torque ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–289
Page 6A1–289
4 Install the new lower crankshaft bearings (2) into
position in the main bearing caps (1). The lower
crankshaft bearings are ident ified by no grooves or
holes. The bearings must fit flush with the crankshaft
bearing caps.


Figure 6A1 – 517
Crankshaft Main Bearing Clearance Measurement
1 Place a length of fresh, room temperature plastic
gauging material all the way across all the crankshaft
bearing journals.
2 Install the crankshaft main bearing caps.
3 Loosely install the original inner main cap bolts (1).
4 Loosely install the original outer main cap bolts (2).

Figure 6A1 – 518
5 Loosely install the original short/inner side main cap bolts.
6 Loosely install the original long/outer side main cap
bolts (3).
7 Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.
8 Tighten the main caps bolts to the correct torque specification, and in the following sequence.
Crankshaft main bearing cap inboard
attaching bolt torque specification:
Stage 1 .........................20.0 Nm
Stage 2................................. 80°
Crankshaft main bearing cap outboard
attaching bolt torque specification:
Stage 1 .........................15.0 Nm
Stage 2............................... 110°
Crankshaft main bearing cap side
attaching bolt torque specification:
Stage 1 .........................30.0 Nm
Stage 2................................. 60°

Figure 6A1 – 519

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Engine Mechanical – V6 Page 6A1–291
Page 6A1–291
Crankshaft Final Installation Procedure
1 If removed, install the crankshaft sprocket drive
pin (1). Lightly tap the pin in place with a small soft
face, bronze/plastic, hammer until it bottoms in the
hole.

Figure 6A1 – 522
CAUTION
Ensure the crankshaft position sensor has
been removed from the cylinder block prior
to loading the crankshaft, as damage to the
sensor may occur.
2 Apply a liberal amount of clean engine oil to the upper and lower bearing surfaces.
3 Gently lower the crankshaft (1) into position in the cylinder block (2).

Figure 6A1 – 523
4 Install the crankshaft main bearing caps.
5 Loosely install the original inner main cap bolts (1).
CAUTION
The outer crankshaft bearing cap bolts (2)
are yield tightened during assembly and
must be replaced prior to reassembly. Outer
crankshaft bearing cap bolts that are not
replaced will not torque to the correct clamp
load and can lead to serious engine damage.
6 Loosely install the new outer main bearing cap bolts (2).
7 Gently tap the crankshaft main bearing caps with a soft-faced hammer to help seat the caps.

Figure 6A1 – 524

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Engine Mechanical – V6 Page 6A1–292
Page 6A1–292
8 Loosely install new short / inner side main cap
bolts (4).
CAUTION
• The short / inner side main cap bolts
originally have a sealant on the flange of
the bolt head. New bolts must be used. If
new bolts are not used, oil can leak from
the crankcase past the bolts.
• The long / outer side main cap bolts
originally have a sealant on the flange of
the bolt head. New bolts must be used. If
new bolts are not used, oil can leak from
the crankcase past the bolts.
9 Loosely install the new long / outer side main cap bolts (3).
10 Tighten the main caps bolts to the correct torque specification, and in the following sequence.
„ Crankshaft main bearing cap inboard
attaching bolt torque specification:
Stage 1 .........................20.0 Nm
Stage 2................................. 80°
„ Crankshaft main bearing cap outboard
attaching bolt torque specification:
Stage 1 .........................15.0 Nm
Stage 2............................... 110°
„ Crankshaft main bearing cap side
attaching bolt torque specification:
Stage 1 .........................30.0 Nm
Stage 2................................. 60°

Figure 6A1 – 525
11 Ensure the crankshaft turns without binding or noise.
12 Install the remaining components in the reverse order to removal, refer to the appropriate Section.

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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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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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Engine Mechanical – V6 Page 6A1–302
Page 6A1–302
10 Install the cylinder block-to-oil pan alignment
dowels (1).


Figure 6A1 – 549
11 Install the new right-hand front oil pan rail oil gallery expansion plug (1).


Figure 6A1 – 550
12 Install the oil jet (2), three places.
13 Install the oil jet attaching bolt (1), three places and tighten to the correct torque specification.



Oil jet attaching bolt
torque specificatio n ................................... 8. 0 – 12.0 Nm


Figure 6A1 – 551

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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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Engine Mechanical – V6 Page 6A1–355
Page 6A1–355
Tool Number Illustration Description
EN-46117
Valve Stem Key Remover / Installer
Used in conjunction with J-8062 or EN-46110 to remove and
reinstall the valve stem keys.
EN-46119
Off-vehicle Valve Spring Compressor Adaptor
Used in conjunction with J-8062 to remove valve springs with
the engine disassembled.
EN-46120 and
J-42096
Valve Guide Reamer
Used to oversize valve guides prior to the installation of new
oversized valves.
EN-46121
Connecting Rod Guide Pin Set
Used to guide connecting rods onto the crankshaft journals
and prevent damage to the cylinder bores, journal faces and
piston cooling jets during engine assembly procedures.
EN-46122
Oil Control Valve Check Ball Remover / Installer
EN-7115

Torque Angle Wrench
Used to accurately tighten fasteners when an angle torque is
required.

