ISUZU KB P190 2007 Workshop Repair Manual
Manufacturer: ISUZU, Model Year: 2007, Model line: KB P190, Model: ISUZU KB P190 2007Pages: 6020, PDF Size: 70.23 MB
Page 3121 of 6020
Engine Mechanical – V6 Page 6A1–344
Page 6A1–344
Oil Pan Front
Figure 6A1 – 626
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
2 M8 x 1.25 206 207 208 209 210 28.5 23.0
3 M8 x 1.25 610 n/a 208 209 620 37.5 32.0
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ISUZU KB P190 2007
Page 3122 of 6020
Engine Mechanical – V6 Page 6A1–345
Page 6A1–345
Oil Pan Rear
Figure 6A1 – 627
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M10 x 1.5 211 212 213 214 215 Thru Thru
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ISUZU KB P190 2007
Page 3123 of 6020
Engine Mechanical – V6 Page 6A1–346
Page 6A1–346
Oil Pan Bottom
Figure 6A1 – 628
Legend Hole Tool Number J 42385 Max. Depth in mm
Number Thread Size Drill Counter-
bore Tap Driver Insert Drill Tap
1 M6 x 1.0 701 n/a 203 204 205 22.5 18.0
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ISUZU KB P190 2007
Page 3124 of 6020
Engine Mechanical – V6 Page 6A1–347
Page 6A1–347
5 Specifications
General
Engine Type .................................................................................................................... .... V6
Bank An gle ..................................................................................................................... .... 60°
Displacement ............................................................................................ 3.6 litre (3,565 cm3)
Bore ........................................................................................................................... .... 94 mm
Stroke ......................................................................................................................... 85.6 mm
Compression Ratio......................................................................................................... 10. 2:1
Cranking Speed at 40 °C .............................................................................................80 r.p.m.
Spark Plug Gap ............................................................................................................ 1.1 mm
Firing Order ............................................................................................................ 1- 2-3-4-5-6
Cylinder Block
Cylinder Bore Diame ter ........................................................................... 93.992 – 94.008 mm
Cylinder Out-of-Round – Pr oduction Maximum ........................................................ 0.013 mm
Crankshaft Main bearing bor e Diameter .................................................. 72. 867 – 72.881 mm
Cylinder Head Deck Surf ace Flatness ........................................................................ 0. 05 mm
Crankshaft
Connecting Rod Journal Diameter........................................................... 55. 992 – 56.008 mm
Connecting Rod Journa l Out-of-Round..................................................................... 0.005 mm
Connecting Rod Jour nal Taper................................................................................ .0. 005 mm
Connecting Rod Journal Width (Production)........................................................... 22.000 mm
Connecting Rod Journal Width (Service limit)......................................... 21. 920 – 22.080 mm
Crankshaft End Pl ay .................................................................................... 0.100 – 0.330 mm
Crankshaft Main Bearing Clearance ............................................................ 0.010 – 0.060 mm
Crankshaft Main Journal Diameter......................................................... .67. 992 – 68.008 mm
Crankshaft Main Journa l Out-of-Round .................................................................... 0.005 mm
Crankshaft Main Journal Taper ............................................................................... .0. 005 mm
Crankshaft Main Journal Width, #2, 4 (Pr oduction)....................................................... 24 mm
Crankshaft Main Journal Width, #2, 4 (Service)...................................... 23. 900 – 24.100 mm
Crankshaft Main Journal Wi dth, #3 (Production) .................................................... 24.400 mm
Crankshaft Main Journal Width, #3 (Service).......................................... 24. 360 – 24.440 mm
Crankshaft Main Journal Thru st Wall Runout.............................................. 0.
