2007 ISUZU KB P190 Workshop Repair Manual

timing belt wiring diagram diagram brake rotor AUX jack points

Page 2505 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–26

CAUTION
Anaerobic sealed joints that are partially
tightened and allowed to cure more than five
minutes may result in incorrect shimming and
sealing of

Engine Mechanical – V6 Page 6A1–26

CAUTION
Anaerobic sealed joints that are partially
tightened and allowed to cure more than five
minutes may result in incorrect shimming and
sealing of the joint.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
• After correctly tightening the fasteners, remove the excess sealer from the outside of the joint.
Pipe Joint Compound
• Pipe joint compound is a pliable sealer that does not completely harden. This type of sealer is used where two non-
rigid parts (such as pressed steel and machined surfaces) are assembled together.
• Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include the
exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
• Follow all safety recommendations and directions that are on the container.
• To remove the sealant or the gasket material, refer to Replacing Engine Gaskets.
• Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run
the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes as it may prevent
the bolt from clamping correctly or cause component damage when the bolt is tightened.
• Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be
clean and dry.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
Separating Parts
CAUTION
Many internal engine components will
develop specific wear patterns on their
friction surfaces. When disassembling the
engine, internal components must be
separated, marked and organised in a way to
ensure reinstallation in their original location
and position.
Separate, mark, or organise the following components:
• Piston and the piston pin.
• Piston to the specific cylinder bore.
• Piston rings to the specific piston.
• Connecting rod to the crankshaft journal.
• Connecting rod to the bearing cap.
• Crankshaft main and connecting rod bearings.
• Camshaft and rocker arms.
• Rocker arms and stationary hydraulic lash adjusters to cylinder head location.
• Valve to the valve guide.
• Valve spring and shim to the cylinder head location.
• Engine block main bearing cap location and direction.
• Oil pump drive and driven gears.
Tools and Equipment
Special tools are listed and illustrated throughout this Section with a complete listing at the end, refer to 7 Special
Tools. These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations for which
they are intended. The use of these special tools will also minimise possible damage to engine components. Some
precision measuring tools are required for inspection of certain critical components. A commercially available torque
wrench and torque angle wrench, Tool No. EN-7115 are required for the correct tightening of various fasteners.
To correctly service the engine assembly, the following items should be readily available:
• Approved eye protection and safety gloves.

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Page 2506 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–27

• A clean, well-lit, work area.
• A suitable parts cleaning tank.
• A compressed air supply.
• Trays or storage containers to keep parts and fas

Engine Mechanical – V6 Page 6A1–27

• A clean, well-lit, work area.
• A suitable parts cleaning tank.
• A compressed air supply.
• Trays or storage containers to keep parts and fasteners organised.
• An adequate set of hand tools.
• Approved engine repair stand.
• An approved engine lifting device that will adequately support the weight of the components.
Fasteners
Fasteners are central to the reliable operation of an engine.
W henever any bolt or any other threaded component is
removed, allow the engine to cool (inset A) before
attempting fastener removal.
Because of the greater thermal expansion of aluminium,
bolt threads will change dimension to a greater extent when
hot with this material (inset B) when compared to cast iron.
If a bolt or other threaded component is removed before the
engine is allowed to cool to at least 50 ° C, threads could be
pulled from the cylinder block or cylinder head.
Do not use impact tools to remove bolts during engine
disassembly. W hile this may be common practice with cast
iron engine components, use of these tools is more likely to
pull the aluminium threads in the cylinder block or head of
this engine.
Figure 6A1 – 19
Clamp Load
W hen torque is applied to a fastener, the fastener stretches
and the joint compresses. The force developed in the
fastener due to its stretch is called tension (C), while the
force applied to the joint is called clamp load (B).
As shown, only a small portion of the applied torque (A) is
transferred to the clamp load (inset 1). Friction under the
bolt head (inset 3) and in the threads (inset 2) absorbs
much of the applied torque (A). Typically, only 10% (inset 1)
of the torque is available to develop stretch (or tension) in
the fastener and clamp load in the joint.
Therefore, a slight variation in friction in the thread or under
the bolt head, results in a wide variation in the clamp load
applied to the joint.
Figure 6A1 – 20
Torque Angle and Torque to Yield Fasteners
The torque angle method of applying torque to a fastener has been developed to overcome the effects of friction
variation in fastener applications.
The application of the torque angle method does not always mean the fastener has to be replaced after loosening. It is
only when the fastener has been angle tightened to the extent the yield point has been exceeded, that the fastener must
be replaced.
Examples are the main bearing caps that are angle tightened but the bolts can be re-used, whereas the M11 cylinder
head bolts that are torque to yield fasteners, must be replaced after loosening.

