check engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–221

7 Remove connecting rod guide pin set, Tool No.
EN-46121 (1) from the connecting rod bolt holes.
Figure 6A1 – 406
Connecting Rod Bearing Clearance Measurement Procedure
NOTE
Before final assembly, check the clearance of the
new connecting rod bearings.
1 Place a length of fresh, room temperature plastic gauging material all the way across the connecting
rod bearing journal.
2 Install the connecting rod bearing into the connecting rod cap.
3 Install the connecting rod end cap (1) on its original connecting rod and ensure the bearing lock tangs are
aligned on the same side of the rod.
Figure 6A1 – 407
NOTE
Reuse the old connecting rod bolts only for
measuring the connecting rod bearing clearance.
4 Install the connecting rod cap bolts into the connecting rod cap and tighten to the correct torque specification using torque angle wrench, Tool No. EN-7115.
Connecting rod cap attaching
bolt torque specification:
Stage 1 .........................30.0 Nm
Stage 2 ........ Loosen completely
Stage 3 .........................25.0 Nm
Stage 4 .................. 110 degrees
5 Allow the assembly to sit for at least 2 minutes.
6 Remove the connecting rod cap bolts and discard.
7 Remove the connecting rod cap.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–296

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 W rench
Used to accurately tighten fasteners when an angle torque is
required.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–2
Page 6A1–2
Visual / Physical Inspection ................................................................................................... .............................31
Intermittent ................................................................................................................... ........................................31
2.3 Engine Misfire without In ternal Engine Noises .................................................................................. ...............32
2.4 Engine Misfire with Abnormal In ternal Lower Engine Noises...................................................................... ....34
2.5 Engine Misfire with Abno rmal Valve Train Noise ................................................................................. .............35
2.6 Engine Misfire with Coolant Consumption ........................................................................................ ................36
2.7 Engine Misfire with E xcessive Oil Consumption .................................................................................. ............37
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds ....................................................................... .....38
2.9 Upper Engine Noise, Rega rdless of Engine Speed................................................................................. ..........39
2.10 Lower Engine Noise, Rega rdless of Engine Speed ................................................................................. .........40
2.11 Engine Noise Under Load ................................................................................................................................... 41
2.12 Engine Will Not Crank – Crankshaft Will Not Rotate ............................................................................. ...........42
2.13 Coolant in Com bustion Chamber .................................................................................................. .....................43
Definition ..................................................................................................................... .........................................43
2.14 Coolant in Engine Oil........................................................................................................................................... 44
Definition ..............................................................................................................................................................44
2.15 Engine Compression Test........................................................................................................ ...........................45
Preliminary Steps................................................................................................................................................. 45
Engine Cylinder Compression Test ............................................................................................... ....................45
Test Result Evaluation ......................................................................................................... ...............................45
2.16 Cylinder Leakage Test .......................................................................................................... ...............................46
2.17 Engine Oil Consumption Diagnosis ............................................................................................... ....................47
Definition ..................................................................................................................... .........................................47
2.18 Engine Oil Leak Diagnosis .................................................................................................................................. 48
Introduction ..........................................................................................................................................................48
Locating and Identifying the Leak .............................................................................................. ........................48
Visual Inspection .............................................................................................................. ...................................48
Powder Method .................................................................................................................. ..................................48
Black Light and Dye Method ............................................................................................................................... 48
Possible Causes for Engine Oil Leaks ........................................................................................... ....................49
2.19 Engine Oil Pressu re Diagnosis .................................................................................................. .........................50
2.20 Accessory Drive Belt Diagnosis ................................................................................................. ........................51
Tension Check .................................................................................................................. ...................................51
Inspect ........................................................................................................................ ..........................................52
Drive Belt Chirp .................................................................................................................................................... 53
Definition ..................................................................................................................... .....................................53
Diagnostic Aids................................................................................................................................................. 53
Test Description ............................................................................................................... ................................53
Diagnostic Table............................................................................................................... ................................54
Drive Belt Squeal .............................................................................................................. ...................................55
Definition ..................................................................................................................... .....................................55
Diagnostic Aids................................................................................................................................................. 55
Test Description ............................................................................................................... ................................55
Diagnostic Table............................................................................................................... ................................55
Drive Belt Whine .................................................................................................................................................. 57
Definition ..................................................................................................................... .....................................57
Diagnostic Aids................................................................................................................................................. 57
Test Description ............................................................................................................... ................................57
Diagnostic Table............................................................................................................... ................................57
Drive Belt Rumble .............................................................................................................. ..................................58
Definition ..................................................................................................................... .....................................58
Diagnostic Aids................................................................................................................................................. 58
Test Description ............................................................................................................... ................................58
Diagnostic Table............................................................................................................... ................................58
Drive Belt Vibration........................................................................................................... ...................................60
Definition ..................................................................................................................... .....................................60
Diagnostic Aids................................................................................................................................................. 60
Test Description ............................................................................................................... ................................60
Diagnostic Table............................................................................................................... ................................60
