engine ISUZU KB P190 2007 Workshop Repair Manual
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ENGINE LUBRICATION 6G-7
Inspection and Repair
CAUTION: Make necessary correction or parts replacement if wear, damage or any other
abnormal conditions are found through
inspection.
Reassembly
To install, follows the disassembly steps in the reverse order.
Important
Sealer - Apply silicon into groove in oil pan lugs prior to fitment of oil pan to block, remove excess sealer after oil pan
is bolted to block.
(2.4L 4 ×4 Model)
4
3
1
2
(2.4L 4 ×2 Model)
4
3
1
2
Torque
Bolts - Tighten bolts to the specified torque.
Torque : 20 N xm (2.0 kgf xm)
Engine oil - Refill engine oil to the oil pan. (Lit)
Replacement Oil Fill Volume 2.4L
W ithout filter change 4.00
W ith filter change 4.25
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Page 2472 of 6020
EN G IN E SPEED C O NTR O L S Y STEM ( C 24SE) 6 H
SECTION 6H
ENGINE SPEED CONTROL SYSTEM (C24SE)
TABLE OF CONTENTS
Sevice Precaution ....................................................................................................... ..... 6 H - 1
PA
GE
Accele rator Pedal Control Cable .................................................................................... 6 H - 2
Removal ................................................................................... ........................................ 6 H - 2
Inspection ................................................................................... ..................................... 6 H - 3
Installation ................................................................................... ..................................... 6H - 3
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Page 2474 of 6020
6H-2 ENGINE SPEED CONTROL SYSTEM (C24SE)
Accelerator Pedal Control Cable
RHD MODEL
RTW 46HLF000501
Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from
accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in indirection an arro
w
90 °.
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Page 2475 of 6020
4. Remove the accelerator control cable from the
throttle.
LHD MODEL
RTW 46AMH000101
Inspection
Check the following items and replace the control
cable if any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should not be damage o
r
corrosion.
Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam o
f
engine.
3. Install accelerator control cable to accelerato
r
bracket.
1) Rotate the ratchet ring in direction an arrow 90 °
until both white marking are aligned.
2) Confirm marking of outer cap must be uppe
r
side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
EN
GIN E SPEED CONTR O L SY STEM (C 24SE) 6H-3
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Page 2479 of 6020
Section 6A1 Engine Mechanical ................................................................................... 2480 PAGE
Section 6A1 Engine Mechanical Update....................................................................... 2778
Section 6C1-1 Engine Management General Information ......................................... 3243
Section 6C1-2 Engine Management Diagnostics........................................................ 3279
Section 6C1-3 Engine Management Service Operations ........................................... 3525
Section 6D1-1 Charging System V6 ............................................................................ 3588
SECTION 6
ENGINE
TA BLE OF CONTENTS
Section 6D1-3 Battery V6 ............................................................................................. 3641
Section 6E1 Powertrain Interface Module V6 .............................................................. 3662
HFV6 MODEL
ENGINE HFV6
Section 6B Engine Cooling .......................................................................................... 3136
Section 6C Fuel System V6 .......................................................................................... 3203
Section 6 D1-2 St art ing Syste m V 6 ............................................................................... 36 09
Section 6F Exhaust System V6 .................................................................................... 3749
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Page 2480 of 6020
Engine Mechanical – V6 Page 6A1–1
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
1.1 WARNING, CAUTION and NOTES .................................................................................................... ................... 8
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 8
WARNING defined ............................................................................................................................................. 8
CAUTION defined .............................................................................................................................................. 8
NOTE defined..................................................................................................................................................... 9
1.2 Engine Components .............................................................................................................................................. 9
Major Component Assemblies..................................................................................................... ......................... 9
Intake Manifold Assembly ................................................................................................................................... 10
Engine Front Cover.............................................................................................................................................. 12
Camshaft Timing Components ..................................................................................................... ...................... 13
Camshaft Cover 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........................................................................................................... ............................... 20
1.4 Engine Construction............................................................................................................................................ 21
Cylinder Block ...................................................................................................................................................... 21
Cylinder Heads ................................................................................................................. .................................... 21
Crankshaft ............................................................................................................................................................ 22
Pistons, Pins and Connecting Rods .............................................................................................. .................... 22
Camshaft Drive System ....................................................................................................................................... 22
1.5 Engine Lubrication System ...................................................................................................... ........................... 24
Lubrication Description....................................................................................................................................... 24
1.6 Service Notes ....................................................................................................................................................... 24
Cleanliness and Care........................................................................................................... ................................ 24
Replacing Engine Gaskets ....................................................................................................... ........................... 24
Re-Using Gaskets and Applying Sealants......................................................................................... ............... 24
Separating Components................................................................................................................................... 24
Cleaning Gasket Surfaces................................................................................................................................ 24
Assembling Components .......................................................................................................... ....................... 25
Use of Room Temperature Vulcanising and Anaerobic Sealer....................................................................... .25
Room Temperature Vulcanising Sealer............................................................................................................ 25
Anaerobic Sealer .............................................................................................................................................. 25
Pipe Joint Compound ............................................................................................................ ........................... 26
Separating Parts .................................................................................................................................................. 26
Tools and Equipment ............................................................................................................ .............................. 26
Fasteners .............................................................................................................................................................. 27
Clamp Load ..................................................................................................................... ................................. 27
Torque Angle and Torque to Yield Fasteners..................................................................................... .............. 27
