recommended oil ISUZU KB P190 2007 Workshop Service Manual

Engine Mechanical – V6 Page 6A1–351
Page 6A1–351
6 Torque Wrench Specifications
ATTENTION
„ 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.

Oil Pan Drain Plug ................................................................................ 25.0 Nm
Oil Filter Adaptor Attach ing Bolt................................................ 20.0 – 26.0 Nm
Oil Level Indicator Tube Atta ching Bolt........................................ 8.0 – 12.0 Nm
Accessory Drive Belt Idler Pu lley Attaching Bolt................................... 50.0 Nm
Accessory Drive Belt Tensio ner Attaching Bolt .................................... 50.0 Nm
Power Steering Reserv oir Bracket Attaching Screw.............................. 9.0 Nm
Power Steering Pump Bracket A ttaching 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 Cylind er Head Attaching Bolt........................ 23.0 Nm
Fuel Injector Wiring Harness Br acket Attaching bolt .............................. 9. 0 Nm
Exhaust Manifold to Cylinder He ad 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 Attachi ng Bolt................................................... 8.0 – 12.0 Nm
Engine Ground Connec tor Bolt............................................................. 10.0 Nm
Engine Wiring Harness Former A ttaching Bolt .......................... 12.0 – 16.0 Nm
„ Crankshaft Balancer A ssembly Attaching Bolt:
Stage 1 ..................................................................................... 90.0 –110.0 Nm
Stage 2 ....................................................................................................... 150 °
Engine Front Cover Assembly A ttaching Bolt ............................ 20. 0 – 26.0 Nm
Camshaft Intermediate Sprocket Attaching Bolt ........................ 58. 0 – 72.0 Nm
Secondary Timing Chai n Guide Attaching Bolt.......................... 20.0 – 26.0 Nm
Secondary Timing Chai n Shoe Attaching Bolt ........................... 20.0 – 26.0 Nm
Secondary Timing Chain Tensioner Attachi ng Bolt ................... 20.0 – 26.0 Nm
Primary Timing Chain Upper Gui de Attaching Bolt.................... 20.0 – 26.0 Nm
Primary Timing Chain Tensioner Attaching Bolt........................ 20. 0 – 26.0 Nm
Oil Pump Assembly Attach ing Bolt............................................ 20.0 – 26.0 Nm
Camshaft Sprocket Attachi ng Bolt............................................. 49.0 – 67.0 Nm
Exhaust Camshaft Sprocket Atta ching Bolt............................... 49.0 – 67.0 Nm
Camshaft Bearing Cap Attach ing Bolt......................................... 8.0 – 12.0 Nm
Cylinder Head Thr eaded 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 Bl ock Attaching Bolt............ 43.0 – 57.0 Nm
Engine Mount to Bracket Atta ching Nut..................................... 70.0 – 90.0 Nm
Engine Mount to Frame Atta ching Nut...................................... 44.0 – 60.0 Nm
Engine Lift Bracket Attachi ng Bolt.......................................... 58.0 – 72.0.0 Nm
Knock Sensor Attach ing Nut................................................................. 23.0 Nm

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Engine Cooling – V6 Engine Page 6B1–17

3 Top up as required, using a 50 / 50 mix of clean water and the recommended coolant, which is either DEX-COOL®
long-life coolant or its equivalent, known as Extended Life Anti-freeze Coolant conforming to GM specification
6277M. Refer to 3.2 Coolant Maintenance and 3.3 Draining and Filling Cooling System in this Section, for the
necessary procedures and further information.
3.2 Coolant Maintenance

Do not mix different types of anti-freeze or
corrosion inhibitors, as they may be
incompatible. If a different type has been used
in the cooling system, flush the system with
clean water, refer to 3.4 Cleaning Cooling
System – Cooling System Flush in this
Section and refill cooling system with the
correct coolant. Refer to 3.3 Draining and
Filling Cooling System in this Section.
The cooling system is designed to use a coolant (a mixture of ethylene glycol antifreeze with added corrosion inhibitors,
and water), rather than plain water. The use of glycol also raises the boiling point and increases the cooling system
efficiency. For this reason, it is of the utmost importance that the correct concentration level of ethylene glycol in the
cooling system is maintained.
Addition of plain water into the cooling system when 'topping-up' may dilute the coolant mixture to a point where the
antifreeze / anti-boil and corrosion inhibitor properties of ethylene glycol become ineffective.
The coolant should comprise of a mixture 50% ethylene glycol antifreeze / inhibitor with 50% clear, clean water.
Ethylene glycol conforming to the correct specification is either named DEX-COOL® long-life coolant or its equivalent,
known as Extended Life Anti-freeze Coolant conforming to GM specification 6277M. Both are available in a number of
different quantities. Check the current release of Partfinder™ for specific details.

