engine coolant ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–222
Page 6A1–222
Clean
CAUTION
Due to the aluminium alloy construction of
the cylinder head, wire brushes and steel
scrapers must not be used during the
cleaning process, as damage to sealing
surfaces may occur. Use a wood or plastic
scraper as an alternative.
1 Remove any old thread sealant, gasket material or seal ant using commercially available plastic or wooden scraper.
2 Clean all cylinder head surfaces with non-corrosive solvent.

Safety glasses must be worn when using
compressed air.
3 Blow out all the oil galleries using compressed air.
4 Remove any carbon deposits fr om the combustion chambers.
5 Clean any debris or build-up from the lifter pockets.
Inspect
Visual Inspection
1 Inspect the cylinder head (1) camshaft bearing surfaces for the following conditions:
• excessive scoring or pitting,
• discoloration from overheating, and
• deformation from excessive wear.
2 If any of the above conditions exist on the camshaft bearing surfaces, replace the cylinder head. Do not
machine the camshaft bearing journals.


Figure 6A1 – 377
3 Inspect the cylinder head for the following: • Cracks, damage or pitting in the combustion chambers.
• Debris in the oil galleries. continue to cl ean the galleries until all debris is removed.
• Coolant leaks or damage to the deck face sealing surfac e. if coolant leaks are present, measure the surface
warpage as described under Cylinder Head M easurement within this Section.
• Burrs or any defects that would degrade the sealing of a new secondar y camshaft chain tensioner gasket.
• Damage to any gasket surfaces.
• Damage to any threaded bolt holes.
• Burnt or eroded areas in the combustion chamber.
• Cracks in the exhaust ports and combustion chambers.
• External cracks in the water passages.
• Restrictions in the intake or exhaust passages.
• Restrictions in the cooling system passages.
• Rusted, damaged or leaking core plugs.
4 If the cylinder head is cracked or damaged, it must be r eplaced. No welding or patching of the cylinder head is
recommended.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–230
Page 6A1–230
Assemble
1 Install the cylinder head coolant threaded plugs (1)
and tighten to the correct torque specification.




Cylinder head thre aded plug .............................. 31.0 Nm


Figure 6A1 – 388
2 Install the cylinder head oil gallery expansion plugs (1).

Figure 6A1 – 389
CAUTION
• Never reuse a valve stem oil seal. Always
use new seals when assembling the
cylinder head.
• Force should only be applied to the valve
spring contact area of the new valve stem
oil seal during installation.
3 Fit the valve stem oil seal s onto the guides using Tool
No. EN-46116 (1).
4 Push and twist the valve stem oil seal into position on the valve guide until the s eal positively locks on the
guide using Tool No. EN-46116.
5 Lubricate the valve stem and valve guide ID with clean engine oil.


Figure 6A1 – 390

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–240
Page 6A1–240
Remove
1 Remove the skid plate.
2 Drain the radiator coolant, refer to Section 6B1 Engine Cooling – V6.
3 Disconnect the battery negative and positive terminal, refer to Section 8A Electrical Body & Chassis.
4 Remove the battery from the vehicle.
5 Depressurise the fuel sy stem pressure, refer to Section 6C Fuel System – V6 .
6 Make alignment marks on the bonnet and hinges in order to return the bonnet to the exact original position.
7 Remove the bonnet, refer to Section 2B Sheet Metal.
8 Remove the rubber hose (2) and air duct (1).


Figure 6A1 – 407

9 Disconnect the barometric sensor connector (1).

Figure 6A1 – 408

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–249
Page 6A1–249
54 Remove the power steering pump bracket mounting
bolts (three places) then remove the pump bracket
(1).

Figure 6A1 – 432
55 Release the lower radiator hose clamp (1) and remove the lower hose from the coolant pipe (2).

Figure 6A1 – 433
56 Release the upper radiator hose clamp (1) and remove the upper hose from the coolant pipe (2).

Figure 6A1 – 434

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–252
Page 6A1–252
65 Remove the engine mount attaching nuts (1), (two
places) on the chassis si de of the left-hand and right-
hand engine mounts.


Figure 6A1 – 441
66 Slowly raise the engine using the engine hoist continue to lift and manoeuvre the engine assembly
clear of the engine compartment.

