engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–236

5 Remove the right-hand side M14 coolant drain
threaded plug (1).

Figure 6A1 – 440
6 Remove the rear M14 oil gallery threaded plug (1).

Figure 6A1 – 441
7 Remove the left-hand side M14 coolant drain threaded plug (1).

Figure 6A1 – 442

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Engine Mechanical – V6 Page 6A1–237

8 Remove the left-hand side M20 oil gallery threaded
plug (1).

Figure 6A1 – 443
CAUTION
Do not force coolant expansion plugs
downwards during removal procedure as the
cylinder block will be damaged.
9 Remove the coolant expansion plugs (1).


Figure 6A1 – 444
10 Remove the cylinder block-to-transmission alignment dowels (1).

Figure 6A1 – 445

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Engine Mechanical – V6 Page 6A1–238

11 Remove the front oil gallery expansion plug (1).

Figure 6A1 – 446
12 Remove the cylinder block-to-cylinder head alignment dowels (1).

Figure 6A1 – 447
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.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–239

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 found, the cylinder block assembly must be replaced.
2 Inspect the primary camshaft chain tensioner 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 cylinder 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 cracks. 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 more than 0.25 mm, the
cylinder block must be replaced.
Figure 6A1 – 448
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 thrust surfaces, perpendicular to the crankshaft centreline, at 100 mm below the deck surface and record the measurement.
3 Calculate the difference between the two measurements. The result 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 exceeds 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.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–240

2 Calculate the difference between the two measurements. The result will indicate out-of-round at the upper end of
the cylinder.
3 Measure both the thrust and non-thrust cylinder diameter at 100 mm below the deck surface. Record your measurements.
4 Calculate the difference between the two 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 exceeds 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 than 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 required 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 – 449
Reassemble
1 Install the cylinder block-to-cylinder head alignment
dowels (1).
Figure 6A1 – 450

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Engine Mechanical – V6 Page 6A1–241

2 Install a new front oil gallery expansion plug (1).
Figure 6A1 – 451
3 Install the cylinder block-to-transmission alignment dowels (1).
Figure 6A1 – 452
4 Place RTV sealant on new coolant expansion plugs (1) and install the new coolant expansion plugs.
Figure 6A1 – 453

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Engine Mechanical – V6 Page 6A1–242

5 Install the left-hand side M20 oil gallery threaded plug
(1) and tighten to the correct torque specification.




Left-hand side M20 cylinder block
oil gallery threaded plug
torque specification .................................27.0 – 35.0 Nm
Figure 6A1 – 454
6 Install the left-hand side M14 coolant drain threaded plug (1) and tighten to the correct torque specification.




Left-hand side M14 cylinder block
coolant drain threaded plug
torque specification .................................27.0 – 35.0 Nm
Figure 6A1 – 455
7 Install the M14 rear oil gallery threaded plug (1) and tighten to the correct torque specification.




M14 cylinder block rear oil gallery
threaded plug torque specification ..........27.0 – 35.0 Nm

Figure 6A1 – 456

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–243

8 Install the right-hand side M14 coolant drain threaded
plug (1) and tighten to the correct torque specification.




Right-hand side M14 cylinder block
coolant drain threaded plug
torque specification .................................27.0 – 35.0 Nm

Figure 6A1 – 457
9 Install the right-hand side M14 oil gallery threaded plug (1) and tighten to the correct torque specification.




Right-hand side M14 cylinder block
oil gallery threaded plug
torque specification .................................27.0 – 35.0 Nm

Figure 6A1 – 458
10 Install the cylinder block-to-oil pan alignment dowels (1).

Figure 6A1 – 459

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Engine Mechanical – V6 Page 6A1–244

11 Install the new right-hand front oil pan rail oil gallery
expansion plug (1).

Figure 6A1 – 460
12 Install the oil jet (2), three places.

13 Install the oil jet attaching bolt (1), three places and tighten to the correct torque specification.



Oil jet attaching bolt
torque specification ...................................8.0 – 12.0 Nm

Figure 6A1 – 461
4.8 Thread Repairs
General Information
The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert. During the insert
installation process, the installation driver tool cold-rolls the bottom internal threads and expands the bottom external
threads of the insert into the base material. This action mechanically locks the insert into place.
This Section describes the recommended method of repairing threads in three specific areas of the engine.
• general thread repair,
• cylinder block main bearing cap bolt hole thread repair, and
• cylinder head bolt hole thread repair.
For detailed descriptions of all thread specifications used refer to 4.9 Thread Repair Specifications.
The drill-bit and counter-bore tool from the thread repair kit, Tool No. J-42385-700 and J-42385-2000 are designed for
use with either a suitable tap wrench or drill motor. Limited access and larger hole repair may process better using a tap
wrench. An extension from Tool J 43965 may also be required to drive the thread repair tooling dependent on access to
the hole being repaired. Use only a tap wrench when tapping the hole and during installation of the insert.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–245

1 It is critical the drilling, counter boring and tapping of
the hole to be repaired follows the same centreline (1)
as the original hole.
Figure 6A1 – 462
2 During the drilling and tapping of the hole being repaired, ensure the tooling is consistently machining
perpendicular to the surface of the base material.
Figure 6A1 – 463
3 If the threaded hole being repaired has a base surface perpendicular to the hole centreline, tapping
guides are available to aid in tapping the hole.


Tap
Size Tap
Guide Tap
Size Tap
Guide Tap
Size Tap
Guide
- J 42385 - J
42385 - J
42385
6 x 1.0 729 10 x
1.5 731 14 x
1.5 736
8 x
1.25 730 12 x
1.5 732 20 x
1.5 737

Figure 6A1 – 464

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