engine mount ISUZU KB P190 2007 Workshop Repair Manual

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 6A1–292

6 Torque Wrench Specifications
ATTENTION
„
„„
„
Fasteners must be replaced after loosening.



Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and
should only be re-used once. If in doubt, replacement is recommended.

Oil Pan Drain Plug ................................................................................ 25.0 Nm
Oil Filter Adaptor Attaching Bolt ................................................ 20.0 – 26.0 Nm
Oil Level Indicator Tube Attaching Bolt........................................ 8.0 – 12.0 Nm
Accessory Drive Belt Idler Pulley Attaching Bolt................................... 50.0 Nm
Accessory Drive Belt Tensioner Attaching Bolt .................................... 50.0 Nm
Power Steering Reservoir Bracket Attaching Screw.............................. 9.0 Nm
Power Steering Pump Bracket Attaching Bolt ........................... 49.0 – 67.0 Nm
Upper Intake Manifold to Lower Intake Manifold Attaching Bolt ........... 23.0 Nm
Upper Intake Manifold to Cylinder Head Attaching Bolt........................ 23.0 Nm
Lower Intake Manifold to Cylinder Head Attaching Bolt........................ 23.0 Nm
Fuel Injector Wiring Harness Bracket Attaching bolt .............................. 9.0 Nm
Exhaust Manifold to Cylinder Head Attaching Bolt ..................... 17.0 - 23.0 Nm
Exhaust Manifold Heat Shield Attaching Bolt ............................... 8.0 - 12.0 Nm
Battery Harness Ground Terminal Attaching Nut ................................. 13.0 Nm
Camshaft Cover Attaching Bolt ................................................... 8.0 – 12.0 Nm
Engine Ground Connector Bolt............................................................. 10.0 Nm
Engine Wiring Harness Former Attaching Bolt .......................... 12.0 – 16.0 Nm
„ Crankshaft Balancer Assembly Attaching Bolt:
Stage 1 ..................................................................................... 90.0 –110.0 Nm
Stage 2 ....................................................................................................... 150 °
Engine Front Cover Assembly Attaching Bolt ............................ 20.0 – 26.0 Nm
Camshaft Intermediate Driveshaft Sprocket Attaching Bolt ....... 58.0 – 72.0 Nm
Secondary Timing Chain Guide Attaching Bolt.......................... 20.0 – 26.0 Nm
Secondary Timing Chain Shoe Attaching Bolt ........................... 20.0 – 26.0 Nm
Secondary Timing Chain Tensioner Attaching Bolt ................... 20.0 – 26.0 Nm
Primary Timing Chain Upper Guide Attaching Bolt.................... 20.0 – 26.0 Nm
Primary Timing Chain Tensioner Attaching Bolt ........................ 20.0 – 26.0 Nm
Oil Pump Assembly Attaching Bolt ............................................ 20.0 – 26.0 Nm
Camshaft Sprocket Attaching Bolt ............................................. 49.0 – 67.0 Nm
Exhaust Camshaft Sprocket Attaching Bolt ............................... 49.0 – 67.0 Nm
Camshaft Bearing Cap Attaching Bolt ......................................... 8.0 – 12.0 Nm
Cylinder Head Threaded Plug .............................................................. 31.0 Nm
„ Cylinder Head M11 Attaching Bolt:
Stage 1 ...................................................................................... 40.0 – 50.0 Nm
Stage 2 ....................................................................................................... 120 °
„ Cylinder Head M8 Attaching Bolt:
Stage 1 ...................................................................................... 12.0 – 18.0 Nm
Stage 2 ......................................................................................................... 60 °
Engine Mount Bracket to Cylinder Block Attaching Bolt ............ 43.0 – 57.0 Nm
Engine Mount to Bracket Attaching Nut ..................................... 70.0 – 90.0 Nm
Engine Mount to Frame Attaching Nut....................................... 44.0 – 60.0 Nm
Engine Lift Bracket Attaching Bolt .......................................... 58.0 – 72.0.0 Nm
Knock Sensor Attaching Nut................................................................. 23.0 Nm

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Engine Mechanical – V6 Page 6A1–293

