2007 ISUZU KB P190 Workshop Repair Manual

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Page 2865 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–88
Page 6A1–88
Clean
CAUTION
Due to the aluminium alloy construction of
the intake manifold, wire brushes and steel
scrapers must not be used during the

Page 2866 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–89
Page 6A1–89
5 Place a straight edge (1) across the lower intake
manifold sealing surface (2).
6 Using a feeler gauge (3), measure the clearance
betwee

Engine Mechanical – V6 Page 6A1–89
Page 6A1–89
5 Place a straight edge (1) across the lower intake
manifold sealing surface (2).
6 Using a feeler gauge (3), measure the clearance
between the manifold and the straight edge.
7 If the clearance between the lower intake manifold sealing surface and the straight edge exceeds the
specified maximum warpage, replace the manifold.

Lower manifold maximum
warpage ............................................................ 0.05 mm
Figure 6A1 – 55
Reassemble
Reassembly of the upper to lower intake manifold is the reverse of the disassembly procedure noting the following:
1 Ensure that both the manifo lds have been cleaned and inspected.
2 Ensure that the warpage of the mati ng surfaces is within tolerances.
3 New upper to lower intake m anifold gaskets must be used.
4 Do not tighten the intake manifold to lower intake manifold attaching bolt at this stage. The intake manifold
attaching bolts must be tightened at the specif ied sequence during the reinstallation procedure.
Reinstall
Reinstallation of the upper intake manifold and the upper and lower intake manifo ld assembly is the reverse of the
removal procedure, noting the following:
1 Install the EVAP hose to the clip atta ched to the lower intake manifold.
2 Only new gaskets are to be fitted betw een the upper and lower intake manifolds.
3 If undamaged, the lower intake manifold to cylinder head gasket may be re-used, however its replacement is
strongly recommended.
CAUTION
Tighten the intake manifold bolts in a circular
pattern starting at the centre bolt and moving
outward.
4 Ensure that all fasteners are tightened to the correct torque specification.
Upper intake manifold to lower intake
manifold attaching bolt torq ue specification .......23.0 Nm
Upper intake manifold to cylinder
head attaching bolt torque specification .............23.0 Nm
Lower intake manifold to cylinder
head attaching bolt torque specification .............23.0 Nm
Fuel injector wiring harness bracket
attaching bolt torque specification ........................9.0 Nm

Incorrect wiring connector installation may
cause component malfunction or component
damage.

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ISUZU KB P190 2007

Page 2867 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–90
Page 6A1–90
5 Ensure all wiring connectors are fully engaged and if applicable, locked in place.
6 Ensure all wiring harnesses are correctly routed and a

Page 2868 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–91
Page 6A1–91
3.11 Exhaust Manifold Assembly
Remove

Allow the engine to cool before commencing.

Disconnection of the battery affects
certain vehicl

Page 2869 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–92
Page 6A1–92
9 Progressively loosen the seven exhaust manifold
attaching bolts (2), working from the outside to the
centre and then remove the bolts.
10

Page 2870 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–93
Page 6A1–93
Inspect
Inspect the exhaust manifold (1) for the following:
• Damage to the threaded holes for the heat shield
mounting.
• Damage to

Engine Mechanical – V6 Page 6A1–93
Page 6A1–93
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 exhaus t 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.
2 Position a new exhaust manifold gasket onto the exhaust manifold.
3 Apply a 5 mm bead of Loctite 272 thread sealant (or equival ent) 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 spec ification ........... 17.0 – 23.0 Nm
8 Apply an anti seize compound such as Caltex Kopr-Kot e (or equivalent) to the cleaned heat shield bolt threads.
Install the heat shield attaching bolts and ti ghten to the correct torque specification.
Exhaust manifold heat shield attaching
bolt torque specificat ion ............................ 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 s pecification.......................13.0 Nm

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ISUZU KB P190 2007

Page 2871 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–94
Page 6A1–94
3.12 Camshaft Cover
Remove
1 Remove the intake manifold assembly, refer to 3.10 Intake Manifold Assembly – Complete .
2 For the left-han

Page 2872 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Mechanical – V6 Page 6A1–95
Page 6A1–95
6 Remove the bolt (1) attaching the ground connector
(2) to the cylinder head.
7 Fro the left-hand side, disconnect the engine coolant temp

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