ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–84
Page 6A1–84
4 Retract the throttle body wiring connector lock (3).
5 While pressing the connector latch in the direction of
the arrow (4), disconnect the throttle body wiring
connector.
6 Disconnect the throttle body connector wiring harness from its retaining clip (5).
7 Remove the main wiring harness retainer pin (6) from the intake manifold by pushing from the front to the
rear using a suitable piece of 5 mm steel rod (or an
Allen key).

The following precautions must be followed
when disconnecting the throttle body wiring
connector:
• Do not use any mechanical device such
as a screwdriver to disengage the
harness connector (1) from the throttle
body (2).
• When retracting the throttle wiring
connector lock (3), take care not to
disengage the lock from the connector.
• Do not pull on the connector wires.
• Take care not to break the barbed
harness retainer pin (6) while removing
the harness retainer from the intake
manifold.
• Should the pin be broken, then it is vital
that a new harness retainer is fitted to the
wiring harness shield. If not, the harness
will foul the engine drive belt.

Figure 6A1 – 44
8 Disconnect the brake booster hose (1), from the upper
intake manifold:


Figure 6A1 – 45

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Engine Mechanical – V6 Page 6A1–85
Page 6A1–85
9 Disconnect the wiring harness connector from the
barometric (BARO) pressure sensor (1).


Figure 6A1 – 46
10 Disconnect the PCV tube connector (1) from the upper intake manifold assembly.


Figure 6A1 – 47
11 Disconnect the fuel feed hose from the fuel rail (1).
12 Pull out the release bar (2) (broad arrow) of the fuel
injector harness wiring connector (3).
13 Disconnect the fuel injector harness wiring connector from the fuel injector wiring harness (4).


Plug the fuel feed hose opening after
removal to prevent dirt and other
contaminants from entering the fuel system.

Figure 6A1 – 48

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Engine Mechanical – V6 Page 6A1–86
Page 6A1–86
14 Remove the wiring harness connector (2) from the
EVAP valve (1).
15 Disconnect the quick connect (3 ) from the rear of the
EVAP valve, as follows:
a Squeeze the two barbed lugs together, push the quick
connect into the valve, t hen pull out to separate the
connection.
b Plug both open ends to prevent the entry of foreign
matter.


Figure 6A1 – 49
16 Remove the bolt (3) attaching the EVAP valve and the fuel injector wiring harness connector mounting
bracket to the upper inta ke manifold assembly.
17 Move the EVAP valve and the fuel injector wiring harness connector mounting bracket clear of the
upper intake manifold assembly.
18 Disconnect the PCV fresh air tube (1) from its upper intake manifold mounting clip (2).

Figure 6A1 – 50
19 Remove the four long (1) bolts (165 mm) securing the complete intake manifo ld to the cylinder heads.
20 Remove the two short (2) bolts (45 mm) securing the lower intake manifold to the cylinder heads.



Do not loosen nor remove the short bolts ( 8)
(70 mm) holding the upper intake manifold to
the lower. These bolts are at the front left
and rear right of the upper intake manifold.

Figure 6A1 – 51

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Engine Mechanical – V6 Page 6A1–87
Page 6A1–87

When the intake manifold is removed, plug
each of the cylinder head intake openings
with lint free cloth, to stop the entry of foreign
material into the intake ports.
21 Remove the upper and lower intake manifold assembly from the engine.
22 Remove lower intake mani fold to cylinder head gasket.
Disassemble
1 Disconnect the EVAP hose (1) from the upper intake
manifold (2).
2 Remove the bolts (3) (70 mm long) attaching the upper intake manifold to the lower intake manifold (4).
NOTE
These bolts are located at the front left and rear
right of the upper intake manifold, as shown.
3 Remove the upper intake manifold from the lower intake manifold.
4 Remove and discard the upper to lower intake manifold gaskets.