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ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–23

1 W ith the engine off, remove the coolant filler cap on
the coolant outlet housing, located at the front left-
hand side of the engine.

Figure 6B1 – 19
2 If filling a completely empty cooling system for automatic transmission models, mix 5 litres of clean
water with 5 litres of the recommended coolant or
5.2 litres of each for manual transmission models.
3 Add coolant via the engine coolant filler neck on the coolant outlet housing.
NOTE
Do not replace the coolant filler cap before
starting the engine (in step 6). Leaving the filler
cap off allows the engine to warm up without
pressurising.
4 Reconnect battery ground lead. Refer to 6D1 – 3 Battery – V6.
5 Start the engine and set the HVAC controls to: • Full hot
• Low fan
Figure 6B1 – 20
6 Run the engine at approximately 2,000 rpm to warm up the engine.
7 W ait until the radiator fan switches on.
8 W hen the radiator fan has switched on, let the engine rpm drop back to idle.
9 Turn the engine off when the radiator fan switches off.
10 Top up the coolant until full.
11 Replace the coolant filler cap.

Do not loosen or remove the radiator filler cap
when the coolant temperature is high. Steam
or boiling coolant will gush out and you may
be burnt. To open the radiator filler cap, cover
the filler cap with a thick cloth when the
coolant has cooled, release the pressure by
slowly turning the filler cap, and remove the
cap.


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Engine Cooling – V6 Engine Page 6B1–57

Radiator Repair Procedure
Repairable Leaks

Figure 6B1 – 64
Legend:
1 Left-hand Side Tank Seal
2 Core Tubes
3 Right-hand Side Tank Seal 4 Oil Cooler Pipe Fittings
5 Joint Between Tube and Header
There are two types of leaks that can be repaired on the aluminium-plastic radiator; core leaks and automatic
transmission oil cooler seal leaks. Leaks in the plastic tanks or the seals between the side tanks and the headers cannot
be repaired; therefore the radiator must be replaced.
Core leaks may occur in a tube or in the joints between the tubes and the headers. Seal leaks may occur in the joints
between the plastic tanks and the headers or in the joints between the oil cooler fittings and the tank (vehicles with
automatic transmission).
W hile some leaks can be repaired while the radiator is installed in the vehicle, it is strongly recommended that the
radiator is first removed from the vehicle.
NOTE
Minor damage to tubes, or tube to header joint
(holes up to 1 mm diameter max.) can be
repaired. Core replacement is necessary if
damage is any greater.

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Engine Cooling – V6 Engine Page 6B1–60

Transmission Oil Cooler Leak Test
If the transmission oil cooler is suspected of leaking oil, test it before the radiator is replaced, as follows:
1 Disconnect oil cooler pipes at the flexible hose connections. Refer to 3.14 Flexible Transmission Cooler Hose, in this Section.
2 Plug one of the connections, using a blocked pipe fitting and attach an air supply to the other flexible hose.
3 Remove coolant filler cap and check that the coolant is filled to the coolant filler cap filler neck.
4 Apply air pressure gradually, increasing up to an absolute maximum of 110 kPa. If bubbles appear in radiator neck, the oil cooler is leaking and the radiator assembly must be replaced.
Transmission Oil Cooler Seal Replacement.
It is strongly recommended that the transmission oil cooler connector fittings to the right-hand side radiator header tank,
not be disturbed. If coolant is found to leak from either of these two areas, then the radiator should be replaced.


