ISUZU KB P190 2007 Workshop Repair Manual

Exhaust System – V6 Page 6F – 3


The Catalytic converter can be damaged or
rendered ineffective, if:
• operated outside the limits of the closed
loop mixture control system
• the engine burns excessive amount of oil
• the exhaust temperature at the converter
is too high (exceeds 840°C).
The catalytic material is very sensitive to the effects of a rich or lean fuel mixture, which may cause the temperature of
the converter to rise rapidly. The catalytic converter normally operates at approximately 600 °C.
The catalytic converter is also sensitive to the use of leaded petrol. Using leaded fuel can cause deposits to form in the
converter, which restrict exhaust flow and prevent the catalyst from working. This will result in an increase in exhaust
backpressure and converter temperature.
NOTE
The use of unleaded petrol results in black
tailpipe deposits rather than the grey colour that
some people may normally associate with an
acceptable combustion condition. This black
colour resulting from the use of unleaded fuel
does not necessarily indicate a state of poor
engine tune. For V6 engines, Refer to: 6C1 – 1
Engine Management General Information.
Euro 3 Emissions Standards
The Euro 3 emissions standard is a European standard which aims at setting vehicle emissions targets to encourage
vehicle manufacturers to reduce harmful vehicle emissions such as Carbon Monoxide (CO), Hydrocarbons (HC) and the
various oxides of Nitrogen (NOx).

This vehicle is fitted with a supplemental
restraint system (SRS). Refer to section 9A
Restraints, in order to determine whether you
are performing service on or near the SRS
components or the SRS wiring.

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 identify those fasteners
that require a replacement after removal and
fasteners that require thread lockers or thread
sealant. Unless otherwise specified, do not
use supplemental coatings (Paints, greases
or corrosion inhibitors) on thread fasteners or
fastener joints. Generally such coatings
adversely effect the fastener torque and the
joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and torque
specifications.


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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 4


Figure 6F– 3
Legend
1 Front Exhaust Pipe LH side
2 Front Exhaust Pipe RH side
3 Three Way Catalytic Converter 4 Centre Exhaust Pipe
5 Exhaust Silencer and Tail Pipe
1.2 General Description

W hen inspecting or replacing the exhaust system components, make sure there is adequate clearance from all points
on the underbody to prevent overheating of 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 misaligned components, 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.
Various types of hangers are used to support exhaust systems, these include conventional rubber straps, rubber rings
or rubber blocks. The installation of exhaust system supports is very important, Improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.



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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 5

Service Notes
1. Vehicles fitted with catalytic converters should not be operated with leaded petrol. Lead will contaminate
the ceramic monolith.
2. Do not drop the catalytic converter as it will damage the ceramic monolith.
3. Replace the catalytic converter if it is damaged.
4. Do not allow water, oil or fuel to enter the converter as the ceramic monolith will be contaminated.
5. Do not use engine and/or fuel additives unless approved by General Motors. Many additives contain phosphorous that will contaminate the ceramic monolith.
6. The vehicle must not be started by pushing or towing, as unburned fuel could reach the catalytic converter and destroy the ceramic monolith. Always use jumper leads to start a vehicle that has a flat or
defective battery.
7. W hen carrying out a compression test, for V6 engines use Tech 2 to ensure the output control Engine Compression Test is set to enable, refer to 6A1 Engine Mechanical. This prevents fuel injection and
ignition during engine cranking.
8. Do not drive the vehicle with the engine misfiring or with any of the spark plug leads disconnected, as the catalytic converter will overheat.
9. Do not coast downhill with the engine misfiring or with any of the spark plug leads disconnected.
10. The catalytic converter is serviceable as part of the front exhaust assembly only. Refer to the service operations in this section for details of front exhaust pipe assembly removal and reinstallation.
11. The exhaust flange gaskets must be replaced whenever a new exhaust pipe, muffler or catalytic converter is installed.
1.3 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
1.1 Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is
ignored, the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,

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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 6

• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.


