Isuzu KB P190. Manual - part 768

Engine Mechanical – V6 

Page 6A1–295 

 

Page 6A1–295 

7 

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

 

 

Figure 6A1 – 532 

8 

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

 

 

Figure 6A1 – 533 

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 – 534 

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 (1). 

 

 

Figure 6A1 – 536 

12 

Remove the cylinder block-to-cylinder head alignment 
dowels (1). 

 

 

Figure 6A1 – 537 

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 

N O T E  

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

. 

 

N O T E  

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 – 538 

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 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

. 

N O T E  

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. 

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

. 

N O T E  

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 – 539