2007 ISUZU KB P190 indicator

Engine Mechanical – V6 Page 6A1–292

6 Torque Wrench Specifications
ATTENTION
„
„„
„
Fasteners must be replaced after loosening.



Fasteners either have micro encapsulated sealant applied 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 Attaching Bolt ................................................ 20.0 – 26.0 Nm
Oil Level Indicator Tube Attaching Bolt........................................ 8.0 – 12.0 Nm
Accessory Drive Belt Idler Pulley Attaching Bolt................................... 50.0 Nm
Accessory Drive Belt Tensioner Attaching Bolt .................................... 50.0 Nm
Power Steering Reservoir Bracket Attaching Screw.............................. 9.0 Nm
Power Steering Pump Bracket Attaching 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 Cylinder Head Attaching Bolt........................ 23.0 Nm
Fuel Injector Wiring Harness Bracket Attaching bolt .............................. 9.0 Nm
Exhaust Manifold to Cylinder Head 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 Attaching Bolt ................................................... 8.0 – 12.0 Nm
Engine Ground Connector Bolt............................................................. 10.0 Nm
Engine Wiring Harness Former Attaching Bolt .......................... 12.0 – 16.0 Nm
„ Crankshaft Balancer Assembly Attaching Bolt:
Stage 1 ..................................................................................... 90.0 –110.0 Nm
Stage 2 ....................................................................................................... 150 °
Engine Front Cover Assembly Attaching Bolt ............................ 20.0 – 26.0 Nm
Camshaft Intermediate Driveshaft Sprocket Attaching Bolt ....... 58.0 – 72.0 Nm
Secondary Timing Chain Guide Attaching Bolt.......................... 20.0 – 26.0 Nm
Secondary Timing Chain Shoe Attaching Bolt ........................... 20.0 – 26.0 Nm
Secondary Timing Chain Tensioner Attaching Bolt ................... 20.0 – 26.0 Nm
Primary Timing Chain Upper Guide Attaching Bolt.................... 20.0 – 26.0 Nm
Primary Timing Chain Tensioner Attaching Bolt ........................ 20.0 – 26.0 Nm
Oil Pump Assembly Attaching Bolt ............................................ 20.0 – 26.0 Nm
Camshaft Sprocket Attaching Bolt ............................................. 49.0 – 67.0 Nm
Exhaust Camshaft Sprocket Attaching Bolt ............................... 49.0 – 67.0 Nm
Camshaft Bearing Cap Attaching Bolt ......................................... 8.0 – 12.0 Nm
Cylinder Head Threaded 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 Block Attaching Bolt ............ 43.0 – 57.0 Nm
Engine Mount to Bracket Attaching Nut ..................................... 70.0 – 90.0 Nm
Engine Mount to Frame Attaching Nut....................................... 44.0 – 60.0 Nm
Engine Lift Bracket Attaching Bolt .......................................... 58.0 – 72.0.0 Nm
Knock Sensor Attaching Nut................................................................. 23.0 Nm

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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

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–46
Page 6A1–46
2.16 Cylinder Leakage Test
A leakage test may be performed to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate
one or more of the following:
• worn or burnt valves,
• broken valve springs,
• stuck valve lifters,
• incorrect valve lash/adjustment,
• damaged piston,
• worn piston rings,
• worn or scored cylinder bore,
• damaged cylinder head gasket,
• cracked or damaged cylinder head, or
• cracked or damaged engine block.

