engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–238
Page 6A1–238
4 Replace the engine mount if any of the following conditions are found:
• The hard rubber surface is cove red with heat check cracks,
• The rubber is split through the centre of the engine mount, or
• The rubber is separated from the me tal plate portion of the engine mount.

5 Remove the engine lift brackets, Tool No. EN-46114 from the engine.
Reinstall
The reinstallation procedure for the engi ne mounts is the reverse of the removal procedure, noting the following:
Ensure all fasteners are tightened to the correct torque specification.


Engine mount bracket to
cylinder block attaching bolt
torque specification
................................................................ 43.0 – 57.0 Nm
Engine mount to bracket attaching nut
torque specification
................................................................ 70.0 – 90.0 Nm
Engine mount to frame attaching nut
torque specification
................................................................ 44.0 – 60.0 Nm




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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–239
Page 6A1–239
4 Major Service Operations
ATTENTION
The V6 engine is a combination of numerous components, containing machined, honed, polished and lapped
surfaces manufactured on the latest, high technology production equipment. Many of the components
contain tolerances measured in thousa ndths of a millimetre. Consequently, when any e ngine component is to
be serviced, care and cleanliness are extremely important.
Prior to re-assembly of the V6 engi ne, all components must be cleaned and inspected in accordance with the
relevant procedures throughout this section, and replaced or repaired where required.
In addition to cleaning and inspecting components, a liberal coating of engine oil should be applied to friction
surfaces during assembly to protect and lubr icate the surfaces on initial operation.
When performing any service operation contained in this Section, it should be understood that correct
cleaning and protection of machined surfaces and fricti on areas is part of the repair procedure. This is
considered standard workshop practice, even if not specifically stated. Torque values must be used as
specified during reassembly to ensure correct retention of all components.
Through out this section, fastener torque wrench sp ecifications may be accompanied with the following
identification marks:
â–  Fasteners must be replaced after loosening.
Fasteners either have micro encapsulated sealant a pplied or incorporate a mechanical thread lock and
should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongs ide a fastener torque wrench specification, the
recommendation regarding that fastener must be adhered to.
4.1 Engine Removal
CAUTION
• Allow the engine to cool to at least 50 ° C,
before attempting fastener removal.
• As aluminium has a greater rate of thermal
expansion than that of cast iron,
aluminium bolt hole threads will change
dimension to a larger extent than cast iron
bolt threads.
• If a bolt or other threaded component is
removed before the engine is allowed to
cool to at least 50 ° C, threads could be
pulled from the cylinder block or cylinder
head.
• Do not use impact tools to remove bolts
during engine disassembly. While this may
be common practice with cast iron engine
components, use of th ese tools is likely to
pull the aluminium threads in the cylinder
block or head of this engine.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–240
Page 6A1–240
Remove
1 Remove the skid plate.
2 Drain the radiator coolant, refer to Section 6B1 Engine Cooling – V6.
3 Disconnect the battery negative and positive terminal, refer to Section 8A Electrical Body & Chassis.
4 Remove the battery from the vehicle.
5 Depressurise the fuel sy stem pressure, refer to Section 6C Fuel System – V6 .
6 Make alignment marks on the bonnet and hinges in order to return the bonnet to the exact original position.
7 Remove the bonnet, refer to Section 2B Sheet Metal.
8 Remove the rubber hose (2) and air duct (1).


Figure 6A1 – 407

9 Disconnect the barometric sensor connector (1).

Figure 6A1 – 408

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–241
Page 6A1–241
10 Disconnect the vacuum booster hose (1).


Figure 6A1 – 409
11 Disconnect the EVAP purge solenoid connector (1).

Figure 6A1 – 410

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–242
Page 6A1–242

Plug the fuel feed hose after removal to
prevent dirt entering the pipe.
12 Disconnect the fuel pipe connector and injector harness connector.
13 Disconnect the fuel feed hose from the fuel rail (1),
refer to Section 6C Fuel system .
14 Pull out release bar (2) of the fuel injector harness
wiring connector (3).
15 Disconnect the fuel injector harness wiring connector from the fuel injector wiring harness (4).


Figure 6A1 – 411
16 To disconnect the throttle body connector (1) the following procedure must be followed.
17 Retract the throttle body wiring connector lock (3) while pressing the connector la tch in the direction of
the arrow (4).
18 Disconnect the throttle body wiring connector (1).
19 Release the throttle body connector wiring harness from its retaining clip (5).

