Isuzu KB P190. Manual — part 675

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

N O T E

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

N O T E

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.

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

Engine Mechanical – V6

Page 6A1–223

N O T E

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

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