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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 7

2 Front and Centre Exhaust Pipe

Figure 6F– 4
1 Front Exhaust Flange Nuts
2 Front O2 Sensor
3 Three Way Catalytic Converter RH side
4 Rear O2 Sensor
5 Three Way Catalytic Converter LH side 6 Front Exhaust Pipe Mounting Rubber
7 Centre Exhaust Flange Attaching Nuts
8 Centre Exhaust Pipe
9 Rear Exhaust Flange Nuts

Removal
1. Disconnect the battery ground cable.
2. Remove the suspension cross member, Refer to 7B1 Manual transmission.
3. Remove the two front torsion bar springs, Refer to 3C Suspension.
4. Disconnect the O2 sensor harness connectors (2 and 4), two each bank.
5. Remove the front exhaust flange attaching nuts (1), three each bank.
6. Remove the centre exhaust pipe flange nuts (7), two each bank.
7. Remove the centre exhaust pipes from the rubber mounts (6).
8. Remove the front left and right hand exhaust pipes from the vehicle.
9. Remove the two rear exhaust flange nuts and bolts (9).
10. Remove the centre exhaust pipe from the vehicle.
11. Remove the O2 sensors if required, Refer to 6C1 – 1 Engine Management General Info.


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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 8

NOTE:
• Support the exhaust system at all times.

• Clean the threads of the attaching bolts, nuts,
studs and flanges with a suitable cleaning
solvent.
• Apply a high temperature anti-seize
compound to the manifold front pipe flange
joint studs, then align the flange over the
studs.
Reinstallation
1. Install any removed O2 sensors, Refer to 6C1 – 1 Engine Management General Info.
2. Position the centre exhaust pipe into location under the vehicle.
3. Install the two rear exhaust flange nuts and bolts (9).
4. Position the front exhaust pipes into location under the vehicle.
5. Install the centre exhaust pipes into the rubber mounts (6).
6. Install the exhaust flange fixing nuts (1), three each bank.
7. Install the rear exhaust pipe flange nuts (7), two each bank.
8. Reconnect the O2 sensor harness connectors (4), two each bank.
9. Install the two front torsion bar springs, Refer to 3C Suspension.
10. Install the suspension cross member, Refer to 7B1 Manual transmission.
11. Reconnect the battery ground cable.


O2 Sensor
tightening torque.....................................................50 Nm
Front Exhaust Flange Nuts
tightening torque.......................................40.0 – 60.0 Nm
Centre Exhaust Flange Nuts
tightening torque.....................................................43 Nm
Rear Exhaust Flange Nuts
tightening torque.....................................................43 Nm

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ISUZU KB P190 2007

Exhaust System – V6 Page 6F – 9

3 Silencer and Rear Exhaust Pipe

Figure 6F– 5
1 Centre Exhaust Pipe
2 Exhaust Flange Bolts
3 Exhaust Flange Nuts 4 Exhaust Silencer Mounting Rubber
5 Exhaust Silencer and Tail Pipe
6 Rear Exhaust Pipe Mounting Rubber
Removal
1. Disconnect the battery ground cable.
2. Remove the exhaust flange bolts (2) and nuts (3).
3. Remove the silencer and rear exhaust pipe mounting rubbers (4 and 6).
4. Remove the silencer and exhaust pipe from the vehicle.
NOTE:
• Support the exhaust system at all times.
• Clean the threads of the attaching bolts, nuts,
studs and flanges with a suitable cleaning
solvent.
Reinstallation
1. Position the silencer and exhaust pipe into the vehicle.
2. Install the silencer and rear exhaust pipe mounting rubbers (4 and 6).
3. Install the exhaust pipe flange bolts (2) and nuts (3).
4. Reconnect the battery ground cable.
Rear Exhaust Flange Nuts
tightening torque.....................................................43 Nm

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Exhaust System – V6 Page 6F – 10

4 Torque Wrench Specifications
..................................................................................................................... Nm
Front Exhaust Flange Nuts...............................................................40.0 – 60.0
Centre Exhaust Flange Nuts .......................................................................43.0
Rear Exhaust Flange Nuts ..........................................................................43.0
O2 Sensor ...................................................................................................50.0



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SECTION 7
TRANSMISSION
TA BLE OF CONTENTS
TRANSMISSION 7
A UTO MATIC TR ANS MISSIO N 4 L 60 E
TRANSMISSION AW30-40LE MODEL
TRANSMISSION JR405E MODEL
MANUAL TRANSMISSION MSG MUA MUX MODELS
CLUTCH
TRANSFER CASE
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ISUZU KB P190 2007

Section 7C1 General Information ................................................................................. 3761 PAGE
Section 7C4 On Vehicle Servicing ................................................................................ 3914
SECTION 7C
AUTOMATIC TRANSMISSION
T A BLE OF CONTENTS
TRANSMISSION
4L60E MODEL
Section 7C2 Electrical Diagnosis ................................................................................. 3787
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ISUZU KB P190 2007