2007 ISUZU KB P190 Workshop Repair Manual

spark plugs replace OBD port child lock service schedule oil capacities hood release

Page 2777 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–298

Tool Number Illustration Description
J-45027
Tensioner Tool
Used to reset the timing chain tensioner plunger.
J-6125-1B
Slide Hammer
Used in conjun

Page 2778 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–1
Page 6A1–1
Section 6A1
Engine Mechanical – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to

Engine Mechanical – V6 Page 6A1–1
Page 6A1–1
Section 6A1
Engine Mechanical – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.1 WARNING,
CAUTION and NOTES for correct workshop practices with regard to safety and/or property damage.
1 General Information ............................................................................................................ ...................8
MY06 Update .................................................................................................................... ......................................8
1.1 WARNING, CAUTION and NOTES .................................................................................................... ...................8
Definition of WARNING, CAUT ION and NOTE Statements ............................................................................. ....8
WARNING defined ................................................................................................................ .............................8
CAUTION defined ................................................................................................................ ..............................8
NOTE defined................................................................................................................... ..................................9
1.2 Engine Components .............................................................................................................. ..............................10
Major Component Assemblies............................................................................................................................ 10
Intake Manifold Assembly ....................................................................................................... ............................11
Engine Front Cover............................................................................................................. .................................12
Camshaft Timing Components ..................................................................................................... ......................13
Camshaft Cove r Assembly........................................................................................................ ..........................14
Cylinder Head Assembly ......................................................................................................... ............................15
Oil Pump ....................................................................................................................... ........................................16
Engine Block Assembly .......................................................................................................... ............................17
Pistons, Rings, Bearing and Connecting Rod ..................................................................................... ..............18
Oil Pan Assembly............................................................................................................... ..................................19
Oil Filter Assembly ............................................................................................................ ..................................20
1.3 Engine Serial Number........................................................................................................... ...............................21
1.4 Engine Construction............................................................................................................ ................................22
Cylinder Block ................................................................................................................. .....................................22
Cylinder Heads ..................................................................................................................................................... 22
Crankshaft ..................................................................................................................... .......................................23
Pistons, Pins and Connecting Rods .............................................................................................. ....................23
Camshaft Driv e System ....................................................................................................................................... 24
1.5 Engine Lubrication System .................................................................................................................................25
Lubrication Description........................................................................................................ ...............................25
1.6 Service Notes .................................................................................................................. .....................................26
Cleanliness and Care........................................................................................................... ................................26
Replacing Engine Gaskets .................................................................................................................................. 26
Re-Using Gaskets and Applying Sealants......................................................................................... ...............26
Separating Co mponents................................................................................................................................... 26
Cleaning Gasket Surfaces ................................................................................................................................ 26
Assembling Components ................................................................................................................................. 26
Use of Room Temperature Vulcanising and Anaerobic Sealer....................................................................... .27
Room Temperature Vu lcanising Sealer............................................................................................ ................27
Anaerobic Sealer ............................................................................................................... ...............................27
Pipe Joint Compound ............................................................................................................ ...........................28
Separating Parts ............................................................................................................... ...................................28
Tools and Equipment ............................................................................................................ ..............................28
Fasteners .............................................................................................................................................................. 29
Clamp Load ..................................................................................................................... .................................29
Torque Angle and Torque to Yield Fastener s................................................................................................... 29
2 Diagnosis ...................................................................................................................... ........................30
2.1 Engine Diagnosis ............................................................................................................... ..................................30
2.2 Symptoms ....................................................................................................................... .....................................31
Strategy Based Diagnosis................................................................................................................................... 31

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Page 2779 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–2
Page 6A1–2
Visual / Physical Inspection ................................................................................................... .................

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

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ISUZU KB P190 2007

Page 2780 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–3
Page 6A1–3
Definition ..................................................................................................................... .................

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

Page 2781 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–4
Page 6A1–4
Reinstall ........................................................................................................................................