000 – 0.040 mm
Crankshaft Main Journal Thru st Wall Square.............................................. 0. 000 – 0.010 mm
Crankshaft Rear Fl ange Runout............................................................................... 0. 025 mm
Crankshaft Reluctor Ring Ru nout - Maximum .......................................................... 1.500 mm
Crankshaft Thrust Bearin g Clearance.......................................................... 0. 076 – 0.305 mm
Crankshaft Thrust Su rface Runout........................................................................... 0. 040 mm
Crankshaft Thrust Surface – Height Diameter ........................................................ 95.000 mm
Connecting Rod
Connecting Rod Length - Bore Centre-to-Centre ................................................. 150.400 mm
Connecting Rod Bore Diameter - Bearing End........................................ 59. 620 – 59.636 mm
Connecting Rod Bore Diamet er - Pin End............................................... 24. 007 – 24.021 mm
Connecting Rod Width ........................................................................................... 21.775 mm
Connecting Rod Side Cl earance.................................................................. 0.095 – 0.355 mm
Connecting Rod Bearing Clearance ............................................................ 0.010 – 0.070 mm
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ISUZU KB P190 2007
Page 3125 of 6020
Engine Mechanical – V6 Page 6A1–348
Page 6A1–348
Piston
Piston Diameter ....................................................................................... 93. 956 – 93.974 mm
Piston Pin Bore Diame ter ........................................................................ 24.005 – 24.009 mm
Piston Ring Groove Width - First (Top) Compression Ring ......................... 1.220 – 1.240 mm
Piston Ring Groove Width - Second Compression Ring.............................. 1. 510 – 1.530 mm
Piston Ring Groove Width - Oil Control Ring ............................................... 2. 510 – 2.530 mm
Piston to Bore Clear ance ............................................................................. 0.026 – 0.052 mm
Piston Pin
Piston Pin Diamet er .................................................................................. 23.997 - 24.000 mm
Piston Pin Length ..................................................................................... 60. 600 – 61.100 mm
Piston Pin Clearance to Connec ting Rod Bore............................................. 0. 007 – 0.024mm
Piston Pin Clearance to Pist on Pin Bore....................................................... 0. 004 – 0.012mm
Piston Rings
Piston Ring to Groove Clearance:
• First (Top) Compression Ring............................................................... 0. 030 – 0.065 mm
• Second Compression Ring ................................................................... 0.015 – 0.060 mm
• Oil Control Ring .................................................................................... 0. 030 – 0.170 mm
Piston Ring End Gap:
• First (Top) Compression Ring............................................................... 0. 150 – 0.300 mm
• Second Compression Ring ................................................................... 0.280 – 0.480 mm
• Oil Control Ring .................................................................................... 0. 150 – 0.600 mm
Cylinder Head
Combustion Chambe r Volume.................................................................................. 53. 600 cc
Valve Guide Bore Diameter – Intake ........................................................... 6.000 – 6.020 mm
Valve Guide Bore Diameter – Exhaust ........................................................ 6.000 – 6.020 mm
Valve Guide Installed Height................................................................... 14. 050 – 14.550 mm
Stationary Hydraulic Lash Adjuster (S HLA) Bore Diameter .....................12.008 – 12.030 mm
Valve Seat Angle – Seating Surface ................................................................................... 45 °
Valve Seat Angle – Relief Surface...................................................................................... 30 °
Valve Seat Angle – Un dercut Surface ................................................................................ 60 °
Valve Seat Runout – Maximum................................................................................ 0. 050 mm
Valve Seat Width – Exhaust S eating Surface.............................................. 1. 400 – 1.800 mm
Valve Seat Width – Exhaust Re lief Surface................................................. 0. 700 – 0.900 mm
Valve Seat Width – Intake Se ating Surface................................................. 1. 000 – 1.400 mm
Valve Seat Width – Intake Relief Surface.................................................... 0. 500 – 0.700 mm
Engine Block Deck Surf ace Flatness .......................................................................... 0. 05 mm
Exhaust Manifold Deck Su rface Flatness ................................................................... 0. 25 mm
Intake Manifold Deck Su rface Flatness ...................................................................... 0. 05 mm
Valve System
Face Angle .................................................................................................................... 4 4.25°
