body ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–72

19 Remove the four long (1) bolts (165 mm) securing the
complete intake manifold to the cylinder heads.
20 Remove the two short (2) bolts (45 mm) securing the lower intake manifold to the cylinder heads.



Do not loosen nor remove the short bolts ( 8
88
8
)
(70 mm) holding the upper intake manifold to
the lower. These bolts are at the front left
and rear right of the upper intake manifold.
Figure 6A1 – 51

When the intake manifold is removed, plug
each of the cylinder head intake openings
with lint free cloth, to stop the entry of foreign
material into the intake ports.
21 Remove the upper and lower intake manifold assembly from the engine.
22 Remove lower intake manifold to cylinder head gasket.
Disassemble
1 Disconnect the EVAP hose (1) from the upper intake manifold (2).
2 Remove the bolts (3) (70 mm long) attaching the upper intake manifold to the lower intake manifold (4).
NOTE
These bolts are located at the front left and rear
right of the upper intake manifold, as shown.
3 Remove the upper intake manifold from the lower intake manifold.
4 Remove and discard the upper to lower intake manifold gaskets.

Do not reuse the upper to lower intake
manifold gaskets (5).
5 Remove the EVAP hose from the retaining clip (6) attached to the lower intake manifold.
6 Remove the following from the upper intake manifold, refer to 6C1-3 Engine Management – V6 – Service
Operations:
• BARO Sensor and
• Throttle Body assembly


Figure 6A1 – 52

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–73

7 Remove the fuel rail and injector assembly. Refer to
6C1-3 Engine Management – V6 – Service
Operations.

The following precautions must be followed
when removing the fuel rail and injector
assembly:
• Care must be taken when removing the
fuel rail and injector assembly to
prevent damage to the injector spray
tips and injector harness connector
terminals.
• Support the fuel rail and injector
assembly after removal.
• Plug all fuel line and manifold openings
after removal to prevent dirt and other
contaminants from entering the fuel
system.

Figure 6A1 – 53
Clean
CAUTION
Due to the aluminium alloy construction of
the intake manifold, wire brushes and steel
scrapers must not be used during the
cleaning process, as damage to sealing
surfaces may occur. Use of a wooden or
plastic scraper is preferred.
1 Clean mating surfaces ensuring any gasket material is removed.
2 Clean the manifold using a suitable solvent

Safety glasses must be worn when using
compressed air.
3 Dry the timing components with compressed air.
Inspect
1 Inspect the intake manifold for the following fault conditions:
• Damaged sealing and mating surfaces.
• Damaged lower intake manifold gasket.
• Damage or excessive debris on the threaded and through holes.
• Cracks or damage to the intake manifold body.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–108

Primary Timing Chain Tensioner

Figure 6A1 – 133
1 Inspect the primary timing chain tensioner for worn shoe surface (1), refer to Figure 6A1 – 133.
2 Inspect the tensioner for a locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner shaft moves freely in and out of the body of the tensioner.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
3 Replace a damaged tensioner as required.
Left-hand Secondary Timing Chain Guide
1 Inspect the left-hand secondary timing chain guide for the following:
• worn guide surface (1),
• cracked or broken guide surface (2), and
• cracked or damaged guide base (3).
2 Replace a damaged guide as required.

Figure 6A1 – 134

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–110

2 Inspect the tensioner for locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner shaft
moves freely in and out of the body of the tensioner.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
3 Replace a damaged tensioner as required.
Right-hand Secondary Timing Chain Guide
1 Inspect the right-hand secondary timing chain guide for the following:
• worn guide surface (1),
• cracked or broken guide surface (2), and
• cracked or damaged guide base (3).
2 Replace a damaged guide as required.

Figure 6A1 – 138
Right-hand Secondary Timing Chain Shoe
1 Inspect the front of the right-hand secondary timing chain shoe for the following:
• worn shoe surface (1),
• cracked or broken shoe surface (2), and
• cracked or damaged shoe (3).

Figure 6A1 – 139

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–111

2 Inspect the back of the shoe for a damaged, worn or
missing timing chain tensioner contact pad (1).
Replace a damaged shoe as required.
Figure 6A1 – 140
Right-hand Secondary Timing Chain Tensioner

Figure 6A1 – 141
1 Inspect the right-hand secondary timing chain tensioner for damaged plunger-to-shoe contact surface (1), refer to Figure 6A1 – 141.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
2 Inspect the tensioner for a locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner shaft moves freely in and out of the body of the tensioner.
3 Replace a damaged tensioner as required.
Reinstall
Left-hand Secondary Timing Chain Components


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–119

24 Install the tensioner shaft (1) into the left-hand
secondary timing chain tensioner body (2).
Figure 6A1 – 161
25 Compress the tensioner shaft into the body and lock the left-hand secondary timing chain tensioner by
inserting Tool No. EN 46112 into the access hole in
the side of the tensioner body.
26 Slowly release pressure on the left-hand secondary timing chain tensioner. The tensioner should remain
compressed.