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Engine Cooling – V6 Engine Page 6B1–63

4.5 Problems Not Requiring Disassembly of
Cooling System
1 Large obstructions blocking radiator or condenser airflow.
• Auxiliary oil coolers
• License plate
• Obstruction of radiator grille, for example, driving lights or mud
2 Loose, damaged or missing air chute side panels.
3 Missing or damaged air baffle.
4 Cracked or loose coolant recovery system hose.
5 Leaking heater component such as the heater core or water valve.
4.6 Problems Requiring Disassembly of Cooling System
1 Damaged cooling fan or faulty motor operation.
2 Pressure test cooling system.
3 Defective coolant pump.
• Eroded or broken impeller vanes
• Failed bearing or seal – check for shaft or bearing end play
4 Internally blocked radiator core.
5 Obstruction of coolant recovery system.
6 Internal system leaks.
• Head gaskets
• Cracked cylinder block
• Engine front cover
• Intake manifold gaskets
7 Blocked coolant passages in cylinder heads or block – remove cylinder heads and check.
4.7 Black Light and Dye Leak Diagnosis Method
It is strongly recommended that this diagnostic method be used to diagnose fluid leaks. This method is a proven and
reliable method that identifies the specific leak source.
The black light kit can be used for the leak detection of a number of fluids, when used with the appropriate tracer dye.
Examples are: Coolant, Engine Oil, Automatic Transmission Fluid and Air Conditioning Refrigerant (R134A).
The following is a summary of the steps involved in detecting a cooling system fluid leak using black light and dye:
1 Pour specified amount of dye into the cooling system via the coolant filler cap on the outlet housing. Refer 3.1 Service Notes in this Section.
2 Road test the vehicle under normal operating conditions.
3 Direct the light towards the suspect area. The fluid leak will appear as a brightly coloured path leading from the source.
4 Repair fluid leak and recheck to ensure that leak has been rectified.
5 Refer to the manufacturer’s directions when using this method.

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–3

1 General Information
All HFV6 engines are fitted with a Mitsubishi starter motor. This consists of a solenoid switch on a DC motor. The motor
has permanent magnet excitation, which has the advantage of low weight a with high output torque and is visually
identifiable by the absence of pole-shoe retaining screws.
The starter motor does not have field coil windings or pole shoes. These parts have been replaced by six permanent
magnets that are held in the pole housing by clips. The positive brushes are now part of the brush plate assembly.
The solenoid switch is the only component of the starter motor assembly that is serviced separately. If any other parts
require replacement, the starter motor must be replaced.
1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:

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ISUZU KB P190 2007

Starting System – V6 Page 6D1-2–4

• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.
1.2 Components
Starting System Components
The main components of the starting system are:
• battery,
• wiring,
• ignition switch,
• theft deterrent engine crank inhibitor (a function of the theft deterrent system),
• park / neutral and back-up switch (on vehicles with 4 speed automatic transmission),
• engine control module (ECM),
• start relay,
• solenoid switch, and
• starter motor.
Starter Motor and Solenoid Switch Components
Solenoid Switch
The solenoid switch is used to activate the DC motor and has two windings; the pull-in winding and the hold-in winding.
The pull-in winding has heavier wire and is grounded through the DC motor winding and brushes. The hold-in winding is
grounded through the solenoid casing.
Planetary Drive Train
The planetary drive train consists of an internally toothed ring gear and three planetary gear wheels, which rotate on
sleeve bearings on the planetary drive shaft. The ring gear is keyed into the drive-end housing and is made from
high-grade polyamide with mineral additives.
W hen the starter motor operates, the armature turns the planetary gears inside the fixed planetary ring gear. This drives
the planetary shaft at a reduced speed ratio which turns the drive assembly. A fork lever in the drive-end housing forces
the drive assembly forward to engage with the flexplate / flywheel ring gear on the engine and transmit cranking torque.
An internal clutch allows the drive assembly pinion gear to rotate freely when the engine starts. This prevents the
armature from being driven at excessive speed by the engine.
Armature
The armature shaft is supported at each end by oil absorbent, sintered metal bushes; one in the commutator end shield
and one in the planetary drive shaft. The front end of the armature has a gear profile. This meshes with the three
planetary gear wheels. These in turn, mesh with the internal teeth of the ring gear.
Brushes
A brush plate supports four commutator brushes. This plate is fixed to the commutator end shield with two retaining
screws. Two negative brushes are grounded to the pole housing. The two positive brushes are insulated from the pole
housing and connected to the solenoid switch M terminal, refer to Figure 6D1-2 – 1.