Face Run out ............................................................................................................. 0.038 mm
Valve Face Width – Exhaust..................................................................................... 2. 750 mm
Valve Face Width – Intake........................................................................................ 2. 180 mm
Valve Head Diameter – Ex haust .............................................................. 30.470 – 30.730 mm
Valve Head Diameter – Intake ................................................................. 36. 830 – 37.090 mm
Valve Installed He ight .................................................................................. 35.26 – 36.69 mm
Valve Length – Exhaust.......................................................................................... 97. 110 mm
Valve Length – Intake ........................................................................................... 101.230 mm
Valve Stem Diameter (s tandard).................................................................. 5. 955 – 5.975 mm
Valve Stem Diameter (o versize).................................................................. 6.013 – 6.033 mm
Valve Stem to Guide Clearance................................................................... 0. 025 – 0.065 mm
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ISUZU KB P190 2007
Page 3126 of 6020
Engine Mechanical – V6 Page 6A1–349
Page 6A1–349
Hydraulic Lash Adjuster Diameter ........................................................... 11.986 – 12.000 mm
Hydraulic Lash Adjuster to Bore Clearance................................................. 0. 037 – 0.041 mm
Rocker Arm/Camshaft Fo llower Ratio............................................................................. 1. 68:1
Rocker Arm/Camshaft Follower Ro ller Diameter..................................... 17. 740 – 17.800 mm
Valve Spring Free Le ngth ........................................................................ 42.500 – 45.500 mm
Valve Spring Installed He ight – Closed................................................................... 35. 000 mm
Valve Spring Installed Height – Open ..................................................................... 24.000 mm
Valve Spring Load – Closed................................................................................. 247 – 273 N
Valve Spring Load – Open.................................................................................... 598 – 662 N
Valve Spring Diameter – In side Top ........................................................ 12.200 – 12.700 mm
Valve Spring Diameter – Ou tside Top ..................................................... 18.000 – 20.500 mm
Valve Spring Diameter – In side Bottom ................................................... 17.950 – 18.450 mm
Valve Spring Diameter – Outside Bottom ............................................................... 26. 000 mm
Valve Spring Coil Thi ckness ........................................................................ 3.250 – 3.900 mm
Valve Spring Total Nu mber of Coils..................................................................................... 7.1
Camshaft
Camshaft Bearing Inside Diameter – Front Number 1 ............................. 35. 000 – 35.020 mm
Camshaft Bearing Inside Diam eter – Middle & Rear Number 2 - 4..........27.000 – 27.020 mm
Camshaft End Play ...................................................................................... 0. 045 – 0.215 mm
Camshaft Journal Diameter – Fr ont Number 1........................................ 34. 936 – 34.960 mm
Camshaft Journal Diameter – Middle & Rear Number 2 - 4..................... 26. 936 – 26.960 mm
Camshaft Journal Ou t-of-round................................................................................ 0. 006 mm
Camshaft Journal to Bore Clearance ........................................................... 0.040 – 0.084 mm
Camshaft Runout – Front & R ear Number 1 and 4................................................... 0. 025 mm
Camshaft Runout – Middle Number 2 and 3............................................................ .0 .050 mm
Camshaft Lobe Duration – Ex haust (@ 0.150 mm Lift) .................................................... 238 °
Camshaft Lobe Duration – In take (@ 0.150 mm Lift) ....................................................... 237 °
Camshaft Lobe Height – Exhaust ................................................................................. 6.6 mm
Camshaft Lobe Height – Intake.................................................................................... 6.5 mm
Camshaft Lobe Overlap (@ 0.150 mm Lift) ..................................................... -5 ° (no overlap)
Valve Opens – Exhaust .........................................................................................229 ° BTDC
Valve Opens – Intake ...............................................................................................14 ° ATDC
Centre-line – Exhaust .............................................................................................111 ° BTDC
Centre-line – Intake ................................................................................................132 ° ATDC
Valve Closes – Exhaust ..............................................................................................9 ° ATDC