Drive Belt Falls Off ........................................................................................................... ....................................62

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–3
Page 6A1–3
Definition ..................................................................................................................... .....................................62
Diagnostic Aids................................................................................................................................................. 62
Test Description ............................................................................................................... ................................62
Diagnostic Table............................................................................................................... ................................62
Drive Belt Excessive Wear ...................................................................................................... ............................64
Definition ..................................................................................................................... .....................................64
Diagnostic Aids................................................................................................................................................. 64
Test Description ............................................................................................................... ................................64
Diagnostic Table............................................................................................................... ................................64
Accessory Drive Belt Tensioner Diagnosis ....................................................................................... ................65
Diagnostic Table............................................................................................................... ................................65
3 Minor Service Operations ....................................................................................................... .............66
3.1 Engine Oil ..................................................................................................................... ........................................66
Check.................................................................................................................................................................... 66
Replace ........................................................................................................................ .........................................67
Pressure Check ................................................................................................................. ...................................68
3.2 Oil Filter Cartridge ........................................................................................................... ....................................69
Replace ........................................................................................................................ .........................................69
3.3 Oil Filter Adaptor............................................................................................................. .....................................70
Remove ................................................................................................................................................................. 70
Reinstall ................................................................................................................................................................ 70
3.4 Oil Level Indicator Tube ...................................................................................................................................... 71
Remove ................................................................................................................................................................. 71
Reinstall ................................................................................................................................................................ 71
3.5 Accessory Drive Belt ........................................................................................................................................... 72
RWD Vehicle ......................................................................................................................................................... 72
Remove ............................................................................................................................................................72
Reinstall ...................................................................................................................... .....................................73
3.6 Accessory Drive Belt Idler Pulley .............................................................................................. .........................74
Remove ................................................................................................................................................................. 74
Reinstall ................................................................................................................................................................ 74
3.7 Accessory Drive Belt Tensioner Assembly ........................................................................................ ...............75
Remove ................................................................................................................................................................. 75
Reinstall ................................................................................................................................................................ 75
3.8 Power Steering Pump Bracket .................................................................................................... ........................76
Remove ................................................................................................................................................................. 76
Reinstall ................................................................................................................................................................ 76
3.9 Upper Intake Manifold .......................................................................................................... ...............................77
Remove ................................................................................................................................................................. 77
Disassemble ......................................................................................................................................................... 80
Clean..................................................................................................................................................................... 80
Inspect ........................................................................................................................ ..........................................81
Reassemble .......................................................................................................................................................... 81
Reinstall ................................................................................................................................................................ 82
3.10 Intake Manifold Assembly – Complete............................................................................................ ...................83
Remove ................................................................................................................................................................. 83
Disassemble ......................................................................................................................................................... 87
Clean..................................................................................................................................................................... 88
Inspect ........................................................................................................................ ..........................................88
Reassemble .......................................................................................................................................................... 89
Reinstall ................................................................................................................................................................ 89
3.11 Exhaust Manifold Assembly ...................................................................................................... .........................91
Remove ................................................................................................................................................................. 91
Inspect ........................................................................................................................ ..........................................93
Reinstall ................................................................................................................................................................ 93
3.12 Camshaft Cover ................................................................................................................. ..................................94
Remove ................................................................................................................................................................. 94
Clean and Inspect .............................................................................................................. ..................................96

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–15
Page 6A1–15
Cylinder Head Assembly

Figure 6A1 – 7
Legend
1 Cylinder Head, Left-hand
2 Cylinder Head, Right-hand
3 Cylinder Head Gasket, Left-hand
4 Cylinder Head Gasket, Right-hand
5 Cylinder Head Bolt
6 Cylinder Head Front Bolt
7 Cylinder Head Coolant Hole Threaded Plug
8 Spark Plug Sleeve
9 Cylinder Head Oil Gallery Expansion Plug
10 Exhaust Valve
11 Intake Valve
12 Valve Rocker Arm Assembly
13 Hydraulic Valve Lash Adjuster Assembly
14 Valve Stem Oil Seal 15 Valve Spring
16 Valve Spring Cap
17 Valve Stem Key
18 Cylinder Head Camshaft Front Thrust Bearing Cap
19 Camshaft Oil Seal Ring
20 Exhaust Camshaft
21 Intake Camshaft, Left-hand (bank 2)
22 Intake Camshaft, Right-hand (bank 1)
23 Exhaust Camshaft, Right-hand (bank 1)
24 Cylinder Head Camshaft Cap – Intermediate
25 Cylinder Head Camshaft Cap Bolt
26 Cylinder Head Oil Galley Check Valve
27 Engine Coolant Temperature Sensor

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–31
Page 6A1–31
2.2 Symptoms
Strategy Based Diagnosis
1 Review the system operations to familiarise yourself with the system functions, refer to 1 General Information and
6C1-1 Engine Management General Information.
