lock ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–108
Page 6A1–108
Reinstall
Reinstallation of the front cover is the reverse of the removal procedure, noting the following:
1 Install the guide pins, Tool No. EN-46109 (1) into the engine block, two places.
Figure 6A1 – 93
2 Install a new engine front cover to cylinder block seal (1).

Figure 6A1 – 94
3 Apply a 3 mm bead of RTV sealant (1) to the front cover.

Figure 6A1 – 95

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–109
Page 6A1–109
4 Place the front cover onto the special tools and slide
into position.
5 Remove the special tools from the cylinder block.
Figure 6A1 – 96
6 Hand start the front cover bolts (1).
Figure 6A1 – 97
7 Tighten the engine front cover bolts to the correct torque specification, in the sequence shown.


Engine front cover assembly attaching
bolt torque specificat ion .......................... 20.0 – 26.0 Nm


8 Fill the cooling system, refer to Section 6B1 Engine
Cooling – V6 .
9 Change the engine oil, refer to 3.1 Engine Oil.



Figure 6A1 – 98

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–114
Page 6A1–114
Remove
Right-hand Secondary Timing Chain
CAUTION
After removing the upper intake manifold, and
spark plugs, plug any openings to prevent dirt
and other contaminants from entering.
1 Remove the engine front cover assembly, refer to 3.15 Front Cover Assembly.
2 Remove the spark plugs to aid crankshaft/engine rotation, refer to Section 6C1-3 Engine Management – V6 –
Service Operations .
3 Install Tool No. EN46111 (1) onto the crankshaft (2).

Figure 6A1 – 103
4 Using Tool No. EN46111 (1), rotate the crankshaft in a clockwise direction until the crankshaft sprocket
timing mark (2) is aligned with the indexing mark (3)
on the oil pump housing.
NOTE
Graphic shows 'Early Type' crankshaft sprocket,
'Late Type' similar.

Figure 6A1 – 104

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–118
Page 6A1–118
Primary Timing Chain
1 Remove the right-hand secondary timing chain, refer to Right-hand Secondary Timing Chain in this Section.
2 Remove the two primary timing chain tensioner bolts (1), and remove the tensioner (2).


NOTE
Take care when removing the tensioner bolts.
The tensioner plunger is subjected to spring
tension and may spring apart during tensioner
removal.


Figure 6A1 – 114
3 Remove the gasket (1) from the tensioner (2) and discard the gasket.
4 Inspect the primary timi ng chain tensioner mounting
surface on the engine block for burrs or any defects
that would affect the s ealing of a new tensioner
gasket.


Figure 6A1 – 115
5 Remove the two primary timing chain upper guide bolts (1) and remove the guide (2).


Figure 6A1 – 116

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–124
Page 6A1–124
Inspect
Timing Chains
1 Inspect the primary and/or secondary timing chains
for the following:
• binding or worn rollers (1),
• loose links (2), and
• loose pins (3).
2 Replace a damaged timing chain as required.


Figure 6A1 – 130
Camshaft Intermediate Sprockets

Figure 6A1 – 131

1 Inspect the camshaft intermediate sprockets for the following:
• Damage to the primary and secondary timing chai n sprocket (1), refer to Figure 6A1 – 129.
• Damage to the hub bearing (2). Ensure the hub bearing sp ins freely. If the hub bearing wobbles, is noisy or
feels rough when rotated replace t he camshaft intermediate sprocket, and
• Damage to the bolt flange seating / sealing surface (3).
• Damage to the bearing hub-to-engi ne block sealing surface.
Inlet and Exhaust Camshaft Sprocket
Inspect the camshaft sprocket assemblies, refer to 3.18 Camshaft Sprocket .

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–126
Page 6A1–126
Primary Timing Chain Tensioner

Figure 6A1 – 135
1 Inspect the primary timing chain tensioner for wo rn shoe surface (1), refer to Figure 6A1 – 133.
2 Inspect the tensioner for a locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner
shaft moves freely in and out of the body of the tensioner.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
3 Replace a damaged tens ioner as required.
Left-hand Secondary Timing Chain Guide
1 Inspect the left-hand secondary timing chain guide for
the following:
• worn guide surface (1),
• cracked or broken guide surface (2), and
• cracked or damaged guide base (3).
2 Replace a damaged guide as required.


Figure 6A1 – 136

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–128
Page 6A1–128
2 Inspect the tensioner for locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner shaft
moves freely in and out of the body of the tensioner.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
3 Replace a damaged tens ioner as required.
Right-hand Secondary Timing Chain Guide
1 Inspect the right-hand secondary timing chain guide
for the following:
• worn guide surface (1),
• cracked or broken guide surface (2), and
• cracked or damaged guide base (3).
2 Replace a damaged guide as required.


Figure 6A1 – 140
Right-hand Secondary Timing Chain Shoe
1 Inspect the front of t he right-hand secondary timing
chain shoe for the following:
• worn shoe surface (1),
• cracked or broken shoe surface (2), and
• cracked or damaged shoe (3).


Figure 6A1 – 141

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–129
Page 6A1–129
2 Inspect the back of the shoe for a damaged, worn or
missing timing chain tensioner contact pad (1).
Replace a damaged shoe as required.

Figure 6A1 – 142
Right-hand Secondary Timing Chain Tensioner

Figure 6A1 – 143
1 Inspect the right-hand secondary timing chain tensioner for damaged plunger-to-shoe contact surface (1), refer to
Figure 6A1 – 141.
NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver or Tool No. J 45027 (4) to wind
the plunger in a clockwise direction, into the
tensioner shaft.
2 Inspect the tensioner for a locked or binding tensioner shaft (2). Reset the plunger (3) and ensure the tensioner
shaft moves freely in and out of the body of the tensioner.
3 Replace a damaged tens ioner as required.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–130
Page 6A1–130
Reinstall
Left-hand Secondary Timing Chain Components – Excluding MY06 Update
1 Install the crankshaft sprocket (1) onto the
crankshaft (2) by aligning the keyway to the key on
the crankshaft.
2 Slide the crankshaft sprocket on the crankshaft until the crankshaft sprocket contacts the step in the
crankshaft.


Figure 6A1 – 144
NOTE
Ensure that the crankshaft sprocket is installed
with the timing mark (1) visible.

Figure 6A1 – 145
CAUTION
In order to install Tool No. EN 46105 onto the
camshafts, rotate the camshafts in an anti-
clockwise direction. There should be no
need to rotate the camshaft more than 45
degrees.

Figure 6A1 – 146

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–131
Page 6A1–131
3 Install Tool No. EN 46105-1 (1) onto the rear of the
left-hand cylinder head camshafts (2), and Tool No.
EN 46105-2 onto the rear of the right-hand cylinder
head camshafts.
4 Ensure that Tool No. EN 46105 is fully seated onto the camshafts.


CAUTION
All camshafts must be locked in place before
installation of any timing chains.

Figure 6A1 – 147
5 Using Tool No. EN46111 (1), rotate the crankshaft in a clockwise direction until the crankshaft sprocket
timing mark (2) is aligned with the indexing mark (3)
on the oil pump housing.

Figure 6A1 – 148
6 Install the left-hand secondary timing chain (1) aligning the chain in the following manner:


Figure 6A1 – 149

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ISUZU KB P190 2007