1 Disconnect the battery ground negative cable.
2 Remove the spark plugs from all cylinders, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
3 Rotate the crankshaft to place the piston in the cyli nder being tested at top dead centre (TDC) of the compression
stroke.
4 Install a commercially available cylinder head leak down tester into the spark plug hole.
NOTE
If required, hold the crankshaft balancer bolt to
prevent the engine from rotating.
5 Apply shop air pressure to the cylinder head leak dow n tester and adjust according to the manufacturers
instructions.
6 Record the cylinder leakage value. Cylinder leakage t hat exceeds 25 percent is considered excessive and may
require component service. In excessive leakage situations, inspect for the following conditions:
• air leakage sounds at the throttle body or air inlet duct that may indicate a worn or burnt intake valve or a
broken valve spring,
• air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken
valve spring,
• air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston
rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder
head, or
• air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7 Perform the leakage test on the rema ining cylinders and record the values.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–47
Page 6A1–47
2.17 Engine Oil Consumption Diagnosis
Definition
Excessive oil consumption (not due to leaks) is the use of 3 litres or more of engine oil within 10,000 kilometres. Prior to
performing oil pressure testing, a prelim inary inspection of the vehicle should be performed. During the preliminary visual
inspection, the following likely causes of excessive oil usage should be investigated.
Cause Correction
External oil leaks. Refer to 2.18 Engine Oil Leak Diagnosis.
Incorrect oil level or reading of the oil level indicator. C heck for the correct oil level, refer to 3.1 Engine Oil.
Incorrect oil viscosity.
Replace the engine oil, using the recommended SAE grade
of engine oil, refer to 3.1 Engine Oil.
Continuous high-speed driving or severe usage. Service vehicle more frequently, refer to 0B Lubrication and
Service.
Crankcase ventilation system restricted or malfunctioning. Repair or replace crankcase ventilation system components
as required, refer to 6C1-3 Engine Management – V6 –
Service Operations.
Worn valve guides and or valve stems. Inspect and repair valves and valve guides as required,
refer to 3.22 Cylinder Head Assembly.
Worn or damaged valve stem oil seal. Replace valve stem oil seals as required, refer to 3.22
Cylinder Head Assembly.
Piston rings broken, worn or not seated correctly. Allowing adequate time for the piston rings to seat correctly,
replace piston rings as required, refer to 4.5 Pistons, Pins,
Rings, Connecting Rods and Big-end Bearings.
Piston rings incorrectly installed or not matched to cylinder
bore oversize. Replace piston rings as required, refer to 4.5 Pistons, Pins,
Rings, Connecting Rods and Big-end Bearings.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–66
Page 6A1–66
3 Minor Service Operations
ATTENTION
The V6 engine is a combination of numerous components, containing machined, honed, polished and lapped
surfaces manufactured on the latest, high technology production equipment. Many of the components
contain tolerances measured in thousa ndths of a millimetre. Consequently, when any e ngine component is to
be serviced, care and cleanliness are extremely important.
Prior to re-assembly of the engine, all components mu st be cleaned and inspected in accordance with the
relevant clean and inspect procedur es throughout this Section, and repl aced or repaired where required.
In addition to cleaning and inspecting components, a liberal coating of engine oil should be applied to friction
surfaces during assembly to protect and lubr icate the surfaces on initial operation.
When performing any service operation, it should be understood that correct cleaning and protection of
machined surfaces and friction areas is part of the repair procedure. This is considered standard workshop
practice, even if not specifically stated. Torque va lues must be used as specified during reassembly to
ensure correct retention of all components.
Through out this section, fastener torque wrench sp ecifications may be accompanied with the following
identification marks:
■ 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.
If one of these identification marks is present alongs ide a fastener torque wrench specification, the
recommendation regarding that fastener must be adhered to.
3.1 Engine Oil
The procedure outlined below is typically the same for both rear wheel drive and all wheel drive vehicles.
Check
The following procedure is applicable to both rear wheel and all wheel drive vehicles
1 Run the engine to bring it to normal operating temperature.
2 Park the vehicle on a level surface. A vehicle that is not level will affect the accuracy of the level reading.
3 Stop the engine and wait 5 to 10 minutes to a llow the oil to drain back into the oil pan.
4 Remove the oil level indicator (1) and wipe clean.
5 Insert the indicator, ens uring it is fully seated.
6 Slowly remove the indicator to avoid smearing. Hold it horizontally or with lower end slightly down to avoid
oil running along indicator.
7 Observe the oil level where it passes over the centre
line of the indicator.
8 If the level is lower than the Add mark (2), add enough oil to the engine to reach the Upper mark (3).
Do not add too much oil as the reading should never
be above the Upper mark.
NOTE
When topping up the oil, allow approximately 5
to 10 minutes for the added oil to fully drain into
the oil pan.
Figure 6A1 – 23

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–71
Page 6A1–71
3.4 Oil Level Indicator Tube
Remove
1 Remove the oil level indicator from the oil level indicator tube.
2 Remove the bolt (2) attaching the oil level indicator tube (1) and engine wiring harness retaining bracket.
3 Withdraw the oil level indi cator tube from the oil pan.
4 Remove and discard the o-ring at the bottom of the oil level indicator tube.
Figure 6A1 – 28
Reinstall
Reinstallation of the oil level indicator tube is the reverse of the removal procedure, noting the following:
1 Install a new oil level indicator o-ring.
2 Ensure the attaching bolt passes through the engine wiring harness retaining bracket.
3 Tighten bolt to the correct torque specification.
Oil level indicator tube attaching bolt
torque specificatio n ................................... 8. 0 – 12.0 Nm


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–91
Page 6A1–91
3.11 Exhaust Manifold Assembly
Remove

Allow the engine to cool before commencing.

Disconnection of the battery affects
certain vehicle electronic systems, refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Disconnect the battery negative terminal.
2 Remove the oxygen sensor harness connector (1) from the retaining bracket.
3 Disconnect the oxygen sensor wiring harness connector from the engine wiring harness connector
(2).
4 Unclip the oxygen sensor wiring harness retaining clip and move aside.
5 For the left-hand side: Remove the oil level indicator tube.
6 Raise the front of the vehicle and place on stands,
refer to Section 0A General Information .
7 Working from under the vehicle, remove the two exhaust manifold to exhaust pipe flange nuts, refer to
Section 6F Exhaust System - V6 .
Figure 6A1 – 56
8 Remove the three bolts attaching the exhaust manifold outer heat shield (1) to the exhaust manifold
(2).

Figure 6A1 – 57

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–206
Page 6A1–206
4 Measure the camshaft runout using a dial
indicator (1).


Figure 6A1 – 339
5 Measure the camshaft thrust width for wear using a depth micrometer (A).


Figure 6A1 – 340
6 Measure the camshaft thrust wall surface for runout using a dial indicator (1).


Figure 6A1 – 341

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ISUZU KB P190 2007