ISUZU KB P190 2007 Workshop Repair Manual

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 6A1–294

7 Special Tools
Tool Number Illustration Description
E-308 Seal Remover
Previously released.
EN-46101
Spark Plug Tube Seal Guide Set
Used to protect the spark plug lip seals when installing the
camshaft cover to the cylinder head.
EN-46103
Camshaft Actuator Valve Seal Installer
Used to install the camshaft actuator valve seals into the front
cover.
EN-46105 –
1 and 2
Camshaft Locking Tool Set
Used to retain camshaft position during timing chain or
camshaft actuator replacement.
EN-46106
Flexplate Holding Tool
Used to retain crankshaft position during valve-train overhaul
and harmonic balancer removal.
EN-46108
Timing Chain Retention Tool Set
Used to retain timing chain tension during camshaft and
sprocket removal.

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Engine Mechanical – V6 Page 6A1–295

Tool Number Illustration Description
EN-46109
Engine Front Cover / Oil Pan / Crankshaft Rear Oil Seal
Housing Installation Guide Pins
Used to align the engine front cover/oil pan/crankshaft rear oil
seal housing during engine assembly.
EN-46110
On-vehicle Valve Spring Compressor
Used to remove valve springs with the cylinder heads
assembled to the cylinder block.
EN-46111
Crankshaft Rotation Socket
Used to rotate the crankshaft during engine overhaul.
EN-46112
Timing Chain Tensioner Retraction Springs
Used to retain the timing chain tensioner plunger within the
tensioner bore during assembly of timing chains to engine.
EN-46114
Engine Lift Brackets
Used in conjunction with commercially available lifting
equipment to lift engine.
EN-46116
Valve Stem Seal Remover / Installer
Used to remove/install the valve stem seals.

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Engine Mechanical – V6 Page 6A1–296

Tool Number Illustration Description
EN-46117
Valve Stem Key Remover / Installer
Used in conjunction with J-8062 or EN-46110 to remove and
reinstall the valve stem keys.
EN-46119
Off-vehicle Valve Spring Compressor Adaptor
Used in conjunction with J-8062 to remove valve springs with
the engine disassembled.
EN-46120 and
J-42096

Valve Guide Reamer
Used to oversize valve guides prior to the installation of new
oversized valves.
EN-46121
Connecting Rod Guide Pin Set
Used to guide connecting rods onto the crankshaft journals
and prevent damage to the cylinder bores, journal faces and
piston cooling jets during engine assembly procedures.
EN-46122
Oil Control Valve Check Ball Remover / Installer
EN-7115 Torque Angle W rench
Used to accurately tighten fasteners when an angle torque is
required.

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Engine Mechanical – V6 Page 6A1–297

Tool Number Illustration Description
J-29184
Crankshaft Front Oil Seal Installer

J-36648-A
Oil Pressure Gauge Adaptor
j-41816 three legged puller

J-41818
Main Bearing Cap Removal Tool
Used in conjunction with J-6125-1B to remove the main
bearing caps from the cylinder block during engine
disassembly procedures.
J-41998-B
Crankshaft Balancer Installer
J-42385-2000

Thread Insert Kit
Used to repair damaged threads during engine overhaul.
J-42385-700
High Feature Thread Repair Kit
Used to repair damaged threads during engine overhaul.

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Engine Mechanical – V6 Page 6A1–298

Tool Number Illustration Description
J-45027
Tensioner Tool
Used to reset the timing chain tensioner plunger.
J-6125-1B
Slide Hammer
Used in conjunction with J-41818 to remove the main bearing
caps from the cylinder block during engine disassembly.
J-8062
Valve Spring Compressor
Used in conjunction with EN-46119 to remove valve springs
with the engine disassembled.
J-8087
Cylinder Bore Gauge
Commercial equivalent also available