2 Diagnosis ..............................................................................................................................................28
2.1 Engine Diagnosis ............................................................................................................... .................................. 28
2.2 Symptoms............................................................................................................................................................. 28
Strategy Based Diagnosis ....................................................................................................... ............................ 28
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Engine Mechanical – V6 Page 6A1–2
Visual / Physical Inspection ................................................................................................................................ 28
Intermittent ........................................................................................................................................................... 28
2.3 Engine Misfire without Internal Engine Noises .................................................................................. ............... 29
2.4 Engine Misfire with Abnormal Internal Lower Engine Noises...................................................................... .... 30
2.5 Engine Misfire with Abnormal Valve Train Noise .............................................................................................. 31
2.6 Engine Misfire with Coolant Consumption ........................................................................................................ 31
2.7 Engine Misfire with Excessive Oil Consumption .................................................................................. ............ 31
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds ....................................................................... ..... 31
2.9 Upper Engine Noise, Regardless of Engine Speed........................................................................................... 33
2.10 Lower Engine Noise, Regardless of Engine Speed ................................................................................. ......... 34
2.11 Engine Noise Under Load ................................................................................................................................... 35
2.12 Engine Will Not Crank – Crankshaft Will Not Rotate ............................................................................. ........... 35
2.13 Coolant in Combustion Chamber ....................................................................................................................... 37
Definition .............................................................................................................................................................. 37
2.14 Coolant in Engine Oil.......................................................................................................... ................................. 37
Definition .............................................................................................................................................................. 37
2.15 Engine Compression Test ........................................................................................................ ........................... 38
Preliminary Steps................................................................................................................................................. 38
Engine Cylinder Compression Test ............................................................................................... .................... 38
Test Result Evaluation......................................................................................................................................... 38
2.16 Cylinder Leakage Test .......................................................................................................... ............................... 39
2.17 Engine Oil Consumption Diagnosis ............................................................................................... .................... 39
Definition .............................................................................................................................................................. 39
2.18 Engine Oil Leak Diagnosis ...................................................................................................... ............................ 40
Introduction .......................................................................................................................................................... 40
Locating and Identifying the Leak .............................................................................................. ........................ 40
Visual Inspection ................................................................................................................................................. 40
Powder Method .................................................................................................................. .................................. 40
Black Light and Dye Method ..................................................................................................... .......................... 40
Possible Causes for Engine Oil Leaks ........................................................................................... .................... 41
2.19 Engine Oil Pressure Diagnosis ........................................................................................................................... 42
2.20 Accessory Drive Belt Diagnosis ................................................................................................. ........................ 42
Tension Check ..................................................................................................................................................... 42
Inspect .................................................................................................................................................................. 42
Drive Belt Chirp .................................................................................................................................................... 43
Definition .......................................................................................................................................................... 43
Diagnostic Aids................................................................................................................................................. 43
Test Description ............................................................................................................... ................................ 43
Diagnostic Table............................................................................................................................................... 44
Drive Belt Squeal .............................................................................................................. ................................... 45
Definition .......................................................................................................................................................... 45
Diagnostic Aids................................................................................................................................................. 45
Test Description ............................................................................................................... ................................ 45
Diagnostic Table............................................................................................................................................... 46
Drive Belt Whine ............................................................................................................... ................................... 46
Definition .......................................................................................................................................................... 46
Diagnostic Aids................................................................................................................................................. 46
Test Description ............................................................................................................... ................................ 46
Diagnostic Table............................................................................................................................................... 47
Drive Belt Rumble .............................................................................................................. .................................. 47
Definition .......................................................................................................................................................... 47
Diagnostic Aids................................................................................................................................................. 48
Test Description ............................................................................................................... ................................ 48
Diagnostic Table............................................................................................................................................... 48
Drive Belt Vibration........................................................................................................... ................................... 49
Definition .......................................................................................................................................................... 49