2 Perform an engine management Diagnostic System Check, refer to Section 6C1-2 Engine Management – V6 –
Diagnostics .
All diagnosis on a vehicle should follow a logical process. Strategy based diagnosis is a uniform approach for repairing
all vehicle systems. The strategy based diagnostic flow chart may always be used to resolve a system problem. The
diagnostic flow chart is the place to start when repairs are required. For a detailed explanation of strategy based
diagnosis and the flow chart, refer to Section 6C1-2 Engine Management – V6 – Diagnostics .
Visual / Physical Inspection
1 Inspect the vehicle for aftermarket accessories which may adversely affect engine operation.
2 Inspect the easily accessible or visible system components for obvious signs of damage or conditions that may cause the symptom.
3 Check the engine lubrication system for the following:
• correct oil level,
• correct lubricant viscosity,
• correct oil filter application, and
• contaminated or burnt oil.
4 Confirm the exact operating conditions under whic h the fault occurs. Note factors such as:
• engine speed (r.p.m.),
• ambient temperature,
• engine temperature,
• engine warm-up time, and
• vehicle road speed.
5 Compare the engine sounds, if applic able, to a known good engine, and ensure you are not trying to diagnose a
normal operating condition.
Intermittent
For intermittent faults, test the vehicle under the same conditions the customer reported in order to confirm whether the
system is operating correctly.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–32
Page 6A1–32
2.3 Engine Misfire without Internal Engine
Noises
Cause Correction
Abnormalities, severe cracking, bumps or missing areas in
the accessory drive belt.
Abnormalities in the accessory drive system and/or
components may cause engine speed variations that result
in a misfire diagnostic trouble code (DTC). A misfire code
may be present without an ac tual misfire condition. Replace the accessory drive belt, refer to 3.5 Accessory
Drive Belt.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs.
Worn, damaged or misaligned accessory drive components
and excessive pulley run-out may lead to a misfire DTC.
A misfire code may be present without an actual misfire
condition. Inspect the components and repair or replace as required.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs.
Loose or incorrectly fitted flexplate or crankshaft balancer
assembly.
A misfire DTC may be present without an actual misfire
condition. Repair or replace the flexplat
e or crankshaft balancer as
required, refer to 3.13 Crankshaft Balancer Assembly or
4.3 Flexplate Assembly.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs
Restricted exhaust system.
A severe restriction in the exhaust flow can cause
significant loss of engine performance and may set a DTC.
Possible causes of restrict ions in the exhaust system
include collapsed/dented pipes and blocked mufflers and/or
catalytic converters. Repair or replace exhaust syst
em components as required,
refer to 8B Exhaust System.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs
Incorrectly installed or damaged vacuum hoses. Repair or replace vacuum hoses as required.
Incorrect sealing between the intake manifold and cylinder
heads, upper intake manifold and lower intake manifold,
throttle body and intake manifold. Repair or replace the intake
manifold, throttle body gaskets,
cylinder heads, throttle body as required.
Incorrectly installed or damaged barometric
pressure(BARO) sensor and/or seal. The seal should not
be torn or damaged. Repair or replace the BARO sensor and/or seal as
required, refer to 6C1-3 Engine Management – V6 –
Service Operations.
Incorrectly installed or damaged EVAP purge solenoid
and/or O-ring seal. Repair or replace the EVAP purge solenoid and/or seal as
required, refer to 6C1-3 Engine Management – V6 –
Service Operations
Worn or loose stationary hydraulic lash adjusters (SHLA)
and/or rocker arms.
The SHLAs, rocker arms and roller bearings should be
intact and in the correct position. Replace the SHLAs and/or rocker arms as required, refer to
3.21 Stationary Hydraulic Las h Adjuster or 3.20 Rocker
Arm.
Stuck valves.