Take care not to break the barbed retainer
pin (6), when removing the harness. Should
the pin be damaged it is vital that a new
harness retainer be fitted.
20 Remove the main wiring harness retainer pin (6) from the intake manifold by pushing from the front to the
rear using a suitable lengt h of 5mm steel rod or an
allen key.


Figure 6A1 – 412
21 Disconnect the PCV fresh air tube (1) from the upper intake manifold mounting clip (2) and remove the
fixing bolt (3).


Figure 6A1 – 413

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–243
Page 6A1–243
22 Disconnect the EVAP valve outlet tube, (1) from the
upper intake manifold (2).
23 Remove the four long bolts, (3) attaching the upper intake manifold, (2) to the cylinder heads and lower
intake manifold.

Figure 6A1 – 414
23 Remove the six bolts, (1) attaching the lower intake manifold (2), then remove the manifold from the
engine.
24 Remove the following from the engine and engine compartment :
• Lower intake manifold to cylinder head gasket
• The Heater hose
• The Air Cleaner assembly


Figure 6A1 – 415
25 Remove the transmission support (1).
26 Remove the front and rear propeller shafts, (4WD Only), refer to Section 4C1 Front Wheel Drive and
Section 4C2 Drive Line (For 4WD Vehicles).
27 Remove the front torsion bar springs, refer to Section 3C Suspension .


Figure 6A1 – 416

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–244
Page 6A1–244
28 Remove the centre exhaust pipe (1), refer to
Section 6F Exhaust System - V6 .


Figure 6A1 – 417
29 Disconnect the two post-catalytic converter oxygen sensor wiring harness connectors, 1 each bank.



Figure 6A1 – 418
30 Disconnect the two pre-catalytic converter oxygen sensor wiring harness connectors, 1 each bank.
31 Remove the front exhaust flange nuts, three each bank.
32 Remove the front left-hand exhaust pipe from the rubber mount.

33 Remove the front exhaust pipes from the vehicle, for further information, refer to Section 6F Exhaust
System - V6 .

Figure 6A1 – 419
34 Remove the transfer case from t he vehicle (4WD Only), refer to Section 7D Transfer Case and Adaptor Housing .

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–245
Page 6A1–245
35 Disconnect the harness connector from the transmission, refer to Section 7B1 Manual Transmission – V6 or
Section 7C1, Section 7C2, Section 7C3 or Section 7C4 for automatic transmission.
36 Remove the left-hand side exhaust manifold upper heat shield (1), (Automatic transmission only).

Figure 6A1 – 420
37 Progressively loosen the seven exhaust manifold attaching bolts (2), working from the outside to the
centre and then remove the bolts.
38 Manoeuvre the exhaust manifold (3), away from the cylinder head.
39 Remove and discard the exhaust manifold to cylinder head gasket.


Figure 6A1 – 421
40 Remove the engine oil level indicator assembly (1), (automatic transmission only).
41 Remove the left-hand side exhaust manifold, (automatic transmission only).


Figure 6A1 – 422

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–246
Page 6A1–246

Figure 6A1 – 423
Figure 6A1 – 424
42 Fit the engine lifting brackets (1), (EN–46114) and attach the engine hoist, raise the engine to take the weight off the engine mounts.

Engine Lift Bracket Attaching Bolt
torque specification
............................................................. 58.0 – 72.0.0 Nm

43 Remove the left-hand side knock sensor (1).

Figure 6A1 – 425
NOTE
Removal or the starter motor is only required for
vehicles with an Automatic Transmission.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–247
Page 6A1–247
44 Remove the left-hand side engine mount (1),
(automatic transmission only).


Figure 6A1 – 426
45 Unclip the oil level s ensor harness from the heat
shield (1).
a Remove the heat shield retaining screw (2).
b Remove the lower starter motor attaching bolt (3).
c Remove the heat shield.
d Remove the upper starter motor retaining bolt (3).
46 Remove the starter motor from the engine block and lower the starter motor as far as possible to gain
access to the wiring harness connections.
47 Remove the starter moto r, (automatic transmission
only).

Figure 6A1 – 427
48 Reinstall the left-hand side engine mount (1), (automatic transmission only).
49 Remove the transmission assembly, refer to Section 7C1 Automatic – 4L60E – General
Information .



Figure 6A1 – 428

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