indicator ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–66
Page 6A1–66
3 Minor Service Operations
ATTENTION
The V6 engine is a combination of numerous components, containing machined, honed, polished and lapped
surfaces manufactured on the latest, high technology production equipment. Many of the components
contain tolerances measured in thousa ndths of a millimetre. Consequently, when any e ngine component is to
be serviced, care and cleanliness are extremely important.
Prior to re-assembly of the engine, all components mu st be cleaned and inspected in accordance with the
relevant clean and inspect procedur es throughout this Section, and repl aced or repaired where required.
In addition to cleaning and inspecting components, a liberal coating of engine oil should be applied to friction
surfaces during assembly to protect and lubr icate the surfaces on initial operation.
When performing any service operation, it should be understood that correct cleaning and protection of
machined surfaces and friction areas is part of the repair procedure. This is considered standard workshop
practice, even if not specifically stated. Torque va lues must be used as specified during reassembly to
ensure correct retention of all components.
Through out this section, fastener torque wrench sp ecifications may be accompanied with the following
identification marks:
■ Fasteners must be replaced after loosening.
Fasteners either have micro encapsulated sealant a pplied or incorporate a mechanical thread lock and
should only be re-used once. If in doubt, replacement is recommended.
If one of these identification marks is present alongs ide a fastener torque wrench specification, the
recommendation regarding that fastener must be adhered to.
3.1 Engine Oil
The procedure outlined below is typically the same for both rear wheel drive and all wheel drive vehicles.
Check
The following procedure is applicable to both rear wheel and all wheel drive vehicles
1 Run the engine to bring it to normal operating temperature.
2 Park the vehicle on a level surface. A vehicle that is not level will affect the accuracy of the level reading.
3 Stop the engine and wait 5 to 10 minutes to a llow the oil to drain back into the oil pan.
4 Remove the oil level indicator (1) and wipe clean.
5 Insert the indicator, ens uring it is fully seated.
6 Slowly remove the indicator to avoid smearing. Hold it horizontally or with lower end slightly down to avoid
oil running along indicator.
7 Observe the oil level where it passes over the centre
line of the indicator.
8 If the level is lower than the Add mark (2), add enough oil to the engine to reach the Upper mark (3).
Do not add too much oil as the reading should never
be above the Upper mark.
NOTE
When topping up the oil, allow approximately 5
to 10 minutes for the added oil to fully drain into
the oil pan.
Figure 6A1 – 23

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Engine Mechanical – V6 Page 6A1–71
Page 6A1–71
3.4 Oil Level Indicator Tube
Remove
1 Remove the oil level indicator from the oil level indicator tube.
2 Remove the bolt (2) attaching the oil level indicator tube (1) and engine wiring harness retaining bracket.
3 Withdraw the oil level indi cator tube from the oil pan.
4 Remove and discard the o-ring at the bottom of the oil level indicator tube.
Figure 6A1 – 28
Reinstall
Reinstallation of the oil level indicator tube is the reverse of the removal procedure, noting the following:
1 Install a new oil level indicator o-ring.
2 Ensure the attaching bolt passes through the engine wiring harness retaining bracket.
3 Tighten bolt to the correct torque specification.
Oil level indicator tube attaching bolt
torque specificatio n ................................... 8. 0 – 12.0 Nm


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Engine Mechanical – V6 Page 6A1–91
Page 6A1–91
3.11 Exhaust Manifold Assembly
Remove

Allow the engine to cool before commencing.

Disconnection of the battery affects
certain vehicle electronic systems, refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Disconnect the battery negative terminal.
2 Remove the oxygen sensor harness connector (1) from the retaining bracket.
3 Disconnect the oxygen sensor wiring harness connector from the engine wiring harness connector
(2).
4 Unclip the oxygen sensor wiring harness retaining clip and move aside.
5 For the left-hand side: Remove the oil level indicator tube.
6 Raise the front of the vehicle and place on stands,
refer to Section 0A General Information .
7 Working from under the vehicle, remove the two exhaust manifold to exhaust pipe flange nuts, refer to
Section 6F Exhaust System - V6 .
Figure 6A1 – 56
8 Remove the three bolts attaching the exhaust manifold outer heat shield (1) to the exhaust manifold
(2).

Figure 6A1 – 57

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Engine Mechanical – V6 Page 6A1–206
Page 6A1–206
4 Measure the camshaft runout using a dial
indicator (1).


Figure 6A1 – 339
5 Measure the camshaft thrust width for wear using a depth micrometer (A).


Figure 6A1 – 340
6 Measure the camshaft thrust wall surface for runout using a dial indicator (1).


Figure 6A1 – 341

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Engine Mechanical – V6 Page 6A1–207
Page 6A1–207
7 Measure the camshaft lobes for wear using a dial
indicator (1).


Figure 6A1 – 342
8 Place the dial indicator tip on the base circle (1) of the camshaft lobe.
9 Set the dial indicator at zero.
10 Rotate the camshaft until the indicator tip is at the highest point (2) on the lobe. This reading is the lift of
the camshaft lobe.


Figure 6A1 – 343
Reinstall
Right-hand Side
1 Select the correct camshaft for the particular installation location. ID markings are on the rear end
of each camshaft. The ID markings are defined as
follows:
• The first five digits refer to the date and time of
production.
• Example = 3L18H.
• Digits six through nine refer to engine
production code.
• LY7 = Alloytec 190 engine.
• The last two digits refer to position:
• LI = left-hand intake.
• LE = left-hand exhaust.
• RI = right-hand intake.
• RE = right-hand exhaust.