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–1
Page 6A1–1
Section 6A1
Engine Mechanical – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.1 WARNING,
CAUTION and NOTES for correct workshop practices with regard to safety and/or property damage.
1 General Information ............................................................................................................ ...................8
MY06 Update .................................................................................................................... ......................................8
1.1 WARNING, CAUTION and NOTES .................................................................................................... ...................8
Definition of WARNING, CAUT ION and NOTE Statements ............................................................................. ....8
WARNING defined ................................................................................................................ .............................8
CAUTION defined ................................................................................................................ ..............................8
NOTE defined................................................................................................................... ..................................9
1.2 Engine Components .............................................................................................................. ..............................10
Major Component Assemblies............................................................................................................................ 10
Intake Manifold Assembly ....................................................................................................... ............................11
Engine Front Cover............................................................................................................. .................................12
Camshaft Timing Components ..................................................................................................... ......................13
Camshaft Cove r Assembly........................................................................................................ ..........................14
Cylinder Head Assembly ......................................................................................................... ............................15
Oil Pump ....................................................................................................................... ........................................16
Engine Block Assembly .......................................................................................................... ............................17
Pistons, Rings, Bearing and Connecting Rod ..................................................................................... ..............18
Oil Pan Assembly............................................................................................................... ..................................19
Oil Filter Assembly ............................................................................................................ ..................................20
1.3 Engine Serial Number........................................................................................................... ...............................21
1.4 Engine Construction............................................................................................................ ................................22
Cylinder Block ................................................................................................................. .....................................22
Cylinder Heads ..................................................................................................................................................... 22
Crankshaft ..................................................................................................................... .......................................23
Pistons, Pins and Connecting Rods .............................................................................................. ....................23
Camshaft Driv e System ....................................................................................................................................... 24
1.5 Engine Lubrication System .................................................................................................................................25
Lubrication Description........................................................................................................ ...............................25
1.6 Service Notes .................................................................................................................. .....................................26
Cleanliness and Care........................................................................................................... ................................26
Replacing Engine Gaskets .................................................................................................................................. 26
Re-Using Gaskets and Applying Sealants......................................................................................... ...............26
Separating Co mponents................................................................................................................................... 26
Cleaning Gasket Surfaces ................................................................................................................................ 26
Assembling Components ................................................................................................................................. 26
Use of Room Temperature Vulcanising and Anaerobic Sealer....................................................................... .27
Room Temperature Vu lcanising Sealer............................................................................................ ................27
Anaerobic Sealer ............................................................................................................... ...............................27
Pipe Joint Compound ............................................................................................................ ...........................28
Separating Parts ............................................................................................................... ...................................28
Tools and Equipment ............................................................................................................ ..............................28
Fasteners .............................................................................................................................................................. 29
Clamp Load ..................................................................................................................... .................................29
Torque Angle and Torque to Yield Fastener s................................................................................................... 29
2 Diagnosis ...................................................................................................................... ........................30
2.1 Engine Diagnosis ............................................................................................................... ..................................30
2.2 Symptoms ....................................................................................................................... .....................................31
Strategy Based Diagnosis................................................................................................................................... 31

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Engine Mechanical – V6 Page 6A1–2
Page 6A1–2
Visual / Physical Inspection ................................................................................................... .............................31
Intermittent ................................................................................................................... ........................................31
2.3 Engine Misfire without In ternal Engine Noises .................................................................................. ...............32
2.4 Engine Misfire with Abnormal In ternal Lower Engine Noises...................................................................... ....34
2.5 Engine Misfire with Abno rmal Valve Train Noise ................................................................................. .............35
2.6 Engine Misfire with Coolant Consumption ........................................................................................ ................36
2.7 Engine Misfire with E xcessive Oil Consumption .................................................................................. ............37
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds ....................................................................... .....38
2.9 Upper Engine Noise, Rega rdless of Engine Speed................................................................................. ..........39
2.10 Lower Engine Noise, Rega rdless of Engine Speed ................................................................................. .........40
2.11 Engine Noise Under Load ................................................................................................................................... 41
2.12 Engine Will Not Crank – Crankshaft Will Not Rotate ............................................................................. ...........42
2.13 Coolant in Com bustion Chamber .................................................................................................. .....................43
Definition ..................................................................................................................... .........................................43
2.14 Coolant in Engine Oil........................................................................................................................................... 44
Definition ..............................................................................................................................................................44
2.15 Engine Compression Test........................................................................................................ ...........................45
Preliminary Steps................................................................................................................................................. 45
Engine Cylinder Compression Test ............................................................................................... ....................45
Test Result Evaluation ......................................................................................................... ...............................45
2.16 Cylinder Leakage Test .......................................................................................................... ...............................46
2.17 Engine Oil Consumption Diagnosis ............................................................................................... ....................47
Definition ..................................................................................................................... .........................................47
2.18 Engine Oil Leak Diagnosis .................................................................................................................................. 48
Introduction ..........................................................................................................................................................48
Locating and Identifying the Leak .............................................................................................. ........................48
Visual Inspection .............................................................................................................. ...................................48
Powder Method .................................................................................................................. ..................................48
Black Light and Dye Method ............................................................................................................................... 48
Possible Causes for Engine Oil Leaks ........................................................................................... ....................49
2.19 Engine Oil Pressu re Diagnosis .................................................................................................. .........................50
2.20 Accessory Drive Belt Diagnosis ................................................................................................. ........................51
Tension Check .................................................................................................................. ...................................51
Inspect ........................................................................................................................ ..........................................52
Drive Belt Chirp .................................................................................................................................................... 53
Definition ..................................................................................................................... .....................................53
Diagnostic Aids................................................................................................................................................. 53
Test Description ............................................................................................................... ................................53
Diagnostic Table............................................................................................................... ................................54
Drive Belt Squeal .............................................................................................................. ...................................55
Definition ..................................................................................................................... .....................................55
Diagnostic Aids................................................................................................................................................. 55
Test Description ............................................................................................................... ................................55
Diagnostic Table............................................................................................................... ................................55
Drive Belt Whine .................................................................................................................................................. 57
Definition ..................................................................................................................... .....................................57
Diagnostic Aids................................................................................................................................................. 57
Test Description ............................................................................................................... ................................57
Diagnostic Table............................................................................................................... ................................57
Drive Belt Rumble .............................................................................................................. ..................................58
Definition ..................................................................................................................... .....................................58
Diagnostic Aids................................................................................................................................................. 58
Test Description ............................................................................................................... ................................58
Diagnostic Table............................................................................................................... ................................58
Drive Belt Vibration........................................................................................................... ...................................60
Definition ..................................................................................................................... .....................................60
Diagnostic Aids................................................................................................................................................. 60
Test Description ............................................................................................................... ................................60
Diagnostic Table............................................................................................................... ................................60
Drive Belt Falls Off ........................................................................................................... ....................................62