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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 5

Service Notes
1. Vehicles fitted with catalytic converters should not be operated with leaded petrol. Lead will contaminate
the ceramic monolith.
2. Do not drop the catalytic converter as it will damage the ceramic monolith.
3. Replace the catalytic converter if it is damaged.
4. Do not allow water, oil or fuel to enter the converter as the ceramic monolith will be contaminated.
5. Do not use engine and/or fuel additives unless approved by General Motors. Many additives contain phosphorous that will contaminate the ceramic monolith.
6. The vehicle must not be started by pushing or towing, as unburned fuel could reach the catalytic converter and destroy the ceramic monolith. Always use jumper leads to start a vehicle that has a flat or
defective battery.
7. W hen carrying out a compression test, for V6 engines use Tech 2 to ensure the output control Engine Compression Test is set to enable, refer to 6A1 Engine Mechanical. This prevents fuel injection and
ignition during engine cranking.
8. Do not drive the vehicle with the engine misfiring or with any of the spark plug leads disconnected, as the catalytic converter will overheat.
9. Do not coast downhill with the engine misfiring or with any of the spark plug leads disconnected.
10. The catalytic converter is serviceable as part of the front exhaust assembly only. Refer to the service operations in this section for details of front exhaust pipe assembly removal and reinstallation.
11. The exhaust flange gaskets must be replaced whenever a new exhaust pipe, muffler or catalytic converter is installed.
1.3 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
1.1 Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is
ignored, the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,

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Automatic Transmission – 4L60E – General Information Page 7C1–12
General Definition
Check Ball A spherical, hydraulically controlled component (usually of steel) that either seals or
opens fluid circuits. It is also referred to as a check valve.
Clutch Pack An assembly of components generally consisting of clutch plates, an apply plate and a
backing plate.
Clutch Plate A hydraulically activated component that has two basic designs: (1) all steel, or (2) a
steel core with friction material bonded to one or two sides of the plate.
Control Valve Body A machined metal casting that contains valve trains and other hydraulically controlled components that shift the transmission.
Coupling Speed The speed at which a vehicle is travelling and no longer requires torque multiplication through the torque converter. At this point, the stator 'free wheels' to allow fluid leaving
the turbine to flow directly to the pump. (Also see Torque Converter).
De-energise(d) To interrupt the electrical current that flows to an electronically controlled device,
making it electrically inoperable.
Direct Drive A condition in a gears set where the input speed and input torque equals the output
speed and output torque. The gear ratio through the gear set is 1:1.
Downshift A change in a gear ratio where both input speed and torque increases.
Duty Cycle In reference to an electronically controlled solenoid, it is the amount of time (expressed
as a percentage) that current flows through the solenoid coil.
Energise(d) To supply a current to an electronically controlled device, enabling it to perform its
designed function.
Engine Compression Braking A condition where compression from the engine is used with the transmission to decrease vehicle speed.
Exhaust The release of fluid pressure from a hydraulic circuit. (The words 'exhausts' and
'exhausting' are also used and have the same intended meaning.)
Fail-safe Mode A condition whereby a component (i.e. engine or transmission) will partially function even if its electrical circuit is disabled.
Fluid In this Section of the Service Manual, 'fluid' refers primarily to automatic transmission
fluid (or ATF) and, for the Hydra-matic 4L60E transmission, the only recommended
fluid is Dexron
III.
Fluid Pressure A pressure that is consistent throughout a given fluid circuit.
Force A measurable effort that is exerted on an object (component).
Freewheeling A condition where power is lost through a driving or holding device (i.e. roller or sprag
clutches).
Friction Material A heat and wear resistant fibrous material, bonded to clutch plates and bands.
Gear A round, toothed device that is used for transmitting torque through other components.
Gear Range A specific speed to torque ratio at which the transmission is operating (i.e. 1st gear,
2nd gear etc.).
Gear Ratio Revolutions of an input gear as compared to the revolutions of an output gear. It can
also be expressed as the number of teeth on a gear as compared to the number of
teeth on a gear that it is in mesh with.
Hydraulic Circuit A fluid passage which often includes the mechanical components in that circuit
designed to perform a specific function.
Input A starting point for torque, revolutions or energy into another component of the
transmission.
Internal Gear The outermost member of a gear set that has gear teeth in constant mesh with the
planetary pinion gears of the gear set.
Land (Valve Land) The larger diameters of a spool valve that contact the valve bore or bushing.

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