Engine Mechanical – V6 Page 6A1–4
Page 6A1–4
Reinstall ................................................................................................................................................................ 97
3.13 Crankshaft Balancer Assembly ................................................................................................... .....................100
Remove ............................................................................................................................................................... 100
Clean and Inspect .............................................................................................................. ................................101
Reinstall .............................................................................................................................................................. 101
3.14 Crankshaft Front Seal.......................................................................................................... ..............................103
Replace ........................................................................................................................ .......................................103
3.15 Front Cover Assembly........................................................................................................... ............................104
Remove ............................................................................................................................................................... 104
Disassemble ....................................................................................................................................................... 105
Clean................................................................................................................................................................... 106
Inspect ........................................................................................................................ ........................................107
Reassemble ........................................................................................................................................................ 107
Reinstall .............................................................................................................................................................. 108
3.16 Timing Chains, Tensioners, Shoes and Guides .................................................................................... ..........110
Primary and Left-hand Secondary Timing Chain Installation ...................................................................... ..110
Excluding MY 06 Update .......................................................................................................... .......................110
MY06 Update .................................................................................................................... .............................111
Right-hand Secondary Timi ng Chain Installation ........................................................................................... 112
Excluding MY06 Update .......................................................................................................... .......................112
MY06 Update .................................................................................................................... .............................113
Remove ............................................................................................................................................................... 114
Right-hand Secondary Timing Chain.............................................................................................. ................114
Primary Timi ng Chain ........................................................................................................... ..........................118
Left-hand Secondary Timing C hain ............................................................................................... .................120
Clean................................................................................................................................................................... 123
Inspect ........................................................................................................................ ........................................124
Timing Chains .................................................................................................................. ..............................124
Camshaft Intermedi ate Sprockets .................................................................................................................. 124
Inlet and Exhaust Camshaft Sprocket ............................................................................................ ................124
Crankshaft Sprocket ....................................................................................................................................... 125
Primary Timing Chain Upper Guide............................................................................................... .................125
Primary Timing C hain Lower Guide............................................................................................... .................125
Primary Timing C hain Tensioner ................................................................................................. ...................126
Left-hand Secondary Ti ming Chain Guide ......................................................................................... ............126
Left-hand Secondary Ti ming Chain Shoe.......................................................................................... .............127
Left-hand Secondary Timi ng Chain Tensioner ..................................................................................... ..........127
Right-hand Sec ondary Timing Chain Guide ................................................................................................... 128
Right-hand Secondary Timing Chain Shoe ......................................................................................... ...........128
Right-hand Se condary Timing Chain Tensioner .................................................................................... .........129
Reinst all .............................................................................................................................................................. 130
Left-hand Secondary Timing Chain Components – Excluding MY06 Update ................................................ 130
Left-hand Secondary Timing Chain Components – MY06 Update ................................................................. 139
Primary Timing Chain Components – Excluding MY06 Update ..................................................................... 149
Primary Timing Chain Components – MY06 Update .................................................................................. ....156
Right-hand Secondary Timing Chain Components – Excluding MY06 Update .............................................. 164
Right-hand Secondary Timing Chain Components – MY06 Update............................................................... 171
3.17 Oil Pump Assembly .............................................................................................................. .............................180
Remove ............................................................................................................................................................... 180
Disassemble ....................................................................................................................................................... 181
Clean................................................................................................................................................................... 182
Inspect ........................................................................................................................ ........................................183
Reassemble ........................................................................................................................................................ 185
Reinstall .............................................................................................................................................................. 185
3.18 Camshaft Sprocket – Excluding MY06 Update ................................................................................................ 186
Remove ............................................................................................................................................................... 186
Right-hand Side................................................................................................................ ..............................186
Left-hand Side ................................................................................................................................................ 189
Clean................................................................................................................................................................... 191
Inspect ........................................................................................................................ ........................................191

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ISUZU KB P190 2007

Page 2782 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–5
Page 6A1–5
Reinstall ........................................................................................................................................