Power Steering High Pressure Line Attaching Bolt ..................... 8.0 – 12.0 Nm
Power Steering High Pressure Line Flare Nut ........................... 25.0 – 35.0 Nm
Steering Gear Housing Mounting Nut:
Stage 1 ................................................................................................. 60.0 Nm
Stage 2 ................................................................................................40° – 50°
Oil Suction Pipe Attaching Bolt ............................................................. 10.0 Nm
Crankshaft Oil Deflector Attaching bolt................................................. 10.0 Nm
Oil Level Sensor ................................................................................... 20.0 Nm
Oil Pan to Cylinder Block Attaching Bolt .................................... 20.0 – 26.0 Nm
Oil Pan to Crankshaft Rear Oil Seal Housing Attaching Bolt ........ 8.0 - 12.0 Nm
„ Flexplate Attaching Bolt:
Stage 1 ...................................................................................... 26.0 – 34.0 Nm
Stage 2 ......................................................................................................... 45 °
Crankshaft Rear Oil Seal Housing Attaching Bolt........................ 8.0 – 12.0 Nm
„ Connecting Rod Cap Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ................................................................................ Loosen Completely
Stage 3 ................................................................................................. 25.0 Nm
Stage 4 ....................................................................................................... 110 °
Crankshaft Bearing Cap Remover Nut ................................................. 11.0 Nm
„ Crankshaft Main Bearing Cap Inboard Attaching Bolt:
Stage 1 ................................................................................................. 20.0 Nm
Stage 2 ......................................................................................................... 80 °
„ Crankshaft Main Bearing Cap Outboard Attaching Bolt:
Stage 1 ................................................................................................. 15.0 Nm
Stage 2 ....................................................................................................... 110 °
„ Crankshaft main Bearing Cap Side Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ......................................................................................................... 60 °
Cylinder Block Threaded Plug .................................................... 27.0 - 35.0 Nm
Oil Jet Attaching Bolt ................................................................... 8.0 – 12.0 Nm

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Engine Mechanical – V6 Page 6A1–5
Page 6A1–5
Reinstall .............................................................................................................................................................. 192
3.19 Camshaft Sprocket – MY06 Update ................................................................................................ ..................193
Remove ............................................................................................................................................................... 193
Right-hand Side................................................................................................................ ..............................193
Left-hand Side ................................................................................................................................................ 196
Clean................................................................................................................................................................... 199
Inspect ........................................................................................................................ ........................................199
Reinstall .............................................................................................................................................................. 200
3.20 Camshaft ............................................................................................................................................................ 201
Remove ............................................................................................................................................................... 201
Right-hand Side................................................................................................................ ..............................201
Left-hand Side ................................................................................................................................................ 203
Clean................................................................................................................................................................... 204
Inspect ........................................................................................................................ ........................................205
Camshaft Visual Inspection ..................................................................................................... .......................205
Camshaft Meas urement ................................................................................................................................. 205
Reinstall .............................................................................................................................................................. 207
Right-hand Side................................................................................................................ ..............................207
Left-hand Side ................................................................................................................................................ 210
3.21 Rocker Arm......................................................................................................................................................... 213
Remove ............................................................................................................................................................... 213
Clean and Inspect .............................................................................................................. ................................213
Reinstall .............................................................................................................................................................. 214
3.22 Stationary Hydraulic Lash Adjuster ............................................................................................. ....................215
Remove ............................................................................................................................................................... 215
Clean and Inspect .............................................................................................................. ................................215
Reinstall .............................................................................................................................................................. 216
3.23 Cylinder Head Assembly ......................................................................................................... ..........................217
Remove ............................................................................................................................................................... 217
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............217
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................218
Disassemble ....................................................................................................................................................... 219
Clean................................................................................................................................................................... 222
Inspect ........................................................................................................................ ........................................222
Visual Inspection .............................................................................................................. ..............................222
Cylinder Head Measurement.......................................................................................................................... 223
Valve Spring Inspection and Measurement ........................................................................................ ............225
Valve and Seat Grinding ........................................................................................................ ........................225
Assemble ....................................................................................................................... .....................................230
Reinstall .............................................................................................................................................................. 233
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............233
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................234
3.24 Engine Mounts and Brackets ..................................................................................................... .......................236
Remove ............................................................................................................................................................... 236
Engine Mount Location ..................................................................................................................................... 237
Inspect ........................................................................................................................ ........................................237
Reinstall .............................................................................................................................................................. 238
4 Major Service Operations ....................................................................................................... ...........239
4.1 Engine Re moval ................................................................................................................. ................................239
Remove ............................................................................................................................................................... 240
Disassemble ....................................................................................................................................................... 252
Reassemble ........................................................................................................................................................ 253
Reinstall .............................................................................................................................................................. 253
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ...........254
Remove ............................................................................................................................................................... 254
Disassemble ....................................................................................................................................................... 255
Clean................................................................................................................................................................... 255
Inspect ........................................................................................................................ ........................................256