Carbon build up on the valve stem s can result in the valves
not closing correctly. Repair or replace as required, refer to 3.22 Cylinder Head
Assembly.
Excessively worn or misaligned timing chain/s. Replace the timing chain/s and components as required,
refer to 3.16 Timing Chains, Tensioners, Shoes and
Guides.
Worn camshaft lobes. Replace the camshaft/s and SHLAs as required, refer to
3.19 Camshaft or 3.21 Stati onary Hydraulic Lash Adjuster.
Excessive oil pressure.
A lubrication system with ex cessive oil pressure may lead
to excessive lash adjuster pump-up and loss of
compression. 1 Perform an oil pressure tes
t, refer to 3.1 Engine Oil.
2 Repair or replace the engine oil pump as required, refer to 3.17 Oil Pump Assembly.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–33
Page 6A1–33
Cause Correction
Faulty cylinder head gasket and/or cracking or other
damage to the cylinder head and cylinder block coolant
passages.
Coolant consumption may or may not cause the engine to
overheat. 1 Inspect the spark plugs for
coolant saturation, refer to
6C1-3 Engine Management – V6 – Service
Operations.
2 Inspect the cylinder heads, cylinder block and/or head gaskets, refer to 3.22 Cylinder Head Assembly
and/or 4.7 Cylinder Block.
3 Repair or replace components as required.
Worn piston rings.
Oil consumption may or ma y not cause the engine to
misfire. 1 Inspect the spark plugs for oil deposits, refer to 6C1-3
Engine Management – V6 – Service Operations.
2 Check the cylinders for a loss of compression, refer to 2.15 Engine Compression Test.
3 Perform compression testing to identify the cause of
low compression.
4 Repair or replace components as required.
A damaged crankshaft reluctor wheel.
A damaged crankshaft reluctor wheel can result in different
symptoms depending on the severity and location of the
damage.
Systems with severe relu ctor ring damage may exhibit
periodic loss of crankshaft posit ion, stop delivering a signal,
and then re-sync the crankshaft position.
Systems with slight reluctor ring damage may exhibit no
loss of crankshaft position and no misfire may occur,
however, a DTC may set. Replace the crankshaft as required, refer to 4.6 Crankshaft
and Main Bearings.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–34
Page 6A1–34
2.4 Engine Misfire with Abnormal Internal
Lower Engine Noises
Cause Correction
Abnormalities, severe cracking, bumps or missing areas in
the accessory drive belt.
Abnormalities in the accessory drive system and/or
components may cause engine speed variations that result
in a misfire diagnostic trouble code (DTC). A misfire code
may be present without an ac tual misfire condition. Replace the accessory drive belt, refer to 3.5 Accessory
Drive Belt.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs
Worn, damaged or misaligned accessory drive components
and excessive pulley run-out may lead to a misfire DTC.
A misfire code may be present without an actual misfire
condition. Inspect the components and repair or replace as required.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs
Loose or Incorrectly fitted flexplate or crankshaft balancer
assembly.
A misfire code may be present without an actual misfire
condition. Repair or replace the flexplat
e or crankshaft balancer as
required, refer to 3.13 Crankshaft Balancer Assembly or
4.3 Flexplate Assembly.
Worn or broken piston rings.
Oil consumption may or may not cause an actual misfire. 1 Inspect the spark plugs for oil deposits, refer to 6C1-3
Engine Management – V6 – Service Operations.
2 Check the cylinders for a loss of compression, refer to 2.15 Engine Compression Test.
3 Perform compression testing to identify the cause of
low compression.
4 Repair or replace components as required.
Worn crankshaft thrust bearing.
Severely worn thrust surfaces on the crankshaft and/or
thrust bearing may permit fore and aft movement of the
crankshaft and create a DTC wi thout an actual misfire
condition being present. Replace the crankshaft and/or bear
ings as required, refer to
4.6 Crankshaft and Main Bearings.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–37
Page 6A1–37
2.7 Engine Misfire with Excessive Oil
Consumption
Cause Correction
Worn valves, valve guides and/or valve stem oil seals. 1 Inspect the spark plugs for coolant saturation, refer to
6C1-3 Engine Management – V6 – Service
Operations.
2 Repair or replace components as required, refer to 3.22 Cylinder Head Assembly.
Worn or broken piston rings.
Oil consumption may or may not cause an actual misfire. 1 Inspect the spark plugs for oil deposits, refer to 6C1-3
Engine Management – V6 – Service Operations.
2 Check the cylinders for a loss of compression, refer to 2.15 Engine Compression Test.
3 Perform compression testing to identify the cause of
low compression.
4 Repair or replace components as required.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007