CAUTION
If Tool No. EN 46112 (1) is not removed from
the tensioner body (2), the tensioner
shaft (3) will remain in the locked position
and no tension will be placed on the timing
chain, this will cause damage to the engine.
Figure 6A1 – 162
27 Install a new left-hand secondary timing chain tensioner gasket (1) to the tensioner (2).
28 Install the left-hand secondary timing chain tensioner bolts through tensioner and gasket.
29 Ensure the left-hand secondary timing chain tensioner mounting surface on the left-hand cylinder head does
not have any burrs or defects that would affect the
sealing of the new gasket.
Figure 6A1 – 163

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–126

17 Install the tensioner shoe assembly (1) into the
primary timing chain tensioner body (2).

Figure 6A1 – 182
18 Compress the shoe assembly into the body (2) and lock the primary timing chain tensioner by inserting
Tool No. EN 46112 into the access hole in the side of
the body.
CAUTION
If Tool No. EN 46112 (1) is not inserted into
the tensioner body, the plunger will remain
in the locked position and no tension will be
placed on the timing chain.
19 Slowly release pressure on the primary timing chain tensioner. The primary timing chain tensioner should
remain compressed.


Figure 6A1 – 183
20 Install a new primary timing chain tensioner gasket (1) to the tensioner (2).
21 Install the primary timing chain tensioner bolts (3) through tensioner and gasket.
22 Ensure the primary timing chain tensioner mounting surface on the engine block does not have any burrs
or defects that would affect the sealing of the new
gasket.

Figure 6A1 – 184

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–134

18 Install the tensioner shaft (1) into the right-hand
secondary timing chain tensioner body (2).

Figure 6A1 – 205
19 Compress the tensioner shaft into the body and lock the tensioner by inserting Tool No. EN 46112 into the
access hole in the side of the tensioner body.
20 Slowly release pressure on the right-hand secondary timing chain tensioner. The tensioner should remain
compressed.


Figure 6A1 – 206
21 Install a new right-hand secondary timing chain tensioner gasket (1) to the tensioner (2).
22 Install the right-hand secondary timing chain tensioner bolts (3) through the tensioner and gasket.
23 Ensure the right-hand secondary timing chain tensioner mounting surface on the right-hand cylinder
head does not have any burrs or defects that would
affect the sealing of the new tensioner gasket.

Figure 6A1 – 207

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–135

24 Place the right-hand secondary timing chain tensioner
(2) into position and loosely install the bolts (1) to the
engine block.

Figure 6A1 – 208
25 Verify the proper placement of the right-hand secondary timing chain tensioner gasket tab (1).
26 Tighten the right-hand secondary timing chain tensioner bolts (2) to the correct torque specification.




Secondary timing chain tensioner
attaching bolt torque specification ...........20.0 – 26.0 Nm

Figure 6A1 – 209
27 Release the right-hand timing chain tensioner (1) by pulling out Tool No. EN 46112 (2) and unlocking the
tensioner plunger.

CAUTION
If Tool No. EN 46112 (1) is not removed from
the tensioner body (2), the plunger will
remain in the locked position and no tension
will be placed on the timing chain, this will
cause damage to the engine.
Figure 6A1 – 210

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–141

Reassemble
CAUTION
As there are no serviceable components
within the oil pump, a disassembled oil pump
must be replaced.
Reinstall
1 Align the oil pump gerotor with the crankshaft flats and fit the oil pump assembly to the engine block.
2 Align the pump body (2) with the mounting holes in the cylinder block.
3 Install the oil pump bolt (1), three places, and tighten to the correct torque specification.
4 Install the primary timing chain, refer to 3.16 Timing Chains, Tensioners, Shoes and Guides.


Oil pump attaching bolt torque
specification ............................................20.0 – 26.0 Nm

Figure 6A1 – 223
3.18 Camshaft Sprocket
CAUTION
Setting the camshaft timing is required
whenever the camshaft drive system is
disturbed to ensure the relationship between
any chain and sprocket is not lost. Even when
only one sprocket is involved, multiple
crankshaft rotations will not produce
conditions where correct timing can be
confirmed.
If required, follow the Left-hand Secondary
Camshaft Chain Components reinstallation
procedure to reset the camshaft timing.
Remove
Right-hand Side
1 Remove the right-hand camshaft cover, refer to 3.12 Camshaft Cover.
2 Remove the camshaft position sensors, refer to 6C1-3 Engine Management – Service Operations.
3 Remove the camshaft position actuator solenoids, refer to 6C1-3 Engine Management – V6 – Service Operations.
4 Remove the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.

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