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Engine Mechanical – V6 Page 6A1–22
Page 6A1–22
1.4 Engine Construction
Cylinder Block
The cylinder block (1) is constructed from aluminium alloy
with cast-in-place iron cylinder bore liners.
Each of the four copper-inf iltrated sintered steel main
bearing caps are attached to the cylinder block by six bolts.
Along with two outer and two inner bolts, two side bolts are
used in the deep skirt block fo r increased block stiffness.
The crankshaft thrust bearing is mounted in the third main
bearing cap.
To prevent aeration, oil retu rn from the valve train and
cylinder heads is channelled away from the reciprocating
components through oil drain back passages incorporated
into the cylinder heads and engine block. Pressure
actuated piston oil cooling jets are mounted between
opposing cylinders.

Figure 6A1 – 14
Cylinder Heads
The cylinder heads (1) are semi-permanent mould cast
aluminium with powdered metal valve seat inserts and
valve guides.

Figure 6A1 – 15
Each cylinder head contains four valves per cylinder. The
valves (1) are actuated by the rocker arms (2) that pivot on
stationary hydraulic lash adjuste rs (3), which are oil-fed to
maintain valve / rocker lash.

The separate exhaust and intake camshafts are supported
by four bearings machined into the cylinder head. The front
camshaft bearing cap is used as a thrust control surface for
each camshaft.

A tube (4) is pressed into each cylinder head in three
places that shields each spark plug. An ignition coil
assembly is mounted directly on each spark plug, through
each spark plug tube.

Figure 6A1 – 16

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Engine Mechanical – V6 Page 6A1–25
Page 6A1–25
1.5 Engine Lubrication System
Lubrication Description
A structural diecast aluminium oil pan is fitted that incorporates an oil suction pipe, an oil deflector and an oil level
sensor. The oil suction pipe is bolted in to the oil pan and seals to the bottom of the cylinder block with a gasket. The oil
deflector is bolted to the upper portion of the oil pan and ensures oil supply is maintained under all conditions. The oil
level sensor is mounted thr ough the bottom of the oil pan.
A crankshaft driven gerotor oil pump is mounted to the front of the cylinder block. The pump, which incorporates an
internal pressure-relief valve, draws oil from the oil sucti on tube through the lower passage in the cylinder block. Oil is
then directed through an upper passage to the left-hand side of the cylinder block where the oil filter adapter is mounted.
The oil filter adapter incorporat es a top-access, cartridge style oil filter. The filter is accessed through a screw-on cap tha t
incorporates an oil bypass valve. The o il filter adapter housing incorporates a drain back control valve and a threaded oil
pressure sender. Oil flows through a lower passage within the oil filter adapter and through the o il filter cartridge. Filtered
oil travels back through the upper passage of the adapter and into the engine block.
Oil is then directed up and across the front of the cylinder block, through several drilled passages. These front passages
feed oil to each cylinder head, the passage for the main bearings and piston oil jets, the right-hand and left-hand
secondary idler sprockets and to t he primary timing chain tensioner.
Each cylinder head passage directs oil into oiling circuits for the stationary hydraulic la sh adjusters (SHLAs) and the
camshaft bearing journals. An additional passage in the cy linder head also directs oil to the secondary timing chain
tensioner.
The oil passage that supplies oil to the main bearings also s upplies oil to pressure actuated piston cooling oil jets. Each
oil jet is mounted between opposing cylinder bores and directs oil to the two bores to provide extra cooling and control
piston temperatures.
From the front passages, oil is directed to the front of the block where t he right-hand and left-hand intermediate drive
shaft sprockets and the primary timing chain tensioner are mounted. Each camshaft timing chain tensioner relies on a
gasket to maintain an oil rese rve after the engine is turned off. All camshaft timing chain tensioners incorporate a small
oil jet to supply an oil spray onto the camshaft timing chain components.
Oil returns to the oil pan, either through the camshaft timing chain area or through the drain back passages on the
outboard walls of the cylinder heads and cylinder block.