Do not reuse the upper to lower intake
manifold gaskets (5).
5 Remove the EVAP hose from the retaining clip (6) attached to the lower intake manifold.
6 Remove the following from the upper intake manifold, refer to Section 6C1-3 Engine Management – V6 –
Service Operations :
• BARO Sensor and
• Throttle Body assembly


Figure 6A1 – 52
7 Remove the fuel rail and in jector assembly. Refer to
Section 6C1-3 Engine Management – V6 – Service
Operations .

The following precautions must be followed
when removing the fuel rail and injector
assembly:
• Care must be taken when removing the
fuel rail and injector assembly to
prevent damage to the injector spray
tips and injector harness connector
terminals.
• Support the fuel rail and injector
assembly after removal.
• Plug all fuel line and manifold openings
after removal to prevent dirt and other
contaminants from entering the fuel
system.


Figure 6A1 – 53

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Engine Mechanical – V6 Page 6A1–88
Page 6A1–88
Clean
CAUTION
Due to the aluminium alloy construction of
the intake manifold, wire brushes and steel
scrapers must not be used during the
cleaning process, as damage to sealing
surfaces may occur. Use of a wooden or
plastic scraper is preferred.
1 Clean mating surfaces ensuring any gasket material is removed.
2 Clean the manifold using a suitable solvent

Safety glasses must be worn when using
compressed air.
3 Dry the timing components with compressed air.
Inspect
1 Inspect the intake manifold for the following fault conditions:
• Damaged sealing and mating surfaces.
• Damaged lower intake manifold gasket.
• Damage or excessive debris on the threaded and through holes.
• Cracks or damage to the intake manifold body.
NOTE
If the lower intake manifold is cracked or
damaged, it must be repl aced. No welding or
patching of the intake manifold should be
performed.
2 Place a straight edge (1) across the upper intake manifold sealing surface (2).
3 Using a feeler gauge (3), measure the clearance
between the manifold and the straight edge.
4 If the clearance between the upper intake manifold sealing surface and the straight edge exceeds the
specified maximum warpage, replace the manifold.



Upper manifold maximum
warpage ............................................................ 0.05 mm
Figure 6A1 – 54

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Engine Mechanical – V6 Page 6A1–89
Page 6A1–89
5 Place a straight edge (1) across the lower intake
manifold sealing surface (2).
6 Using a feeler gauge (3), measure the clearance
between the manifold and the straight edge.
7 If the clearance between the lower intake manifold sealing surface and the straight edge exceeds the
specified maximum warpage, replace the manifold.


Lower manifold maximum
warpage ............................................................ 0.05 mm
Figure 6A1 – 55
Reassemble
Reassembly of the upper to lower intake manifold is the reverse of the disassembly procedure noting the following:
1 Ensure that both the manifo lds have been cleaned and inspected.
2 Ensure that the warpage of the mati ng surfaces is within tolerances.
3 New upper to lower intake m anifold gaskets must be used.
4 Do not tighten the intake manifold to lower intake manifold attaching bolt at this stage. The intake manifold
attaching bolts must be tightened at the specif ied sequence during the reinstallation procedure.
Reinstall
Reinstallation of the upper intake manifold and the upper and lower intake manifo ld assembly is the reverse of the
removal procedure, noting the following:
1 Install the EVAP hose to the clip atta ched to the lower intake manifold.
2 Only new gaskets are to be fitted betw een the upper and lower intake manifolds.
3 If undamaged, the lower intake manifold to cylinder head gasket may be re-used, however its replacement is
strongly recommended.
CAUTION
Tighten the intake manifold bolts in a circular
pattern starting at the centre bolt and moving
outward.
4 Ensure that all fasteners are tightened to the correct torque specification.
Upper intake manifold to lower intake
manifold attaching bolt torq ue specification .......23.0 Nm
Upper intake manifold to cylinder
head attaching bolt torque specification .............23.0 Nm
Lower intake manifold to cylinder
head attaching bolt torque specification .............23.0 Nm
Fuel injector wiring harness bracket
attaching bolt torque specification ........................9.0 Nm

Incorrect wiring connector installation may
cause component malfunction or component
damage.