Valve Closes – Intake ............................................................................................252 ° ATDC
Valve Lift – Ex haust .................................................................................................... 10.8 mm
Valve Lift – Intake....................................................................................................... 10. 8 mm
Oil Pump
Type........................................................................................................................... ...Gerotor
Gear Diameter – Ou ter ............................................................................ 87.095 – 87.175 mm
Gear Bore Dept h...................................................................................... 15. 565 – 15.600 mm
Gear Bore Diamet er................................................................................. 87.275 – 87.325 mm
Gear Thickness ........................................................................................ 15. 511 – 15.536 mm
Gear to Cover Clear ance ............................................................................. 0.030 – 0.085 mm
Gear to Housing Cle arance......................................................................... 0. 100 – 0.230 mm
Inner Gear Tip Clear ance ............................................................................ 0.075 – 0.180 mm
Crankshaft Clearance to Housing................................................................ 0. 040 – 0.130 mm
Inner Gerotor Hub Di ameter.................................................................... 53. 310 – 53.335 mm
Housing Hub Diamet er ............................................................................ 53.380 – 53.420 mm
Inner Gerotor Hub Clearance to Housing .................................................... 0. 045 – 0.110 mm
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ISUZU KB P190 2007
Page 3127 of 6020
Engine Mechanical – V6 Page 6A1–350
Page 6A1–350
Lubrication System
Oil Type.................................................................................................................. SAE 5 W30
Oil Capacity – with Filter................................................................................................... 6. 5 L
Oil Pressure – Mini mum at idle ......................................................................................69 kPa
Oil Pressure – Minimum at 2000 r.p.m. ....................................................................... 138 kPa
Piston Cooling Jet Valve Op ening Pressure...................................................... 170 – 230 kPa
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ISUZU KB P190 2007
Page 3128 of 6020
Engine Mechanical – V6 Page 6A1–351
Page 6A1–351
6 Torque Wrench Specifications
ATTENTION
„ Fasteners must be replaced after loosening.
Fasteners either have micro encapsulated sealant a pplied or incorporate a mechanical thread lock and
should only be re-used once. If in doubt, replacement is recommended.
Oil Pan Drain Plug ................................................................................ 25.0 Nm
Oil Filter Adaptor Attach ing Bolt................................................ 20.0 – 26.0 Nm
Oil Level Indicator Tube Atta ching Bolt........................................ 8.0 – 12.0 Nm
Accessory Drive Belt Idler Pu lley Attaching Bolt................................... 50.0 Nm
Accessory Drive Belt Tensio ner Attaching Bolt .................................... 50.0 Nm
Power Steering Reserv oir Bracket Attaching Screw.............................. 9.0 Nm
Power Steering Pump Bracket A ttaching Bolt ........................... 49. 0 – 67.0 Nm
Upper Intake Manifold to Lower Intake Manifold Attaching Bolt ........... 23.0 Nm
Upper Intake Manifold to Cylinder Head Attaching Bolt........................ 23.0 Nm
Lower Intake Manifold to Cylind er Head Attaching Bolt........................ 23.0 Nm
Fuel Injector Wiring Harness Br acket Attaching bolt .............................. 9. 0 Nm
Exhaust Manifold to Cylinder He ad Attaching Bolt..................... 17.0 - 23.0 Nm
Exhaust Manifold Heat Shield Attaching Bolt ............................... 8.0 - 12.0 Nm
Battery Harness Ground Terminal Attaching Nut ................................. 13. 0 Nm
Camshaft Cover Attachi ng Bolt................................................... 8.0 – 12.0 Nm
Engine Ground Connec tor Bolt............................................................. 10.0 Nm
Engine Wiring Harness Former A ttaching Bolt .......................... 12.0 – 16.0 Nm
„ Crankshaft Balancer A ssembly Attaching Bolt:
Stage 1 ..................................................................................... 90.0 –110.0 Nm
Stage 2 ....................................................................................................... 150 °
Engine Front Cover Assembly A ttaching Bolt ............................ 20. 0 – 26.0 Nm
Camshaft Intermediate Sprocket Attaching Bolt ........................ 58. 0 – 72.0 Nm
Secondary Timing Chai n Guide Attaching Bolt.......................... 20.0 – 26.0 Nm
Secondary Timing Chai n Shoe Attaching Bolt ........................... 20.0 – 26.0 Nm
Secondary Timing Chain Tensioner Attachi ng Bolt ................... 20.0 – 26.0 Nm
Primary Timing Chain Upper Gui de Attaching Bolt.................... 20.0 – 26.0 Nm
