2007 ISUZU KB P190 engine mount

Engine Mechanical – V6 Page 6A1–71

11 Disconnect the fuel feed hose from the fuel rail (1).
12 Pull out the release bar (2) (broad arrow) of the fuel injector harness wiring connector (3).
13 Disconnect the fuel injector harness wiring connector from the fuel injector wiring harness (4).


Plug the fuel feed hose opening after
removal to prevent dirt and other
contaminants from entering the fuel system.
Figure 6A1 – 48
14 Remove the wiring harness connector (2) from the EVAP valve (1).
15 Disconnect the quick connect (3) from the rear of the EVAP valve, as follows:
a Squeeze the two barbed lugs together, push the quick connect into the valve, then pull out to separate the
connection.
b Plug both open ends to prevent the entry of foreign matter.

Figure 6A1 – 49
16 Remove the bolt (3) attaching the EVAP valve and the fuel injector wiring harness connector mounting
bracket to the upper intake manifold assembly.
17 Move the EVAP valve and the fuel injector wiring harness connector mounting bracket clear of the
upper intake manifold assembly.
18 Disconnect the PCV fresh air tube (1) from its upper intake manifold mounting clip (2).
Figure 6A1 –
––
–
50

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–77

12 Remove the three bolts (1), attaching the exhaust
manifold inner heat shield to the exhaust manifold.

13 Using a suitable commercially available non-corrosive cleaning solvent and a soft bristled parts cleaning
brush, thoroughly clean the exhaust manifold.
14 Dry the exhaust manifold using compressed air.

Safety glasses must be worn when using
compressed air.
Figure 6A1 – 59
NOTE
• The same procedure applies to the Right-
hand exhaust manifold.

• To gain access to the lower rear exhaust
manifold attaching bolts (2), apply a slight
downward movement to the coolant inlet
pipe (1).

Inspect
Inspect the exhaust manifold (1) for the following:
• Damage to the threaded holes for the heat shield
mounting.
• Damage to the exhaust manifold mounting holes.
• Damage to the threads of the exhaust manifold to
exhaust pipe flange studs.
• Damage to the gasket sealing surfaces.
• Using a straight edge (2) and feeler gauges (3), check
the cylinder head mounting face of the exhaust
manifold does not exceed the maximum distortion
specification of 0.25mm.
NOTE
If the surface flatness is not within
specifications, the exhaust manifold is warped
and must be replaced.
Figure 6A1 – 60
Reinstall
Reinstallation of the exhaust manifold assembly is the reverse of the removal procedure, noting the following:
1 Ensure the exhaust manifold, cylinder head and exhaust pipe flange surfaces are clean.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–78

2 Position a new exhaust manifold gasket onto the exhaust manifold.
3 Apply a 5 mm bead of Loctite 272 thread sealant (or equivalent) to the threads of the exhaust manifold attaching bolts.
4 Install the bolts into the exhaust manifold. This will prevent the gasket from falling off the manifold.
5 Manoeuvre the exhaust manifold into position and install the exhaust manifold attaching bolts.
6 From underneath the vehicle install the exhaust manifold to exhaust pipe flange nuts.
7 Tighten the exhaust manifold attaching bolts to the correct torque specification.
NOTE
When tightening the exhaust manifold to cylinder
head attaching bolts, begin with the centre bolts,
then alternate from side to side to the outer bolts.
Exhaust manifold to cylinder head
attaching bolt torque specification ...........17.0 – 23.0 Nm
8 Apply an anti seize compound such as Caltex Kopr-Kote (or equivalent) to the cleaned heat shield bolt threads. Install the heat shield attaching bolts and tighten to the correct torque specification.
Exhaust manifold heat shield attaching
bolt torque specification ............................8.0 – 12.0 Nm
9 For the right-hand side, install the battery harness ground cable attaching nut through the ground terminal and lower coolant tube mounting lug, and tighten to the correct torque specification.
Battery harness ground terminal
attaching nut torque specification.......................13.0 Nm

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–87

3.14 Crankshaft Front Seal
Replace
1 Remove the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
2 Using a flat bladed tool (2) or seal remover, Tool No. E-308, carefully remove the crankshaft front seal (1)
from the front cover.
Figure 6A1 – 81
3 Using crankshaft front seal installer, Tool No. J-29184 (2) and a suitable hammer, install a new crankshaft
front seal (1) until fully seated against the front cover
housing.
4 Install the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
CAUTION
Do not lubricate the crankshaft front oil seal
or crankshaft balancer sealing surfaces. The
crankshaft balancer is installed into a dry
seal.
Figure 6A1 – 82
3.15 Front Cover Assembly
Remove
1 Drain the engine coolant, refer to 6B1_Engine Cooling.
2 Remove the water outlet pipe and coolant pump assembly, refer to 6B1_ Engine Cooling:
3 Remove the camshaft covers, refer to 3.12 Camshaft Cover.
4 Remove the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
5 Disconnect the purge vent hose from the water outlet pipe.
NOTE
Do not disconnect the power steering pipes or
drain the power steering fluid.
6 Remove the power steering pump reservoir mounting bracket, refer to 3.8 Power Steering Pump Bracket.
7 Remove the camshaft position sensor, refer to 6C1-3 Engine Management – V6 – Service Operations.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–98

9 Remove the right-hand secondary 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 – 106
10 Remove the tensioner gasket (1) from the tensioner (2) and discard the gasket.
11 Inspect the tensioner mounting surface on the right- hand cylinder head for burrs or any defects that would
affect the sealing of a new tensioner gasket.
Figure 6A1 – 107
12 Remove the right-hand secondary timing chain shoe bolt (1).
Figure 6A1 – 108

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–100

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 – 112
3 Remove the gasket (1) from the tensioner (2) and discard the gasket.
4 Inspect the primary timing chain tensioner mounting surface on the engine block for burrs or any defects
that would affect the sealing of a new tensioner
gasket.

Figure 6A1 – 113
5 Remove the two primary timing chain upper guide bolts (1) and remove the guide (2).

Figure 6A1 – 114

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–102

8 If required, remove the crankshaft sprocket (1) from
the crankshaft (2).
Figure 6A1 – 118
Left-hand Secondary Timing Chain
1 Remove the primary timing chain, refer to Primary Timing Chain in this Section.
2 Remove the two left-hand secondary 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 – 119
3 Remove the gasket (1) from the tensioner (2) and discard the gasket.
4 Inspect the tensioner mounting surface on the left- hand cylinder head for burrs or any defects that would
affect the sealing of a new tensioner gasket.

Figure 6A1 – 120

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–118

21 Install the left-hand secondary timing chain shoe
bolt (1) and tighten to the correct torque specification.


NOTE
Ensure secondary timing chain shoe is clear of
the left-hand secondary timing chain tensioner
mounting pad, before tightening the attaching
bolt.
Secondary timing chain shoe attaching
bolt torque specification ..........................20.0 – 26.0 Nm

Figure 6A1 – 158
22 Ensure the left-hand secondary timing chain tensioner is selected and orientated correctly.

Figure 6A1 – 159
23 Reset the left-hand secondary timing chain tensioner.

NOTE
To reset the tensioner, use a suitably sized flat
blade screwdriver (1) or Tool No. J 45027 (4) to
wind the plunger in a clockwise direction, into
the tensioner shaft (2).

Figure 6A1 – 160

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ISUZU KB P190 2007