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Engine Mechanical – V6 Page 6A1–90
Page 6A1–90
5 Ensure all wiring connectors are fully engaged and if applicable, locked in place.
6 Ensure all wiring harnesses are correctly routed and attached securely in their retaining clips.
7 Ensure that all hoses and pipes ar e routed correctly and that any retaining clips are correctly installed.
8 After installation pull on any quick connect fittings to check that each is correctly installed.
9 Start and run the engine to c heck for correct operation.

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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 6A1–92
Page 6A1–92
9 Progressively loosen the seven exhaust manifold
attaching bolts (2), working from the outside to the
centre and then remove the bolts.
10 Manoeuvre the exhaust manifold (3), away from the cylinder head.
11 Remove and discard the exhaust manifold to cylinder head gasket.


Figure 6A1 – 58
12 Remove the three bolts (1), attaching the exhaust manifold inner heat shield to the exhaust manifold.

13 Using a suitable commercially available non-corrosive cleaning solvent and a soft bristled parts cleaning
brush, thoroughly clean the exhaust manifold.
14 Dry the exhaust manifold using compressed air.

Safety glasses must be worn when using
compressed air.

Figure 6A1 – 59
NOTE
• The same procedure applies to the Right-
hand exhaust manifold.

• To gain access to the lower rear exhaust
manifold attaching bolts (2), apply a slight
downward movement to the coolant inlet
pipe (1).



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Engine Mechanical – V6 Page 6A1–93
Page 6A1–93
Inspect
Inspect the exhaust manifold (1) for the following:
• Damage to the threaded holes for the heat shield
mounting.
• Damage to the exhaust manifold mounting holes.
• Damage to the threads of the exhaust manifold to
exhaust pipe flange studs.
• Damage to the gasket sealing surfaces.
• Using a straight edge (2) and feeler gauges (3), check
the cylinder head mounting face of the exhaust
manifold does not exceed the maximum distortion
specification of 0.25mm.
NOTE
If the surface flatness is not within
specifications, the exhaus t manifold is warped
and must be replaced.

Figure 6A1 – 60
Reinstall
Reinstallation of the exhaust manifold assembly is the reverse of the removal procedure, noting the following:
1 Ensure the exhaust manifold, cylinder head and exhaust pipe flange surfaces are clean.
2 Position a new exhaust manifold gasket onto the exhaust manifold.
3 Apply a 5 mm bead of Loctite 272 thread sealant (or equival ent) to the threads of the exhaust manifold attaching
bolts.
4 Install the bolts into the exhaust manifold. This will prevent the gasket from falling off the manifold.
5 Manoeuvre the exhaust manifold into position and install the exhaust manifold attaching bolts.
6 From underneath the vehicle install the exhaust manifold to exhaust pipe flange nuts.
7 Tighten the exhaust manifold attaching bolts to the correct torque specification.
NOTE
When tightening the exhaust manifold to cylinder
head attaching bolts, begin with the centre bolts,
then alternate from side to side to the outer bolts.
Exhaust manifold to cylinder head
attaching bolt torque spec ification ........... 17.0 – 23.0 Nm
8 Apply an anti seize compound such as Caltex Kopr-Kot e (or equivalent) to the cleaned heat shield bolt threads.
Install the heat shield attaching bolts and ti ghten to the correct torque specification.
Exhaust manifold heat shield attaching
bolt torque specificat ion ............................ 8.0 – 12.0 Nm
9 For the right-hand side, install the battery harness ground cable attaching nut through the ground terminal and
lower coolant tube mounting lug, and tighten to the correct torque specification.
Battery harness ground terminal
attaching nut torque s pecification.......................13.0 Nm

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