure.
2 Remove the Tool No. EN-46105–1 (1) from the right- hand cylinder head camshafts (2).



NOTE
Tool No. EN-46105 was installed as part of the
right-hand cylinder head camshaft sprocket
removal procedure.

Figure 6A1 – 328
3 Observe the markings (1) on the bearing caps. Each bearing cap is marked to identify its location. The
markings have the following meanings:
• The raised feature must always be oriented
toward the centre of the cylinder head.
• An I indicates t he intake camshaft.
• An E indicates the exhaust camshaft.
• The number indicates the journal position from
the front of the engine.


Figure 6A1 – 329

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