Diagnostic Aids................................................................................................................................................. 49
Test Description ............................................................................................................... ................................ 49
Diagnostic Table............................................................................................................................................... 50
Drive Belt Falls Off ........................................................................................................... .................................... 50
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Page 2482 of 6020
Engine Mechanical – V6 Page 6A1–3
Definition .......................................................................................................................................................... 50
Diagnostic Aids................................................................................................................................................. 50
Test Description ............................................................................................................... ................................ 50
Diagnostic Table............................................................................................................................................... 51
Drive Belt Excessive Wear ...................................................................................................... ............................ 51
Definition .......................................................................................................................................................... 51
Diagnostic Aids................................................................................................................................................. 52
Test Description ............................................................................................................... ................................ 52
Diagnostic Table............................................................................................................................................... 52
Accessory Drive Belt Tensioner Diagnosis ....................................................................................... ................ 52
Diagnostic Table............................................................................................................................................... 52
3 Minor Service Operations ....................................................................................................... .............53
3.1 Engine Oil ............................................................................................................................................................. 54
Check .................................................................................................................................................................... 54
Replace ........................................................................................................................ ......................................... 54
Pressure Check ................................................................................................................. ................................... 55
3.2 Oil Filter Cartridge ............................................................................................................................................... 56
Replace ................................................................................................................................................................. 56
3.3 Oil Filter Adaptor............................................................................................................. ..................................... 57
Remove ................................................................................................................................................................. 57
Reinstall ................................................................................................................................................................ 57
3.4 Oil Level Indicator Tube ....................................................................................................... ............................... 58
Remove ............................................................................................................................................................ 58
Reinstall ........................................................................................................................................................... 58
3.5 Accessory Drive Belt ........................................................................................................... ................................ 59
RWD Vehicle ......................................................................................................................................................... 59
Remove ............................................................................................................................................................ 59
Reinstall ........................................................................................................................................................... 59
3.6 Accessory Drive Belt Idler Pulley .............................................................................................. ......................... 60
Remove ............................................................................................................................................................ 60
Reinstall ........................................................................................................................................................... 60
3.7 Accessory Drive Belt Tensioner Assembly ........................................................................................ ............... 61
Remove ............................................................................................................................................................ 61
Reinstall ........................................................................................................................................................... 61
3.8 Power Steering Pump Bracket .................................................................................................... ........................ 62
Remove ................................................................................................................................................................. 62
Reinstall ................................................................................................................................................................ 62
3.9 Upper Intake Manifold.......................................................................................................... ................................ 62
Remove ................................................................................................................................................................. 63
Disassemble ......................................................................................................................................................... 66
Clean ..................................................................................................................................................................... 66
Inspect .................................................................................................................................................................. 66
Reassemble .......................................................................................................................................................... 67
Reinstall ...................................................................................................................... .......................................... 67
3.10 Intake Manifold Assembly – Complete............................................................................................ ................... 68
Remove ................................................................................................................................................................. 68
Disassemble ......................................................................................................................................................... 72
Clean ..................................................................................................................................................................... 73
Inspect .................................................................................................................................................................. 73
Reassemble .......................................................................................................................................................... 74
Reinstall ...................................................................................................................... .......................................... 74
3.11 Exhaust Manifold Assembly ...................................................................................................... ......................... 75
Remove ................................................................................................................................................................. 75
Inspect .................................................................................................................................................................. 77
Reinstall ................................................................................................................................................................ 77