Figure 6A1 – 442
Disassemble
1 Remove the wiring harness connectors and ground connec tions from the engine and transmission assembly and
carefully set the wiring harness to one side, refer to Section 8A Electrical Body & Chassis.
2 Remove the engine control module (ECM) and mounting bracket, refer to Section 6C1-3 Engine Management – V6
– Service Operations .
3 Mount the engine assembly on a suitable engine stand.
5 Drain the engine oil into a suitable, clean container.
6 Remove the following components: a Oil filter adaptor, refer to 3.3 Oil Filter Adaptor.
b Engine coolant inlet pipe, refer to Section 6B1 Engine Cooling – V6.
c Heater pipe assembly, refer to Section 6B1 Engine Cooling – V6.
d Thermostat assembly, refer to Section 6B1 Engine Cooling – V6.
e Exhaust manifold a ssemblies, refer to 3.11 Exhaust Manifold Assembly .
f Engine coolant outlet pipe, refer to Section 6B1 Engine Cooling – V6.
g Crankshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
h Knock sensors, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
i Engine mounts and brackets, refer to 3.23 Engine Mounts and Brackets.
j Flexplate assemblies, refer to 4.3 Flexplate Assembly.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–253
Page 6A1–253
k Timing chains, tensioners, shoes, guides & sprockets, refer to 3.16 Timing Chains, Tensioners, Shoes and
Guides .
l Cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
m Oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly .
n Piston and connecting rod assemblies, refer to 4.5 Pistons, Pins, Rings, Connecting Rods and Big-end
Bearings .
o Crankshaft assembly, refer to 4.6 Crankshaft and Main Bearings.
p Piston oil nozzles, refer 4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings .
Reassemble
Reassembly of the engine assembly is the reverse of the disassembly procedure.
Reinstall
Reinstallation of the engine assembly is the revers e to the removal procedure, noting the following:
NOTE
Refer to 6 Torque Wrench Specifications for the
correct torque specifications.
1 Tighten the fasteners to the co rrect torque specification.
Engine ground connector bolt
torque specificat ion ............................................ 10.0 Nm
Power steering high pressure line
attaching bolt torque specification ............. 8.0 – 12.0 Nm
Power steering high pressure line
flare nut torque specif ication ................... 25. 0 – 35.0 Nm
Engine mount to frame attaching bolt
torque specification ................................. 44. 0 – 60.0 Nm
Knock Sensor Attaching Nut
torque specification ............................................ 23.0 Nm
2 Use only the specified engine lubricant type and quantity. It is recommended that a fluorescent oil dye, such as that
contained in J 28481-B, be added to assist in any future oil leak diagnosis.
3 Fill the cooling system with the corre ct quantity and grade of coolant, refer to Section 6B1 Engine Cooling – V6.
4 Check transmission fluid level, replenishing as required, using the specified lubricant for the transmission fitted,
refer to Section 7C1 Automatic – 4L60E – General Information .
5 Disable the ignition system, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
6 Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
7 Enable the ignition system. Start t he engine and listen for any unusual noises.
8 Check the vehicle oil pressure gauge or warning indica tor and confirm the engine has acceptable oil pressure. If
required, install an oil pressure gauge and m easure the engine oil pressure, refer to 2.19 Engine Oil Pressure
Diagnosis .
9 Run the engine at about 1,000 r. p.m. until the engine has reached normal operating temperature.
10 Listen for any unusual noises.
11 Check for oil, fuel, coolant and exhaust leaks wh ile the engine is running, correcting as required.
12 Perform a final inspection for correct engine oil and coolant levels.


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–294
Page 6A1–294
4 Remove the right-hand side M14 oil gallery threaded
plug (1).


Figure 6A1 – 529
5 Remove the right-hand side M14 coolant drain threaded plug (1).


Figure 6A1 – 530
6 Remove the rear M14 oil gallery threaded plug (1).


Figure 6A1 – 531

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Engine Mechanical – V6 Page 6A1–295
Page 6A1–295
7 Remove the left-hand side M14 coolant drain
threaded plug (1).


Figure 6A1 – 532
8 Remove the left-hand side M20 oil gallery threaded plug (1).


Figure 6A1 – 533
CAUTION
Do not force coolant expansion plugs
downwards during removal procedure as the
cylinder block will be damaged.
9 Remove the coolant expansion plugs (1).



Figure 6A1 – 534

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–300
Page 6A1–300
4 Place RTV sealant on new coolant expansion plugs
(1) and install the new coolant expansion plugs.

Figure 6A1 – 543
5 Install the left-hand side M20 oil gallery threaded plug (1) and tighten to the correct torque specification.




Left-hand side M20 cylinder block
oil gallery threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm

Figure 6A1 – 544
6 Install the left-hand side M14 coolant drain threaded
plug (1) and tighten to the co rrect torque specification.




Left-hand side M14 cylinder block
coolant drain threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm

Figure 6A1 – 545

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–301
Page 6A1–301
7 Install the M14 rear oil gallery threaded plug (1) and
tighten to the correct torque specification.




M14 cylinder block rear oil gallery
threaded plug torque specif ication .......... 27.0 – 35.0 Nm


Figure 6A1 – 546
8 Install the right-hand side M14 coolant drain threaded
plug (1) and tighten to the co rrect torque specification.




Right-hand side M14 cylinder block
coolant drain threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm


Figure 6A1 – 547
9 Install the right-hand side M14 oil gallery threaded plug (1) and tighten to the co rrect torque specification.




Right-hand side M14 cylinder block
oil gallery threaded plug
torque specificatio n ................................. 27. 0 – 35.0 Nm


Figure 6A1 – 548

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