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Page 2507 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–28

2 Diagnosis
2.1 Engine Diagnosis
Begin engine mechanical system diagnosis by reviewing the disassembled views provided in 1.2 Engine Components
and 1.4

Engine Mechanical – V6 Page 6A1–28

2 Diagnosis
2.1 Engine Diagnosis
Begin engine mechanical system diagnosis by reviewing the disassembled views provided in 1.2 Engine Components
and 1.4 Engine Construction. Reviewing the description and operation information provided will assist in determining
whether the condition described by the customer is a fault or normal engine operation.
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 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 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 which 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 applicable, 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.

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Page 2508 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–29

2.3 Engine Misfire without Internal Engine
Noises
Cause Correction
Abnormalities, severe cracking, bumps or missing areas in
the accessory drive belt.

Engine Mechanical – V6 Page 6A1–29

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 actual 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.
W orn, 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 flexplate 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 restrictions in the exhaust system
include collapsed/dented pipes and blocked mufflers and/or
catalytic converters. Repair or replace exhaust system 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
W orn 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 Lash Adjuster or 3.20
Rocker Arm.
Stuck valves.
Carbon build up on the valve stems 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.
W orn camshaft lobes. Replace the camshaft/s and SHLAs as required, refer to
3.19 Camshaft or 3.21 Stationary Hydraulic Lash
Adjuster.
Excessive oil pressure.
A lubrication system with excessive oil pressure may lead
to excessive lash adjuster pump-up and loss of
compression. 1 Perform an oil pressure test, refer to 3.1
Engine Oil.
2 Repair or replace the engine oil pump as required, refer to 3.17 Oil Pump Assembly.

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Page 2509 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–30

Cause Correction
Faulty cylinder head gasket and/or cracking or other
damage to the cylinder head and cylinder block coolant
passages.
Coolant consumpti

Engine Mechanical – V6 Page 6A1–30

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.
W orn piston rings.
Oil consumption may or may 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 reluctor ring damage may exhibit
periodic loss of crankshaft position, 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
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 actual 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
W orn, 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 flexplate or crankshaft balancer as
required, refer to 3.13 Crankshaft Balancer Assembly
or 4.3 Flexplate Assembly.
W orn 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.
W orn 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 without an actual misfire
condition being present. Replace the crankshaft and/or bearings as required, refer to
4.6 Crankshaft and Main Bearings.
Refer to 6C1-2 Engine Management – V6 – Diagnostics to
check for DTCs

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Page 2510 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–31

2.5 Engine Misfire with Abnormal Valve
Train Noise
Cause Correction
W orn or loose stationary hydraulic lash adjusters (SHLA)
and/or valve rocker arms.

