light ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–172

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 – 294
Valve-to-Seat Concentricity Measurement Procedure
Checking the valve-to-seat concentricity determines whether the valve and seat are sealing correctly.
Measure the valve face and the valve seat to ensure correct valve sealing.
1 Coat the valve face lightly with blue dye (3).
2 Install the valve in the cylinder head.
3 Turn the valve against the seat with enough pressure to wear off the dye.
4 Remove the valve from the cylinder head.
5 Inspect the valve face.
NOTE
• If the valve face is concentric, providing a
correct seal, with the valve stem, a continuous
mark (1) will be made around the entire face (2).
• The wear mark must be at least 0.5 mm from
the margin of the valve. If the wear mark is too
close to the margin, the seat must be
reconditioned to move the contact area away
from the margin.
• If the face is not concentric with the stem, the
mark will not be continuous around the valve
face. The valve should be refaced or replaced
and the seat must be reconditioned, refer to
Valve and Seat Reconditioning Procedure in
this Section.
Figure 6A1 – 295
Valve and Seat Reconditioning Procedure
If the valve seat width, roundness or concentricity are beyond specifications, grind the seats in order to ensure correct
heat dissipation and prevent the build up of carbon on the seats.
If valve seat reconditioning is required, reface the valve face, unless a new valve is used.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–181

3.23 Engine Mounts and Brackets
Remove
1 Remove the exhaust manifold assembly from the side of the engine where the engine mount is to be removed,
refer to 3.11 Exhaust Manifold Assembly.
2 Fit the engine lift brackets, Tool No. EN-46114 (1) to the cylinder heads.
CAUTION
Only lift the engine far enough to take the
weight off the engine mount, or damage to
the mount and lifting equipment failure may
occur.
3 Using an engine lifting crane, raise the side of the engine where the mount is to be removed enough to
remove the weight from the engine mounts, and
create a slight tension in the lifting equipment.

Figure 6A1 – 314
4 Remove the left-hand or right-hand side engine mount and bracket as required.
Figure 6A1 – 315

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–182

Engine Mount Location

Figure 6A1 – 316
Inspect
NOTE
Although the following procedure provides
information regarding on-vehicle engine mount
inspections, it is preferable to inspect the engine
mounts once removed from the vehicle.
1 Fit the engine lift brackets, Tool No. EN-4611 to the cylinder heads.

Only lift the engine enough to take the weight
off the engine mounts, or damage to the
mounts and lifting equipment failure may
occur.
2 Using a commercially available engine lifting crane, have an assistant raise the engine far enough to remove the weight on the engine mounts and create a slight tension in the rubber.
3 Observe the engine mount while raising the engine.

4 Replace the engine mount if any of the following conditions are found:

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–215

3 There is a locating dimple (1) on the compression
rings. Install the compression rings with the dimple
facing up.
4 If the new ring does not reduce the clearance to the correct specification, install a new piston.
5 If the new piston does not meet clearance specifications, the cylinder block may need to be
oversized to 0.25 mm. There is only one size of
oversized pistons and rings available for service.
Figure 6A1 – 390


Connecting Rod Cleaning Procedure
1 Clean the connecting rods in solvent.

Safety glasses must be worn when using
compressed air.
2 Dry the connecting rod using compressed air.
3 Remove the connecting rod cap and clean the threads.
4 Remove the connecting rod bearing and discard. Never reuse a connecting rod bearing that has been used in a running engine.
Connecting Rod Visual Inspection Procedure
1 Inspect the piston pin bushing (4) for scoring or
damage.
2 Inspect the connecting rod beam (1) for twisting or bending.
3 Inspect the rod cap (2) for any nicks or damage caused by possible interference.
4 Inspect for scratches or abrasion on the rod bearing seating surface.
5 If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with
a light emery paper.
6 Retain the original bolts (3) for preliminary assembly. They must be replaced for final assembly.
Figure 6A1 – 391