3.12 Camshaft Cover ................................................................................................................. .................................. 79
Remove ................................................................................................................................................................. 79
Clean and Inspect .............................................................................................................. .................................. 81
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Page 2483 of 6020
Engine Mechanical – V6 Page 6A1–4
Reinstall ................................................................................................................................................................ 81
3.13 Crankshaft Balancer Assembly ................................................................................................... ....................... 84
Remove ................................................................................................................................................................. 84
Clean and Inspect .............................................................................................................. .................................. 85
Reinstall ................................................................................................................................................................ 85
3.14 Crankshaft Front Seal.......................................................................................................... ................................ 87
Replace ................................................................................................................................................................. 87
3.15 Front Cover Assembly........................................................................................................... .............................. 87
Remove ................................................................................................................................................................. 87
Disassemble ......................................................................................................................................................... 89
Clean ..................................................................................................................................................................... 90
Inspect .................................................................................................................................................................. 91
Reassemble .......................................................................................................................................................... 91
Reinstall ...................................................................................................................... .......................................... 92
3.16 Timing Chains, Tensioners, Shoes and Guides .................................................................................... ............ 94
Primary and Left-hand Secondary Timing Chain Installation ...................................................................... .... 94
Right-hand Secondary Timing Chain Installation ............................................................................................. 95
Remove ................................................................................................................................................................. 96
Right-hand Secondary Timing Chain.............................................................................................. .................. 96
Primary Timing Chain ..................................................................................................................................... 100
Left-hand Secondary Timing Chain ............................................................................................... ................. 102
Clean ................................................................................................................................................................... 105
Inspect ................................................................................................................................................................ 106
Timing Chains .................................................................................................................. .............................. 106
Camshaft Intermediate Driveshaft Sprockets ..................................................................................... ............ 106
Inlet and Exhaust Camshaft Sprocket ............................................................................................................ 106
Crankshaft Sprocket ....................................................................................................................................... 107
Primary Timing Chain Upper Guide............................................................................................... ................. 107
Primary Timing Chain Lower Guide................................................................................................................ 107
Primary Timing Chain Tensioner .................................................................................................................... 108
Left-hand Secondary Timing Chain Guide ......................................................................................... ............ 108
Left-hand Secondary Timing Chain Shoe....................................................................................................... 109
Left-hand Secondary Timing Chain Tensioner ..................................................................................... .......... 109
Right-hand Secondary Timing Chain Guide ................................................................................................... 110
Right-hand Secondary Timing Chain Shoe .................................................................................................... 110
Right-hand Secondary Timing Chain Tensioner.................................................................................... ......... 111
Reinstall .............................................................................................................................................................. 111
Left-hand Secondary Timing Chain Components.................................................................................... ....... 111
Primary Timing chain Components ................................................................................................................ 121
Right-hand Secondary Timing Chain Components ................................................................................... ..... 128
3.17 Oil Pump Assembly ........................................................................................................................................... 136
Remove ............................................................................................................................................................... 136
Disassemble ....................................................................................................................................................... 137
Clean ................................................................................................................................................................... 138
Inspect ................................................................................................................................................................ 139
Reassemble ........................................................................................................................................................ 141
Reinstall ...................................................................................................................... ........................................ 141
3.18 Camshaft Sprocket .............................................................................................................. .............................. 141
Remove ............................................................................................................................................................... 141
Right-hand Side................................................................................................................ .............................. 141
Left-hand Side ................................................................................................................................................ 144
Clean ................................................................................................................................................................... 146
Inspect ................................................................................................................................................................ 146
Reinstall ...................................................................................................................... ........................................ 147
3.19 Camshaft....................................................................................................................... ...................................... 147
Remove ............................................................................................................................................................... 147
Right-hand Side................................................................................................................ .............................. 147