Engine Mechanical – V6 Page 6A1–5
Page 6A1–5
Reinstall .............................................................................................................................................................. 192
3.19 Camshaft Sprocket – MY06 Update ................................................................................................ ..................193
Remove ............................................................................................................................................................... 193
Right-hand Side................................................................................................................ ..............................193
Left-hand Side ................................................................................................................................................ 196
Clean................................................................................................................................................................... 199
Inspect ........................................................................................................................ ........................................199
Reinstall .............................................................................................................................................................. 200
3.20 Camshaft ............................................................................................................................................................ 201
Remove ............................................................................................................................................................... 201
Right-hand Side................................................................................................................ ..............................201
Left-hand Side ................................................................................................................................................ 203
Clean................................................................................................................................................................... 204
Inspect ........................................................................................................................ ........................................205
Camshaft Visual Inspection ..................................................................................................... .......................205
Camshaft Meas urement ................................................................................................................................. 205
Reinstall .............................................................................................................................................................. 207
Right-hand Side................................................................................................................ ..............................207
Left-hand Side ................................................................................................................................................ 210
3.21 Rocker Arm......................................................................................................................................................... 213
Remove ............................................................................................................................................................... 213
Clean and Inspect .............................................................................................................. ................................213
Reinstall .............................................................................................................................................................. 214
3.22 Stationary Hydraulic Lash Adjuster ............................................................................................. ....................215
Remove ............................................................................................................................................................... 215
Clean and Inspect .............................................................................................................. ................................215
Reinstall .............................................................................................................................................................. 216
3.23 Cylinder Head Assembly ......................................................................................................... ..........................217
Remove ............................................................................................................................................................... 217
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............217
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................218
Disassemble ....................................................................................................................................................... 219
Clean................................................................................................................................................................... 222
Inspect ........................................................................................................................ ........................................222
Visual Inspection .............................................................................................................. ..............................222
Cylinder Head Measurement.......................................................................................................................... 223
Valve Spring Inspection and Measurement ........................................................................................ ............225
Valve and Seat Grinding ........................................................................................................ ........................225
Assemble ....................................................................................................................... .....................................230
Reinstall .............................................................................................................................................................. 233
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............233
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................234
3.24 Engine Mounts and Brackets ..................................................................................................... .......................236
Remove ............................................................................................................................................................... 236
Engine Mount Location ..................................................................................................................................... 237
Inspect ........................................................................................................................ ........................................237
Reinstall .............................................................................................................................................................. 238
4 Major Service Operations ....................................................................................................... ...........239
4.1 Engine Re moval ................................................................................................................. ................................239
Remove ............................................................................................................................................................... 240
Disassemble ....................................................................................................................................................... 252
Reassemble ........................................................................................................................................................ 253
Reinstall .............................................................................................................................................................. 253
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ...........254
Remove ............................................................................................................................................................... 254
Disassemble ....................................................................................................................................................... 255
Clean................................................................................................................................................................... 255
Inspect ........................................................................................................................ ........................................256