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Engine Mechanical – V6 Page 6A1–27
Page 6A1–27
Use of Room Temperature Vulcanising and Anaerobic Sealer
CAUTION
A number of sealant types are commonly
used in engines. Examples are; room
temperature vulcanising (RTV) sealer,
anaerobic gasket eliminator sealer, and
anaerobic thread sealant and pipe joint
compound. The correct type of sealant and
amount must be used in the specified location
to prevent oil leaks. Do not interchange the
different types of sealers.
Room Temperature Vulcanising Sealer
• Room temperature vulcanising (RTV) s ealant hardens when exposed to air. This type of sealer is used where two
non-rigid parts (such as the intake manifold and the engine block) are assembled together.
• Do not use RTV sealant in areas where extreme temper atures are experienced. These areas include the exhaust
manifold, head gasket, or other surfaces w here a gasket eliminator is specified.
• Follow all safety recommendations and di rections that are on the container.
• To remove the sealant or the gasket mate rial, refer to Replacing Engine Gaskets.
• Apply RTV to a clean surface. Use a bead size as specified in the service procedure. Run the bead to the inside of
any bolt holes. Do not allow the sealer to enter any bli nd threaded holes, as it may prevent the bolt from clamping
correctly or cause damage when the bolt is tightened.
• Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
Anaerobic Sealer
• Anaerobic gasket eliminator or thread sealant, hardens in t he absence of air. This type sealer is used where two
rigid parts (such as castings) are assembled together, w here fasteners are subjected to vibration, or where the
holes are not blind. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts
were probably assembled using a gasket eliminator.
• Follow all safety recommendations and di rections that are on the container.
• To remove the sealant or the gasket mate rial, refer to Replacing Engine Gaskets.
• Apply a continuous bead of gasket eliminator to one flange or on the bolt/stud thread. All surfaces must be clean
and dry.
• Spread the sealer evenly to achieve a uniform coating on the sealing surface.
• Do not allow the sealer to enter any blind threaded holes as it may prevent the bolt from clamping correctly or
cause damage when tightened.
CAUTION
Anaerobic sealed joints that are partially
tightened and allowed to cure more than five
minutes may result in incorrect shimming and
sealing of the joint.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
• After correctly tightening the fasteners, remove t he excess sealer from the outside of the joint.

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Engine Mechanical – V6 Page 6A1–48
Page 6A1–48
2.18 Engine Oil Leak Diagnosis
Introduction
It is important to correctly identify the source of an engine oil leak. For example, a power steering fluid leak or spillage
during servicing can travel across the va lley area of the engine and run-out the weep hole, which is located at the back of
the cylinder block. Failure to correctly identify the source of an engine oil leak can lead to unnecessary replacement of
engine components.
Most fluid leaks can be repaired by repairi ng or replacing the faulty component or resealing the gasket surface. However,
once a leak is identified it is im portant to determine and repair the c ause as well as the leak itself.
Locating and Identifying the Leak
Inspect the leaking fluid and determine whet her it is engine oil, transmission fluid, power steering fluid, brake fluid or
some other fluid. If unsure of the source of the leaking lubricant, a quick check of fluid levels should indicate where the
fluid is coming from, as one or more fluid level should be low.
Visual Inspection
Once the type of leaking fluid has been determined, a visual inspection of the affected system should be performed.
When performing the visual inspection:
1 Bring the vehicle to the normal operating temperature.
2 Park the vehicle over a large s heet of paper or other clean surface.
3 Leave the vehicle idling for 2-3 minut es, then check for dripping fluid.
4 If required, identify the type of fluid leak ing and the approximate location of the leak.
5 Visually inspect the suspected area. A small mirror may assist viewing areas that are difficult to see normally.
6 Check for leaks at all sealing surfaces and fittings.
7 Check for any cracked or damaged components.
8 If the leak cannot be located, completely clean the entire engine and surrounding components, drive the vehicle at
normal operating temperature for several k ilometres and then repeat Steps 3 to 8.
9 If the leak still cannot be located, proceed with either the Powder Method or Black Light and Dye Method as
outlined below.
Powder Method
1 Completely clean the entir e engine and surrounding components.
2 Apply an aerosol type powder (e.g. f oot powder) to the suspected area.
3 Operate the vehicle at normal operating temperature and at varying speeds for several kilometres.
4 Identify the source of the leak from the discoloration of the powder around the suspect components.
5 If required, use a small mirror to assist in vi ewing areas that are difficult to see normally.
6 Refer to Possible Causes for Engine Oil Leaks in this Section, and repair or replace components as required.
Black Light and Dye Method
A black light and die kit Tool No. J28428-E or a commercially av ailable equivalent is available to technicians to aid in
engine oil leak diagnosis. When using a black light and die kit fo r the first time, it is recommended the technician read the
manufacturers instructions prior to using the kit.
1 Add the specified amount of dye, as per manufacturers instructions, into the engine or suspected source of the oil
leak.
2 Operate the vehicle at normal operating temperature and at varying speeds for several kilometres.
3 With the vehicle parked on a flat leve l surface, aim the black light at the suspected component/s. The dyed fluid will
appear as a yellow path leading to the oil leak source
4 Refer to Possible Causes for Engine Oil Leaks in this Section, and repair or replace components as required.