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Engine Cooling – V6 Engine Page 6B1–2

Cooling System Pressure Testing ................................................................................................ ...................... 32
3.8 Thermostat ........................................................................................................................................................... 34
Remove ................................................................................................................................................................. 34
Test ....................................................................................................................................................................... 37
Dismantle ...................................................................................................................... ........................................ 37
Reassembly .......................................................................................................................................................... 37
Install .................................................................................................................................................................... 38
3.9 Coolant Recovery Reservoir ..................................................................................................... .......................... 39
Remove ................................................................................................................................................................. 39
Inspect .................................................................................................................................................................. 39
Install .................................................................................................................................................................... 39
3.10 Coolant Pump................................................................................................................... .................................... 40
Remove ................................................................................................................................................................. 40
Inspect .................................................................................................................................................................. 43
Reinstall ................................................................................................................................................................ 43
3.11 Coolant Outlet Housing ......................................................................................................... .............................. 45
Remove ................................................................................................................................................................. 45
Reinstall ................................................................................................................................................................ 46
3.12 Coolant Inlet Pipe............................................................................................................. .................................... 46
Remove ................................................................................................................................................................. 46
Install .................................................................................................................................................................... 48
3.13 Cooling Fan and Shroud Assembly ................................................................................................ ................... 48
Remove ................................................................................................................................................................. 48
Install .................................................................................................................................................................... 50
Disassemble ......................................................................................................................................................... 51
Reassemble .......................................................................................................................................................... 51
3.14 Flexible Transmission Cooler Hose .............................................................................................. ..................... 51
Replace ................................................................................................................................................................. 51
Reinstall ................................................................................................................................................................ 53
3.15 Radiator ....................................................................................................................... ......................................... 54
Remove ......................................................................................................................... ........................................ 54
Reinstall ................................................................................................................................................................ 56
Radiator Repair Procedure...................................................................................................... ............................ 57
Repairable Leaks ............................................................................................................................................. 57
Repair Method.................................................................................................................................................. 58
Tube Blocking................................................................................................................................................... 58
Header Repair .................................................................................................................. ................................ 58
General Core Repair ............................................................................................................ ............................ 59
Transmission Oil Cooler Leak Test .............................................................................................. .................... 60
Transmission Oil Cooler Seal Replacement. ...................................................................................... .............. 60
4 Engine Cooling System Diagnosis .....................................................................................................61
4.1 Poor Heater Operation......................................................................................................................................... 61
4.2 Leaking Cylinder Head Gasket ................................................................................................... ........................ 61
4.3 Question the Customer ....................................................................................................................................... 61
4.4 Diagnostic Chart .................................................................................................................................................. 61
4.5 Problems Not Requiring Disassembly of Cooling System ........................................................................... .... 63
4.6 Problems Requiring Disassembly of Cooling System ...................................................................................... 63
4.7 Black Light and Dye Leak Diagnosis Method .................................................................................................... 63
5 Specifications .......................................................................................................................................64
6 Torque Wrench Specifications................................................................................................... .........66
7 Special Tools ........................................................................................................................................67

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Engine Cooling – V6 Engine Page 6B1–38

Install

Always wear protective safety glasses when
working with spring-loaded devices. Failure to
do so could result in eye injury.
1 Install the thermostat into the housing (reverse to removal procedure).
2 Ensure that the engine block and thermostat housing mating surfaces are clean and dry.
3 Install a new gasket to the thermostat housing.
4 Install the thermostat housing to the engine block and secure with the attaching bolts (with rubber grommets installed). Tighten all bolts to the correct torque specification.
Thermostat housing to engine
block bolt torque specification ..............................10 N.m
5 Ensure that the heater pipe assembly and thermostat housing mating surfaces are clean and dry.
6 Install new O-rings to the heater pipe assembly.
7 Install heater pipe assembly to thermostat housing and secure with the attaching bolts. Tighten all bolts to the correct torque specification.
Heater pipe assembly to thermostat
housing bolt torque specification ..........................10 N.m
8 Install heater pipe assembly to right-hand cylinder head bolt. Tighten bolt to the correct torque specification. Heater pipe assembly to cylinder
head bolt torque specification ..............................35 N.m

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
9 Reinstall the engine wiring harness, securing the rear harness former to the rear of the engine with the two retaining bolts, tightened to the correct torque specification.
Rear engine harness former
retaining bolts torque specification .......................15 N.m
10 Reinstall the left side engine harness former to the two locating pegs, then push inward to secure.
11 Reinstall the bolt securing the engine harness ground terminal, to the left side of the cylinder block and tighten to the correct torque specification.
Engine harness ground terminal
attaching bolt torque specification ........................12 N.m
12 Reinstall each wiring harness connector to its correct location, ensuring that all security clips are installed correctly.
13 Connect the heater hoses to the heater pipe assembly.
14 Install the coolant inlet pipe. Refer to 3.12 Coolant Inlet Pipe in this Section.
15 Close the radiator drain tap on the lower LHS of the radiator and remove the piece of rubber tubing to the tap outlet.
16 Reinstall the complete intake manifold assembly. Refer to 6A1 Engine Mechanical.
17 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

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