Engine Mechanical – V6 Page 6A1–31

2.5 Engine Misfire with Abnormal Valve
Train Noise
Cause Correction
W orn or loose stationary hydraulic lash adjusters (SHLA)
and/or valve rocker arms.
The SHLAs, rocker arm 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 Lash Adjuster or 3.20
Rocker Arm.
Stuck valves.
Carbon build up on the valve stems 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.
W orn camshaft lobes. Replace the camshaft/s and SHLAs as required, refer to
3.19 Camshaft or 3.21 Stationary Hydraulic Lash
Adjuster.
Sticking camshaft lash adjusters. Replace the lash adjusters as required, refer to 3.21
Stationary Hydraulic Lash Adjuster.
2.6 Engine Misfire with Coolant
Consumption
Cause Correction
Faulty cylinder head gasket and/or cracking or other
damage to the cylinder heads 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.
2.7 Engine Misfire with Excessive Oil Consumption
Cause Correction
W orn 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.
W orn 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.
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds
NOTE
A cold piston knock, which disappears in
approximately 1.5 minutes from start up, should
be considered acceptable. A cold engine knock
usually disappears when the specific cylinder’s

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Page 2511 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–32

secondary ignition circuit is grounded out during
diagnosis.
A light rattle/tapping noise may indicate a valve train/upper engine concern, while a low rumb

Page 2512 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–33

2.9 Upper Engine Noise, Regardless of
Engine Speed
NOTE
A cold piston knock, which disappears in
approximately 1.5 minutes from start up, should
be co

Engine Mechanical – V6 Page 6A1–33

2.9 Upper Engine Noise, Regardless of
Engine Speed
NOTE
A cold piston knock, which disappears in
approximately 1.5 minutes from start up, should
be considered acceptable. A cold engine knock
usually disappears when the specific cylinder’s
secondary ignition circuit is grounded out during
diagnosis.
A light rattle/tapping noise may indicate a valve train/upper engine concern, while a low rumble/knocking may indicate a
crankshaft, piston or lower engine concern.
Cause Correction
Low oil pressure. 1 Perform an oil pressure test, refer to 2.19
Engine Oil Pressure Diagnosis.
2 Repair or replace the engine oil pump as required, refer to 3.17 Oil Pump Assembly.
W orn or loose stationary hydraulic lash adjusters (SHLA)
and/or valve rocker arms.
The SHLAs, rocker arm and roller bearings should be intact
and in the correct position. 1 Clean, inspect and replace the camshaft lash
adjusters as required, refer to 3.21 Stationary
Hydraulic Lash Adjuster.
2 Replace the SHLAs and/or rocker arms as required, refer to 3.21 Stationary Hydraulic Lash Adjuster or
3.20 Rocker Arm.
Incorrect lubrication to the stationary hydraulic lash
adjusters and valve rocker arm. Inspect the following components and repair or replace as
required:
• valve rocker arms, refer to 3.20 Rocker Arm.
• stationary hydraulic lash adjusters, refer to 3.21
Stationary Hydraulic Lash Adjuster.
• oil filter by-pass valve, refer to 3.3 Oil Filter
Adaptor.
• oil pump and suction pipe, refer to 3.17 Oil Pump
Assembly.
• cylinder head oil galleries, refer to 3.22 Cylinder Head
Assembly.
• cylinder block oil galleries, refer to 4.7 Cylinder
Block.
Broken Valve Spring. Replace the valve spring, refer to 3.22 Cylinder Head
Assembly.
Stretched or broken timing chain/s and/or damaged timing
chain sprocket teeth. Replace the timing chains or sprockets as required, refer to
3.16 Timing Chains, Tensioners, Shoes and Guides.
W orn or faulty timing chain tensioner or guide. Replace the timing chains or sprockets as required, refer to
3.16 Timing Chains, Tensioners, Shoes and Guides.
W orn camshaft lobes. Replace the camshaft/s and SHLAs as required, refer to
3.19 Camshaft or 3.21 Stationary Hydraulic Lash
Adjuster.
W orn valve guides and/or valve stems. Inspect and repair or replace valves and valve guides as
required, refer to 3.22 Cylinder Head Assembly.
Stuck valves.
Carbon on the valve stem or valve seat may cause the
valve to stay open. Inspect and repair or replace valves and valve guides as
required, refer to 3.22 Cylinder Head Assembly.

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