Primary Timing Chain Tensioner Attaching Bolt........................ 20. 0 – 26.0 Nm
Oil Pump Assembly Attach ing Bolt............................................ 20.0 – 26.0 Nm
Camshaft Sprocket Attachi ng Bolt............................................. 49.0 – 67.0 Nm
Exhaust Camshaft Sprocket Atta ching Bolt............................... 49.0 – 67.0 Nm
Camshaft Bearing Cap Attach ing Bolt......................................... 8.0 – 12.0 Nm
Cylinder Head Thr eaded Plug.............................................................. 31.0 Nm
„ Cylinder Head M11 Attaching Bolt:
Stage 1 ...................................................................................... 40.0 – 50.0 Nm
Stage 2 ....................................................................................................... 120 °
„ Cylinder Head M8 Attaching Bolt:
Stage 1 ...................................................................................... 12.0 – 18.0 Nm
Stage 2 ......................................................................................................... 60 °
Engine Mount Bracket to Cylinder Bl ock Attaching Bolt............ 43.0 – 57.0 Nm
Engine Mount to Bracket Atta ching Nut..................................... 70.0 – 90.0 Nm
Engine Mount to Frame Atta ching Nut...................................... 44.0 – 60.0 Nm
Engine Lift Bracket Attachi ng Bolt.......................................... 58.0 – 72.0.0 Nm
Knock Sensor Attach ing Nut................................................................. 23.0 Nm
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ISUZU KB P190 2007
Page 3129 of 6020
Engine Mechanical – V6 Page 6A1–352
Page 6A1–352
Power Steering High Pressure Line Attaching Bolt..................... 8.0 – 12.0 Nm
Power Steering High Pressure Li ne Flare Nut ...........................25.0 – 35.0 Nm
Steering Gear Housing Mounting Nut:
Stage 1 ................................................................................................. 60.0 Nm
Stage 2 ................................................................................................ 40° – 50°
Oil Suction Pipe Attaching Bolt ............................................................. 10.0 Nm
Crankshaft Oil Deflector Attaching bolt ................................................. 10. 0 Nm
Oil Level Sens or ................................................................................... 20.0 Nm
Oil Pan to Cylinder Block A ttaching Bolt .................................... 20.0 – 26.0 Nm
Oil Pan to Crankshaft Rear Oil Seal Housing Attaching Bolt ........ 8.0 - 12.0 Nm
„ Flexplate Attaching Bolt:
Stage 1 ...................................................................................... 26.0 – 34.0 Nm
Stage 2 ......................................................................................................... 45 °
Crankshaft Rear Oil Seal Housi ng Attaching Bolt........................ 8.0 – 12.0 Nm
„ Connecting Rod Cap Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ................................................................................ Loos en Completely
Stage 3 ................................................................................................. 25.0 Nm
Stage 4 ....................................................................................................... 110 °
Crankshaft Bearing Cap Remover Nut................................................. 11.0 Nm
„ Crankshaft Main Bearing Cap Inboard Attaching Bolt:
Stage 1 ................................................................................................. 20.0 Nm
Stage 2 ......................................................................................................... 80 °
„ Crankshaft Main Bearing Cap Outboard Attaching Bolt:
Stage 1 ................................................................................................. 15.0 Nm
Stage 2 ....................................................................................................... 110 °
„ Crankshaft main Bearing Cap Side Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ......................................................................................................... 60 °
Cylinder Block Threaded Plug .................................................... 27.0 - 35.0 Nm
Oil Jet Attaching Bo lt ................................................................... 8.0 – 12.0 Nm
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ISUZU KB P190 2007
Page 3130 of 6020
Engine Mechanical – V6 Page 6A1–353
Page 6A1–353
7 Special Tools
Tool Number Illustration Description
E-308
Seal Remover
Previously released.
EN-46101
Spark Plug Tube Seal Guide Set
Used to protect the spark plug lip seals when installing the
camshaft cover to the cylinder head.
EN-46103
Camshaft Actuator Valve Seal Installer
Used to install the camshaft actuat or valve seals into the front
cover.
EN-46105 – 1 and 2
Camshaft Locking Tool Set
Used to retain camshaft position during timing chain or
camshaft actuator replacement.
EN-46106
Flexplate Holding Tool
Used to retain crankshaft position during valve-train overhaul
and harmonic balancer removal.
EN-46108
Timing Chain Retention Tool Set
Used to retain timing chain tension during camshaft and
sprocket removal.
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ISUZU KB P190 2007