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Engine Mechanical – V6 Page 6A1–3
Page 6A1–3
Definition ..................................................................................................................... .....................................62
Diagnostic Aids................................................................................................................................................. 62
Test Description ............................................................................................................... ................................62
Diagnostic Table............................................................................................................... ................................62
Drive Belt Excessive Wear ...................................................................................................... ............................64
Definition ..................................................................................................................... .....................................64
Diagnostic Aids................................................................................................................................................. 64
Test Description ............................................................................................................... ................................64
Diagnostic Table............................................................................................................... ................................64
Accessory Drive Belt Tensioner Diagnosis ....................................................................................... ................65
Diagnostic Table............................................................................................................... ................................65
3 Minor Service Operations ....................................................................................................... .............66
3.1 Engine Oil ..................................................................................................................... ........................................66
Check.................................................................................................................................................................... 66
Replace ........................................................................................................................ .........................................67
Pressure Check ................................................................................................................. ...................................68
3.2 Oil Filter Cartridge ........................................................................................................... ....................................69
Replace ........................................................................................................................ .........................................69
3.3 Oil Filter Adaptor............................................................................................................. .....................................70
Remove ................................................................................................................................................................. 70
Reinstall ................................................................................................................................................................ 70
3.4 Oil Level Indicator Tube ...................................................................................................................................... 71
Remove ................................................................................................................................................................. 71
Reinstall ................................................................................................................................................................ 71
3.5 Accessory Drive Belt ........................................................................................................................................... 72
RWD Vehicle ......................................................................................................................................................... 72
Remove ............................................................................................................................................................72
Reinstall ...................................................................................................................... .....................................73
3.6 Accessory Drive Belt Idler Pulley .............................................................................................. .........................74
Remove ................................................................................................................................................................. 74
Reinstall ................................................................................................................................................................ 74
3.7 Accessory Drive Belt Tensioner Assembly ........................................................................................ ...............75
Remove ................................................................................................................................................................. 75
Reinstall ................................................................................................................................................................ 75
3.8 Power Steering Pump Bracket .................................................................................................... ........................76
Remove ................................................................................................................................................................. 76
Reinstall ................................................................................................................................................................ 76
3.9 Upper Intake Manifold .......................................................................................................... ...............................77
Remove ................................................................................................................................................................. 77
Disassemble ......................................................................................................................................................... 80
Clean..................................................................................................................................................................... 80
Inspect ........................................................................................................................ ..........................................81
Reassemble .......................................................................................................................................................... 81
Reinstall ................................................................................................................................................................ 82
3.10 Intake Manifold Assembly – Complete............................................................................................ ...................83
Remove ................................................................................................................................................................. 83
Disassemble ......................................................................................................................................................... 87
Clean..................................................................................................................................................................... 88
Inspect ........................................................................................................................ ..........................................88
Reassemble .......................................................................................................................................................... 89
Reinstall ................................................................................................................................................................ 89
3.11 Exhaust Manifold Assembly ...................................................................................................... .........................91
Remove ................................................................................................................................................................. 91
Inspect ........................................................................................................................ ..........................................93
Reinstall ................................................................................................................................................................ 93
3.12 Camshaft Cover ................................................................................................................. ..................................94
Remove ................................................................................................................................................................. 94
Clean and Inspect .............................................................................................................. ..................................96

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