engine coolant ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–72
Page 6A1–72
3.5 Accessory Drive Belt
RWD Vehicle
Remove
1 Remove the air intake duct from between the air flow meter and the throttle body, refer to
Section 6C1-3 Engine Management – V6 – Service Operations.
2 Note the accessory drive belt (1) routing.
Figure 6A1 – 29
3 Using a suitable ½” drive socket bar (1), rotate the drive belt tensioner (2) clockwise, to reduce belt
tension.
4 While holding the tensioner in the reduced tension
position, remove the accessory drive belt (3).

NOTE
If required use an assistant to maintain the tensioner in the required position.
CAUTION
If running the engine with the accessory
drive belt removed, the coolant pump will
not be operating and the engine may
overheat if left unsupervised even for a short
period.
Figure 6A1 – 30

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–73
Page 6A1–73
Reinstall
1 Install the drive belt over the A/C compressor, idler pulley, power steering pump, coolant pump, generator and
tensioner pulleys.
2 Using a suitable ½” drive socket bar (1), rotate the driv e belt tensioner (2) clockwise, refer to Figure 6A1 – 30.
3 With an assistant holding the tensi oner in the required position, feed the accessory drive belt (3) over the
crankshaft pulley.
4 Slowly release the drive belt tensioner mechanism.
NOTE
Ensure the drive belt ribs are correctly aligned
with the grooves in the accessory drive pulleys or
damage to the drive belt and accessory drive
components and pulleys may occur.
5 Reinstall the air intake duct to the ai r flow meter and the throttle body, refer to Section 6C1-3 Engine Management
– V6 – Service Operations .
6 Run the engine to ensure correct operation.

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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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–95
Page 6A1–95
6 Remove the bolt (1) attaching the ground connector
(2) to the cylinder head.
7 Fro the left-hand side, disconnect the engine coolant temperature (ECT) sensor wiring connector (3).
8 Unclip the engine wiring harness retaining lugs from the side of the camshaft cover.
Figure 6A1 – 63
9 For the right-hand side, remove the engine wiring harness retaining clip (1) from the engine control
module (ECM) bracket (2).
Figure 6A1 – 64
10 Disconnect the camshaft position (CMP) sensor wiring connector (1).
11 Unclip the engine wiring harness retaining lug (3) from the front of the camshaft cover.
12 Remove the ignition coil assemblies; refer to Section 6C1-3 Engine Management – V6 – Service
Operations .
13 Move the engine wiring harness clear of the camshaft cover.



Figure 6A1 – 65

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–104
Page 6A1–104
3.15 Front Cover Assembly
Remove
1 Drain the engine coolant, refer to Section 6B1 Engine Cooling.
2 Remove the water outlet pipe and coolant pump assembly, refer to Section 6B1 Engine Cooling:
3 Remove the camsha ft covers, refer to 3.12 Camshaft Cover .
4 Remove the crankshaft bal ancer assembly, refer to 3.13 Crankshaft Balancer Assembly .
5 Disconnect the purge vent hose from the water outlet pipe.
NOTE
Do not disconnect the power steering pipes or
drain the power steering fluid.
6 Remove the power steering pump reservoir mounting bracket, refer to 3.8 Power Steering Pump Bracket.
7 Remove the camshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
NOTE
Do not disconnect the A/C compressor pipes.

8 Remove the bolt (2), 22 places, attaching the front cover assembly (1).

CAUTION
Only use the prise points and a bolt in the
jackscrew hole to remove the engine front
cover.

9 Loosely install a 10 x 1.5 mm bolt in the jackscrew hole (1).

10 Using the prise points (2) located at the edge of the
front cover and the jackscrew, shear the RTV sealant.
Figure 6A1 – 83






Figure 6A1 – 84

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Engine Mechanical – V6 Page 6A1–106
Page 6A1–106
3 Remove the coolant pump seal (1) from the engine
front cover (2). Discard the seal.

Figure 6A1 – 88
Clean
4 Remove any RTV sealant (1) from the engine front cover using a plastic or wood scraper.
CAUTION
• Insert a piece of cardboard between the
front of the oil pan and oil pump to
prevent any contaminants from falling
into the oil pan.
• Do not use a sharp or metal gasket
scraper to clean the sealing surfaces.
5 Clean out any debris from the bolt holes.
6 Clean the front cover with a suitable cleaning solvent.
7 Dry the front cover with compressed air.

Safety glasses must be worn when using
compressed air.

Figure 6A1 – 89
8 Use compressed air to remove any engine coolant from the engine cooling passages and from the top of the oil
pan oil deflector.

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Engine Mechanical – V6 Page 6A1–107
Page 6A1–107
Inspect
1 Inspect both sides of the engine front cover for the
following conditions:
• damage to the camshaft position actuator valve
oil seal bores (1),
• damage to the bolt holes (2),
• damage and/or corrosion to the engine coolant
passage (3),
• dents or damage to the exterior (4),
• damage to the crankshaft front oil seal bore (5),
• gouges or damage to the coolant pump sealing
surfaces (6), and
• damage to the coolant pump bolt hole
threads (7).
2 Repair or replace the fr ont cover as required.

Figure 6A1 – 90
Reassemble
1 Install a new crankshaft front oil seal (1) into the front cover (2) using crankshaft front seal installer, Tool
No. J-29184 (3) and a suitable hammer.

CAUTION
Do not lubricate the crankshaft front oil seal
or crankshaft balancer sealing surfaces. The
crankshaft balancer is installed into a dry
seal.

Figure 6A1 – 91
2 Install a new camshaft positi on actuator valve oil seal
(1) into the front cover (2) using Tool No. EN-46103
(3) and a suitable hammer.


Figure 6A1 – 92

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–218
Page 6A1–218
Left-hand Side (Bank 2) Cylinder Head
1 Remove the intake manifold assembly, refer to 3.10 Intake Manifold Assembly – Complete .
2 Remove the exhaust manifold, refer to 3.11 Exhaust Manifold Assembly.
3 Remove the power steering reservoi r and pump mounting brackets, refer to 3.8 Power Steering Pump Bracket.
NOTE
Do not disconnect the power steering pipes
and/or hoses.
4 Remove the oil filter adapter upper bolt. NOTE
Do not remove the oil filter adapter.
5 Remove the engine coolant temper ature (ECT) sensor, refer to Section 6C1-3 Engine Management – V6 – Service
Operations .
6 Remove engine harness ground terminal attach ing bolt from cylinder head, refer to Section 8A Electrical Body &
Chassis .
7 Remove the left-hand bank secondary timing chain, refer to 3.16 Timing Chains, Tensioners, Shoes and Guides.
8 Remove the camshaft position actuators, refer to 3.18 Camshaft Sprocket.
9 Remove the front M8 (1) cylinder head attaching bolt, two places.
10 Remove the cylinder head attaching bolt (2), eight places.
11 Remove the cylinder head (3).


Figure 6A1 – 367
12 Remove and discard the cylinder head gasket (1).


Figure 6A1 – 368

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Engine Mechanical – V6 Page 6A1–221
Page 6A1–221
CAUTION
Never reuse a valve stem oil seal.
8 Remove the valve stem oil seal using Tool No. EN-46116 and discard.
9 Repeat these procedures for the remaining valves.

Figure 6A1 – 374
10 Remove the cylinder head oil gallery expansion plugs (1).


Figure 6A1 – 375
11 Remove the cylinder head coolant threaded plugs (1).


Figure 6A1 – 376

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