Isuzu KB P190. Manual - part 672

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 

Engine Mechanical – V6 

Page 6A1–210 

 

11 

Install connecting rod guide pin set, Tool No.  
EN-46121 (1) to the connecting rod bolt holes. 

 

Figure 6A1 – 376 

CAUTION

 

Do not damage the crankshaft journal, 
cylinder wall and piston cooling jets when 
removing the connecting rod and piston 
assembly. 

12 

Using connecting rod guide pin set, Tool No.  
EN-46121 (1), push the connecting rod and piston 
assembly (2) through the top of the cylinder. 

 

 

Figure 6A1 – 377 

CAUTION

 

When dismantled, ensure the connecting 
rod, connecting rod cap, piston and 
bearings are organised in their original 
position and location. This will also aid 
engine mechanical diagnosis. 

13 

Remove connecting rod guide pin set, Tool No.  
EN-46121 (1) from the connecting rod bolt holes. 

14 

Remove the upper connecting rod bearing from the 
connecting rod (2). 

 

 

Figure 6A1 – 378 

Engine Mechanical – V6 

Page 6A1–211 

 

15 

Remove the lower connecting rod bearing (1) from 
the connecting rod cap (2). 

Figure 6A1 – 379 

N O T E  

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 

Engine Mechanical – V6 

Page 6A1–212 

 

CAUTION

 

Do not reuse the piston pin retainers. 

2 

Remove the piston pin retainers by using the removal 
access notch (1) in the side of the piston. Discard the 
piston pin retainers. 

 

 

Figure 6A1 – 382 

3 

Slide the piston pin (1) out of the piston (2). The 
piston will disconnect from the connecting rod. 

 

Figure 6A1 – 383 

Clean and Inspect 

Piston Cleaning Procedure 

CAUTION

 

Do not use a wire brush to clean any part of 
the piston. 

1 

Clean the piston skirts and the pins with a suitable solvent. 

2 

Clean the piston ring grooves with a groove cleaner. Ensure the oil ring holes and slots are clean. 

 

Safety glasses must be worn when using 
compressed air. 

3 

Dry the piston with compressed air.