ISUZU KB P190 2007 Workshop Repair Manual

6F-2 ENGINE EXHAUST
General Description




RTW 46AMF000501

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE EXHAUST 6F-3





























W hen inspecting or replacing exhaust system components,
make sure there is adequate clearance from all points on the
underbody to prevent overheating the floor pan and possible
damage to the passenger compartment insulation and trim
materials.
Check complete exhaust system and nearby body areas and
rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or
other deterioration which could permit exhaust fumes to seep
into the rear compartment or passenger compartment. Dust or
water in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should be
corrected immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps, rubber
rings, and rubber blocks.
The installation of exhaust system supports is very important,
as improperly installed supports can cause annoying vibrations
which can be difficult to diagnose.
Three Way Catalytic Converter (If applicable)
The three way catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from the
exhaust gas stream.

CAUTION: The catalytic converter requires the use of
unleaded fuel only.
Periodic maintenance of the exhaust system is not required. If
the vehicle is raised for other service, it is advisable to check
the condition of the complete exhaust system.
A dual bed monolith catalytic converter is used in combination
with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction) converter
contains platinum and rhodium which lowers the levels of
nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon
monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust pipe,
muffler or catalytic converter is installed.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6F-4 ENGINE EXHAUST


Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE EXHAUST 6F-5
Exhaust Pipe
Exhaust Pipe and Associated parts




RTW 46FLF000401













Removal
(2.4L)
CAUTION
When you remove or install the front exhaust pipe, make
sure not to damage the fuel evaporative pipe.
1. Damper rubber
2. Exhaust silencer
3. Mid pipe
4. Damper rubber
5. Front exhaust pipe fixing nut
6. Catalytic converter (If applicable)
7. Front exhaust pipe

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6F-6 ENGINE EXHAUST


Installation
To install, follow the removal steps in the reverse order.










Important - Installation
1. Front Exhaust Pipe Flange Nut
Connect the exhaust pipe to the exhaust manifold.
Front exhaust pipe to manifold nut.
Torque
N⋅m (kgf ⋅m)
28 (2.9)
Inspection
Make the necessary adjustments, and part replacements if
excessive wear or damage is discover during inspection.

1. Front Exhaust Pipe
2. Center Exhaust Pipe and Catalytic Converter Flange Nut
3. Exhaust Pipe Damper Rubber
4. Exhaust Silencer with Rear Exhaust Pipe

Check the pipes for for corrosion, cracking , damage or
misalignment and repair if required.
Check the damper rubber for deterioration or damage and
repair if required.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE EXHAUST 6F-7
Front Exhaust Pipe (W/O Catalytic
Converter)
Front Exhaust Pipe and Associated Parts




RTW 46F000101
Legend
1. Front Exhaust Pipe Fixing Nuts
2. Front Exhaust Pipe
3. Mid Exhaust Pipe Fixing Nuts











Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove the front exhaust pipe fixing nuts (1).
4. Remove mid pipe fixing nuts (3).
5. Remove front exhaust pipe (2).




Installation
1. Install front exhaust pipe (2) and tighten four nuts (1). Torque:
Nuts: 28 N ⋅
⋅⋅
⋅
m (2.9 kgf ⋅
⋅⋅
⋅
m)
2. Tighten two nuts (3). Torque: 43 N ⋅
⋅⋅
⋅
m (4.4 kgf ⋅
⋅⋅
⋅
m)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6F-8 ENGINE EXHAUST
Mid Pipe
Mid Pipe and Associated Parts



RTW 46FSF000201
Legend
1. Mid Exhaust Pipe
2. Mid Exhaust Pipe Fixing Nuts
3. Exhaust Silencer Fixing Nuts









Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove mid pipe fixing nuts (2).
4. Remove exhaust silencer fixing nuts (3).
5. Remove the pipe.





Installation
1. Install mid exhaust pipe (1) and tighten four fixing nuts (2)(3) to the specified torque:
Torque:
Fixing nuts: 43 N ⋅
⋅⋅
⋅
m (4.4 kgf ⋅
⋅⋅
⋅
m)


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE EXHAUST 6F-9
Catalytic Converter (If applicable)
Catalytic Converter and Associated Parts



RTW 46FSF000301
Legend
1. Catalytic Converter
2. O
2 Sensor Converter
3. Front Pipe Fixing Nuts
4. Mid Pipe Fixing Nuts









Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove front pipe fixing nuts (3).
4. Remove mid pipe fixing nuts (4).
5. Remove the O
2 sensor connector (2).
6. Remove the front exhaust pipe with catalytic converter (1).





Installation
1. Install Catalytic Converter (1) and tighten four to the specified torque:
Torque:
Fixing nuts: 28 N ⋅
⋅⋅
⋅
m (2.9 kgf ⋅
⋅⋅
⋅
m)
2. Tight two nuts (4) Torque:
Nuts: 43 N ⋅
⋅⋅
⋅
m (4.4 kgf ⋅
⋅⋅
⋅
m)
3. Connect the O
2 sensor connector (2).


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

6F-10 ENGINE EXHAUST
3 WAY CATALYTIC CONVERTER
SYSTEM (If applicable)

N2



Inspection
Make the necessary adjustments, and part replacements if
excessive or damage is discovered during inspection.

Exhaust Pipe Assembly
1. Check connections for looseness or damage.
2. Check clamps for weakness, crack, or damage.


Catalytic Converter
Check for dents or damage.
If any part of the converter is damaged or dented, repair or
replace it.


Removal
1. Jack up the vehicle.
2. Check that the converter is cool.
3. Remove the bolts at the front and rear of the converter.
4. Remove the converter and gaskets.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

ENGINE EXHAUST 6F-11
(2.4L model)

Installation
1. Place new gaskets on the converter front and rear pipes,and connect the converter to the exhaust pipes.
2. Tighten the bolts with the specified torque.
3. Reinstall the bracket bolts and tighten them.


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007