Figure 6A1 – 344

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Engine Mechanical – V6 Page 6A1–224
Page 6A1–224
Valve Guide Measurement
1 Measure the valve stem (1) to-guide (2) clearance.
Excessive valve stem-to-guide clearance may cause
excessive oil consumption and may also cause a
valve to break. Insufficient clearance will result in
noisy and sticky functioning of the valve and will
disturb the engine assembly smoothness.
2 Clamp a dial indicator to the cylinder head at the camshaft cover rail.
3 Locate the dial indicator so the movement of the valve
stem from side to side, crossways to the cylinder
head, will cause a direct mo vement of the indicator
stem. The dial indicator stem must contact the side of
the valve stem just above the valve guide.
4 Drop the valve head about 0.064 mm off the valve seat.
5 Use light pressure when moving the valve stem from side to side to obtain a clearance reading, refer to
5 Specifications .
• If the clearance for the valve is greater than
specified and a new st andard diameter valve
stem will not bring the clearance within
specifications, the valv e guide may be oversized
by 0.075 mm using the valve guide reamer, Tool
No. J 42096 or by 0.375 mm using the valve
guide reamer, Tool No. EN-46120. Two sizes of
oversized valve stems are available for service.
• Valve guide wear at the bottom 10 mm of the
valve guide is not significant enough to affect
normal operation.
• If over sizing the guide does not bring the
clearance within specif ications, replace the
cylinder head.

Figure 6A1 – 379

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–227
Page 6A1–227
2 Measure the seat width on the valve face (1) using a
correct scale.
CAUTION
The seat contact area must be at least
0.5 mm from the outer diameter (margin) of
the valve. If the contact area is too close to
the margins, the seat must be reconditioned
to move the contact area away from the
margin.
3 Compare the measurements with the specifications,
refer to 5 Specifications .
4 If the seat widths are a cceptable, check the valve
seat roundness, refer to Valve Seat Roundness
Measurement Procedure in this Section.
5 If the seat width is not acceptable, grind the valve
seat to bring the width back to specification. Correct
valve seat width is critical to providing the correct
amount of valve heat dissipat ion, refer to Valve and
Seat Reconditioning Procedure in this Section.


Figure 6A1 – 383
Valve Seat Roundness Measurement Procedure
1 Measure the valve seat roundness using a dial indicator a ttached to a tapered pilot installed in the guide. The pilot
should have a slight bind w hen installed in the guide.
CAUTION
The correct size pilot must be used. Do not
use adjustable diameter pilots. Adjustable
pilots may damage the valve guides.
2 Compare your measurements with the specifications, refer to 5 Specifications.
3 If the valve seat exceeds the roundne ss specification, grind the valve and valve seat, refer to Valve and Seat
Reconditioning Procedure in this Section.
4 If new valves are being used, the valv e seat roundness must be within 0.05 mm.
Valve Margin Measurement Procedure
1 Measure the valve margin using an appropriate scale.
2 Refer to 5 Specifications for minimum valve margin
and compare them to your measurements.
3 If the valve margins are beyond specification, replace the valves.
4 If the valve margins are within specification and do not require refacing, test the valve for seat
concentricity, refer to Valve-to-Seat Concentricity
Measurement Procedure in this Section.


Figure 6A1 – 384

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

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


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


Figure 6A1 – 422

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–281
Page 6A1–281
4.6 Crankshaft and Main Bearings
1 Remove the engine assembly, refer to 4.1 Engine .
2 Remove both cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
3 Remove the oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly .
4 Remove the piston and connecting rod assemblies, refer to 4.5 Pistons, Pins, Rings, Connecting Rods and Big-
end Bearings .
5 Remove the oil pump assembly, refer to 3.17 Oil Pump Assembly.
6 Remove the crankshaft rear oil seal and plate assembly, refer to 4.4 Crankshaft Rear Seal and Plate Assembly .
7 Remove the crankshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
Crankshaft End Play Measurement
1 Place a dial indicator at the end of the crankshaft nose.
2 Gently force the crankshaft towards the front and rear of the cylinder block with a lever while monitoring the
movement of the dial indicator.
3 The crankshaft endplay should not exceed specifications, refer to 5 Specifications.
4 If the specifications are ex ceeded, inspect the thrust bearing thrust outer diameter and the crankshaft thrust wall for
wear and/or excessive runout. Compare the va lues with the specifications, refer to 5 Specifications.
5 Replace the thrust bearing or crankshaft as required.
Remove
1 Remove the crankshaft bearing cap side bolts (3).
CAUTION
The crankshaft bearing cap outer bolts are
yield tightened during assembly and must
be replaced prior to reassembly. Crankshaft
bearing cap outer bolts that are not replaced
will not torque to the correct clamp load and
can lead to serious engine damage.
2 Remove the crankshaft bearing cap outer bolts (1).
3 Remove the crankshaft bearing cap inner bolts (2).

Figure 6A1 – 500

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Engine Mechanical – V6 Page 6A1–286
Page 6A1–286
4 Inspect for incorrect seating indicated by bright,
polished sections (1).

Figure 6A1 – 509
Crankshaft Measurement
1 Using a suitable fixture (1 ), support the crankshaft (2).


Figure 6A1 – 510
2 Using a dial indicator (1) and magnetic base (2), rotate the crankshaft (3) carefully by hand. Measure
the crankshaft main journals for runout and compare
with the engine specifications, refer to
5 Specifications .


Figure 6A1 – 511

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