Left-hand Side ................................................................................................................................................ 149
Clean ................................................................................................................................................................... 150
Inspect ................................................................................................................................................................ 150
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Engine Mechanical – V6 Page 6A1–5
Camshaft Visual Inspection ............................................................................................................................ 150
Camshaft Measurement ........................................................................................................... ...................... 151
Reinstall .............................................................................................................................................................. 153
Right-hand Side................................................................................................................ .............................. 153
Left-hand Side ................................................................................................................................................ 155
3.20 Rocker Arm..................................................................................................................... .................................... 158
Remove ............................................................................................................................................................... 158
Clean and Inspect .............................................................................................................. ................................ 158
Reinstall .............................................................................................................................................................. 159
3.21 Stationary Hydraulic Lash Adjuster ............................................................................................. .................... 160
Remove ............................................................................................................................................................... 160
Clean and Inspect .............................................................................................................. ................................ 160
Reinstall .............................................................................................................................................................. 161
3.22 Cylinder Head Assembly ......................................................................................................... .......................... 161
Remove ............................................................................................................................................................... 161
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... .............. 161
Left-hand Side (Bank 2) Cylinder Head .......................................................................................................... 162
Disassemble ....................................................................................................................................................... 163
Clean ................................................................................................................................................................... 166
Inspect ................................................................................................................................................................ 167
Visual Inspection .............................................................................................................. .............................. 167
Cylinder Head Measurement...................................................................................................... .................... 167
Valve Spring Inspection and Measurement ........................................................................................ ............ 169
Valve and Seat Grinding ................................................................................................................................ 170
Assemble ............................................................................................................................................................ 174
Reinstall .............................................................................................................................................................. 177
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... .............. 177
Left-hand Side (Bank 2) Cylinder Head .......................................................................................................... 178
3.23 Engine Mounts and Brackets ............................................................................................................................ 181
Remove .......................................................................................................................................................... 181
Engine Mount Location .......................................................................................................... ........................... 182
Inspect ................................................................................................................................................................ 182
Reinstall .............................................................................................................................................................. 183
4 Major Service Operations ....................................................................................................... ...........184
4.1 Engine Removal ................................................................................................................................................. 184
Remove .......................................................................................................................................................... 185
Disassemble................................................................................................................................................... 197
Reassemble ................................................................................................................................................... 198
Reinstall ......................................................................................................................................................... 198
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ........... 198
Remove .......................................................................................................................................................... 198
Disassemble................................................................................................................................................... 200
Clean .............................................................................................................................................................. 200
Inspect............................................................................................................................................................ 201
Reassemble ................................................................................................................................................... 201
Reinstall ......................................................................................................................................................... 202
4.3 Flexplate Assembly ............................................................................................................. .............................. 203
Remove ............................................................................................................................................................... 203
Clean ................................................................................................................................................................... 204
Inspect ................................................................................................................................................................ 204
Reinstall ...................................................................................................................... ........................................ 205
4.4 Crankshaft Rear Seal and Plate Assembly ........................................................................................ .............. 205
Remove ............................................................................................................................................................... 205
Reinstall .............................................................................................................................................................. 207
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 208
Remove ............................................................................................................................................................... 208
Disassemble ....................................................................................................................................................... 211
Clean and Inspect .............................................................................................................. ................................ 212
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