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–222

8 Determine the connecting rod bearing clearance by
comparing the width of the flattened plastic
gauging (1) material at its widest point with the
graduation on the gauging material container (2).
9 Compare the measurements with the specifications, refer to 5 Specifications.
10 If the new bearings do not provide the correct crankshaft to connecting rod bearing clearance,
inspect the following:
11 Measure the crankshaft connecting rod journals for the correct specified size and ensure the correct new
bearings are being installed. If the crankshaft
connecting rod journals are incorrectly sized, replace
or regrind the crankshaft. Crankshaft machining is
permitted and undersized bearings are available.
12 Measure the connecting rod bearing bore diameter to ensure correct size. The connecting rod is not
machineable and the connecting rod must be
replaced if out of specification.
13 Clean the plastic gauging material from the connecting rod bearing journals using a soft lint-free
cloth.
Figure 6A1 – 408
Connecting Rod Final Assembly Procedure
1 Carefully guide the connecting rod away from the crankshaft connecting rod journal slightly to lubricate
the crankshaft connecting rod bearing journal.
2 Apply a liberal amount of clean engine oil to the crankshaft connecting rod bearing journal.
3 Guide the connecting rod to the crankshaft connecting rod journal.
4 Install the connecting rod end cap (1) on its original connecting rod and ensure the bearing lock tangs are
aligned on the same side of the rod.
CAUTION
• Do not lubricate the new connecting rod
bolts. The new bolts have a pre-applied
graphite lubricant. Applying lubricant to
the connecting rod bolts will effect the
clamp load when the connecting rod
bolts are tightened to the specified
torque. Incorrect clamp load can lead to
component failure and extensive engine
damage.
• Do not reuse the old connecting rod
bolts.
Figure 6A1 – 409
5 Install new connecting rod bolts into the connecting rod cap and tighten to the correct torque specification. „ Connecting rod cap attaching bolt
torque specification:
Stage 1 .........................30.0 Nm
Stage 2 ........ Loosen completely
Stage 3 .........................25.0 Nm
Stage 4 .................. 110 degrees

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–233

Crankshaft Final Installation Procedure
1 If removed, install the crankshaft sprocket drive
pin (1). Lightly tap the pin in place with a small soft
face, bronze/plastic, hammer until it bottoms in the
hole.
Figure 6A1 – 432
CAUTION
Ensure the crankshaft position sensor has
been removed from the cylinder block prior
to loading the crankshaft, as damage to the
sensor may occur.
2
Apply a liberal amount of clean engine oil to the upper
and lower bearing surfaces.
3 Gently lower the crankshaft (1) into position in the cylinder block (2).
Figure 6A1 – 433
4 Install the crankshaft main bearing caps.
5 Loosely install the original inner main cap bolts (1).
CAUTION
The outer crankshaft bearing cap bolts (2)
are yield tightened during assembly and
must be replaced prior to reassembly. Outer
crankshaft bearing cap bolts that are not
replaced will not torque to the correct clamp
load and can lead to serious engine damage.
6 Loosely install the new outer main bearing cap bolts (2).
7 Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.
Figure 6A1 – 434

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–247

NOTE
A correctly counter bored hole will show a slight
burnishing on the surface of the base material
for 360 degrees around the drilled hole.
4 Counter bore the drilled hole to the full depth permitted by the tool (1).

Figure 6A1 – 468
NOTE
All swarf must be removed from the drilled hole
prior to tapping.


Safety glasses must be worn when using
compressed air.
5 Using compressed air, clean out any swarf.
Figure 6A1 – 469
NOTE
• During the tapping process, repeatedly
remove the tap and clean the swarf from the
hole and the flutes of the tap.
• Ensure the tap has created full threads at
least to the depth equal to the insert length.
6 Using a suitable tapping wrench, tap the threads of the drilled hole by hand only.
• M6 inserts require a minimum drill depth of 15
mm.
• M8 inserts require a minimum drill depth of 20
mm.
• M10 inserts require a minimum drill depth of
23.5 mm.
Figure 6A1 – 470

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–251

17 Inspect the insert for correct installation into the
tapped hole. A correctly installed insert (1) will be
either flush or slightly below flush with the surface of
the base material (2).
Figure 6A1 – 480
18 Any installed insert that restricts or blocks an oil or engine coolant passage (3) will need to have the oil or
engine coolant passage drilled out (4) to the original
size of the oil or engine coolant passage. After drilling
the restriction or blockage, clean out any swarf and
thread the installation driver tool through the insert
again to remove any burrs caused by the drilling of
the oil or engine coolant passage.
Figure 6A1 – 481
Main Bearing Cap Bolt Hole Thread Repair
The crankshaft main bearing bolt hole thread repair tools
are in Tool No. J 42385-2000 and J 42385-700 which
consist of the following:
• Drill (1) for outboard holes J 42385-702
• Tap (2) for outboard holes J 42385-703
• Installation driver (3) for outboard holes J 42385-704
• Bushing (4) for outboard holes J 42385-726
• Alignment pin (5) for outboard holes J 42385-727
• Bolts (6) for outboard holes J 42385-728
• Drill (7) for inboard holes J 42385-720
• Tap (8) for inboard holes J 42385-721
• Installation driver (9) for inboard holes J 42385-722
• Bushing (10) J 42385-713
• Alignment pin (11) J 42385-308
• Bolts (12) J 42385-734
• Fixture plate (13) J 42385-712
Figure 6A1 – 482

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–9
Page 6A1–9
• 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 tool s or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediatel y precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characte ristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performi ng a procedure in the recommended manner, and / or
Present information that gives the tec hnician the benefit of past experience in accomplishing a procedure with greater
ease.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007