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Engine Mechanical – V6 Page 6A1–53
Page 6A1–53
Drive Belt Chirp
Definition
Accessory drive belt chirping can be defined as a high-pitched noise that is heard once per revolution of the drive belt or
a pulley.
NOTE
Chirping during start-up in cold damp conditions
that abates once the engine reaches operating
temperature is considered normal.
Diagnostic Aids
The symptom may be intermittent due to moisture on the driv e belts or pulleys. It may be necessary to spray a small
amount of water on the drive belt to dup licate and confirm a customers concern. If spraying water onto the drive belt
system duplicates the symptom, cleaning the belt pulleys may be the solution.
A loose or incorrectly installed body component, suspension component or other item may be the cause of the noise.
Test Description
The numbers below refer to steps in the diagnostic table.
2 The noise may not be engine related. This step is to confirm the engine is making t he noise. If the engine is not
making the noise, do not proceed further with this diagnostic procedure.
3 The noise may be an internal engine noise. Removing the drive belt and operating the engine briefly will confirm
whether or not the noise is related to the drive belt.
CAUTION
When running the engine with the accessory
drive belt removed, the coolant pump will not
be operating and the engine may overheat if
left unsupervised even for a short period.
NOTE
There may also be a number of DTCs set when
running the engine with the accessory drive belt
removed.
4 Inspect all drive pump pulleys for pilling. NOTE
Pilling is the small balls (p ills) or strings of rubber
in the belt grooves caused by the accumulation of
rubber dust.
6 Misalignment of the accessory drive system pulleys ma y be caused by incorrect mounting of an accessory drive
component (A/C compressor, generator etc.) or pulley. Misa lignment may also be caused by incorrect installation of
a pulley during a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across
two or three pulleys. If a misaligned pulley is found, refer to the relevant component service information for the
correct installation and removal procedures.
10 Inspecting the fasteners can elim inate the possibility that an incorrect fastener has been installed.
12 Inspecting the pulleys for being bent should include inspec ting for a dent or other damage that would prevent the
drive belt from not seating correctly in all of the pulley grooves or on the smooth surface when the back end of the
belt is used as the driving surface.
14 Replacing the drive belt when it is not damaged and there is no excessive p illing will only be a temporary repair.

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Engine Mechanical – V6 Page 6A1–54
Page 6A1–54
Diagnostic Table
Step Action Yes No
1
Did you review the information provided in 2.2 Symptoms, and
perform the required inspections. Go to Step 2 Go to
2.2 Symptoms
2 Confirm the customer compla int. Is there a chirping noise?
Go to Step 3 Refer to Diagnostic
Aids in this Section
3 1 Remove the drive belt, refer to 3.5 Accessory Drive Belt.
2 Operate the engine for no more than 40 seconds.
Does the chirping noise still exist? Accessory drive
system OK.
Go to 2.2
Symptoms, and
restart the diagnosis
of the noise Go to Step 4
4
Inspect for severe pilling, i.e. in excess of 33% of the belt groove
depth.
Do the belt grooves have pilling? Go to Step 5 Go to Step 6
5 Clean the drive belt pulleys with a wire brush.
Are the belt pulleys clean? Go to Step 15 Go to Step 6
6 Inspect for misalignment of the pulleys.
Are the pulleys misaligned? Go to Step 7 Go to Step 8
7 Replace or repair misaligned pulleys.
Did you complete the repair? Go to Step 15 —
8
Inspect for any bent or damaged accessory drive component
mounting brackets.
Did you find any bent or damaged brackets? Go to Step 9 Go to Step 10
9 Replace or repair any bent or damaged Brackets. Did you complete the repairs? Go to Step 15 —
10 Inspect for missing, loose or incorrect fasteners.
Did you find any missing, loose or incorrect fasteners? Go to Step 11 Go to Step 12
11
Tighten any loose fasteners to the to rque specification as provided in
provided in 6. Torque Wrench Specifications.
Replace any incorrect or missing fasteners.
Did you complete the repairs? Go to Step 15 —
12 Inspect for a bent pulley.
Did you find any bent pulleys? Go to Step 13 Go to Step 14
13 Replace bent pulleys as required.
Did you complete the repair? Go to Step 15 —
14 Replace the accessory drive belt, re
fer to 3.5 Accessory Drive Belt.
Did you complete the repair? Go to Step 15 —
15
Reinstall the accessory drive belt and operate the system to confirm
the repair.
Did you correct the chirp noise? Accessory drive
system OK Go to 2.2
Symptoms, and
restart the diagnosis

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