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ISUZU KB P190 2007

Page 2783 of 6020

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

Engine Mechanical – V6 Page 6A1–6
Page 6A1–6
Reassemble ........................................................................................................................................................ 257
Reinstall .............................................................................................................................................................. 257
4.3 Flexplate Assembly ............................................................................................................. ..............................259
Remove ............................................................................................................................................................... 259
Clean................................................................................................................................................................... 259
Inspect ........................................................................................................................ ........................................260
Reinstall .............................................................................................................................................................. 260
4.4 Crankshaft Rear Seal and Plate Assembly ........................................................................................ ..............262
Remove ............................................................................................................................................................... 262
Reinstall .............................................................................................................................................................. 263
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 265
Remove ............................................................................................................................................................... 265
Disassemble ....................................................................................................................................................... 268
Clean and Inspect .............................................................................................................. ................................269
Piston Cleaning Procedure...................................................................................................... .......................269
Piston Inspection Procedure .................................................................................................... ......................269
Piston Measurement ............................................................................................................. .........................270
Piston Ring Measurement ........................................................................................................ ......................271
Connecting Rod Cleaning Procedure .............................................................................................. ...............272
Connecting Rod Visual Inspection Procedure ..................................................................................... ...........272
Connecting Rod Meas urement Procedure ........................................................................................... ..........272
Reasse mble ........................................................................................................................................................ 274
Piston and Piston Pin ..................................................................................................................................... 274
Piston Ring .................................................................................................................... .................................275
Connecting Rod Bearing ................................................................................................................................ 276
Reinstall .............................................................................................................................................................. 277
Piston Connecting Rod and Connecting Rod Bearing Inst allation .................................................................. 277
Connecting Rod Bearing Clearance Measurement Procedure....................................................................... 278
Connecting Rod Final Assembly Procedure ........................................................................................ ...........279
4.6 Crankshaft and Ma in Bearings ................................................................................................... ......................281
Crankshaft End Play Measurement ................................................................................................ ..................281
Remove ............................................................................................................................................................... 281
Crankshaft Bearing............................................................................................................. ............................283
Clean and Inspect .............................................................................................................. ................................283
Crankshaft and Main Bearing Cleaning ........................................................................................... ...............283
Crankshaft and Main Bear ing Visual Inspection .................................................................................. ...........284
Crankshaft Main B earing Inspection............................................................................................. ..................285
Crankshaft M easurement ......................................................................................................... ......................286
Reinstall .............................................................................................................................................................. 288
Crankshaft Bearing Installation Procedure ...................................................................................... ...............288
Crankshaft Main Bearing Clearance Measurement .................................................................................. ......289
Crankshaft Final Instal lation Procedure........................................................................................ ..................291
4.7 Cylinder Block ................................................................................................................. ...................................293
Disassemble ....................................................................................................................................................... 293
Clean................................................................................................................................................................... 297
Inspect ........................................................................................................................ ........................................297
Visual Inspection .............................................................................................................. ..............................297
Measuring Cylinder Bore Diameter ............................................................................................... .................297
Measuring Cylinder Bore Taper.................................................................................................. ....................298
Measuring Cylinder Bo re Out-of-Round ........................................................................................... ..............298
Deck Flatness Inspection ............................................................................................................................... 298
Reassemble ........................................................................................................................................................ 299
4.8 Thread Repairs ................................................................................................................................................... 303
General Information ............................................................................................................ ...............................303
General Thread Repair .......................................................................................................... ............................304
Main Bearing Cap Bolt Hole Thread Repair ....................................................................................... ..............310
Cylinder Head Bolt Hole Thread Repair .......................................................................................... .................315
4.9 Thread Repair Specifications................................................................................................... .........................322
Left-hand Cylinder Head Camshaft Cover Face .................................................................................... ..........322
Left-hand Cylinder H ead Front Face ............................................................................................. ...................323

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ISUZU KB P190 2007

Page 2784 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–7
Page 6A1–7
Left-hand Cylinder Head Intake Face ............................................................................................ .................

Engine Mechanical – V6 Page 6A1–7
Page 6A1–7
Left-hand Cylinder Head Intake Face ............................................................................................ ...................324
Left-hand Cylinder H ead Exhaust Face ........................................................................................... ................325
Left-hand Cylinder H ead Rear Face .............................................................................................. ...................326
Right-hand Cylinder Head Camshaft Cover Face ................................................................................... ........327
Right-hand Cylinder Head Front Face............................................................................................ ..................328
Right-hand Cylinder Head Intake Face ........................................................................................... .................329
Right-hand Cylinder He ad Exhaust Face .......................................................................................... ...............330
Right-hand Cylinder Head Rear Face ............................................................................................. ..................331
Engine Block Front ............................................................................................................................................ 332
Engine Block Left-hand Side .................................................................................................... ........................333
Engine Block Ri ght-hand Side ................................................................................................... .......................334
Engine Block Rear .............................................................................................................. ...............................335
Engine Block Bottom......................................................................................................................................... 336
Engine Block Left-hand Deck Face ............................................................................................... ...................337
Engine Block Righ t-hand Deck Face.............................................................................................. ..................338
Engine Front Cover............................................................................................................. ...............................339
Upper Intake Manifold Top ...................................................................................................... ..........................340
Upper Intake Mani fold Front .................................................................................................... .........................341
Upper Intake Ma nifold Rear..................................................................................................... ..........................342
Lower Intake Ma nifold Top...................................................................................................... ..........................343
Oil Pan Front .................................................................................................................. ....................................344
Oil Pan Rear........................................................................................................................................................ 345
Oil Pan Bottom ................................................................................................................................................... 346
5 Specifications .....................................................................................................................................347
6 Torque Wrench Specifications................................................................................................... .......351
7 Special Tools .................................................................................................................. ....................353

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