2007 ISUZU KB P190 engine oil

Engine Mechanical – V6 Page 6A1–2

Visual / Physical Inspection ................................................................................................................................ 28
Intermittent ........................................................................................................................................................... 28
2.3 Engine Misfire without Internal Engine Noises .................................................................................. ............... 29
2.4 Engine Misfire with Abnormal Internal Lower Engine Noises...................................................................... .... 30
2.5 Engine Misfire with Abnormal Valve Train Noise .............................................................................................. 31
2.6 Engine Misfire with Coolant Consumption ........................................................................................................ 31
2.7 Engine Misfire with Excessive Oil Consumption .................................................................................. ............ 31
2.8 Engine Noise on Start-up, but only Lasting a Few Seconds ....................................................................... ..... 31
2.9 Upper Engine Noise, Regardless of Engine Speed........................................................................................... 33
2.10 Lower Engine Noise, Regardless of Engine Speed ................................................................................. ......... 34
2.11 Engine Noise Under Load ................................................................................................................................... 35
2.12 Engine Will Not Crank – Crankshaft Will Not Rotate ............................................................................. ........... 35
2.13 Coolant in Combustion Chamber ....................................................................................................................... 37
Definition .............................................................................................................................................................. 37
2.14 Coolant in Engine Oil.......................................................................................................... ................................. 37
Definition .............................................................................................................................................................. 37
2.15 Engine Compression Test ........................................................................................................ ........................... 38
Preliminary Steps................................................................................................................................................. 38
Engine Cylinder Compression Test ............................................................................................... .................... 38
Test Result Evaluation......................................................................................................................................... 38
2.16 Cylinder Leakage Test .......................................................................................................... ............................... 39
2.17 Engine Oil Consumption Diagnosis ............................................................................................... .................... 39
Definition .............................................................................................................................................................. 39
2.18 Engine Oil Leak Diagnosis ...................................................................................................... ............................ 40
Introduction .......................................................................................................................................................... 40
Locating and Identifying the Leak .............................................................................................. ........................ 40
Visual Inspection ................................................................................................................................................. 40
Powder Method .................................................................................................................. .................................. 40
Black Light and Dye Method ..................................................................................................... .......................... 40
Possible Causes for Engine Oil Leaks ........................................................................................... .................... 41
2.19 Engine Oil Pressure Diagnosis ........................................................................................................................... 42
2.20 Accessory Drive Belt Diagnosis ................................................................................................. ........................ 42
Tension Check ..................................................................................................................................................... 42
Inspect .................................................................................................................................................................. 42
Drive Belt Chirp .................................................................................................................................................... 43
Definition .......................................................................................................................................................... 43
Diagnostic Aids................................................................................................................................................. 43
Test Description ............................................................................................................... ................................ 43
Diagnostic Table............................................................................................................................................... 44
Drive Belt Squeal .............................................................................................................. ................................... 45
Definition .......................................................................................................................................................... 45
Diagnostic Aids................................................................................................................................................. 45
Test Description ............................................................................................................... ................................ 45
Diagnostic Table............................................................................................................................................... 46
Drive Belt Whine ............................................................................................................... ................................... 46
Definition .......................................................................................................................................................... 46
Diagnostic Aids................................................................................................................................................. 46
Test Description ............................................................................................................... ................................ 46
Diagnostic Table............................................................................................................................................... 47
Drive Belt Rumble .............................................................................................................. .................................. 47
Definition .......................................................................................................................................................... 47
Diagnostic Aids................................................................................................................................................. 48
Test Description ............................................................................................................... ................................ 48
Diagnostic Table............................................................................................................................................... 48
Drive Belt Vibration........................................................................................................... ................................... 49
Definition .......................................................................................................................................................... 49
Diagnostic Aids................................................................................................................................................. 49
Test Description ............................................................................................................... ................................ 49
Diagnostic Table............................................................................................................................................... 50
Drive Belt Falls Off ........................................................................................................... .................................... 50

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–3

Definition .......................................................................................................................................................... 50
Diagnostic Aids................................................................................................................................................. 50
Test Description ............................................................................................................... ................................ 50
Diagnostic Table............................................................................................................................................... 51
Drive Belt Excessive Wear ...................................................................................................... ............................ 51
Definition .......................................................................................................................................................... 51
Diagnostic Aids................................................................................................................................................. 52
Test Description ............................................................................................................... ................................ 52
Diagnostic Table............................................................................................................................................... 52
Accessory Drive Belt Tensioner Diagnosis ....................................................................................... ................ 52
Diagnostic Table............................................................................................................................................... 52
3 Minor Service Operations ....................................................................................................... .............53
3.1 Engine Oil ............................................................................................................................................................. 54
Check .................................................................................................................................................................... 54
Replace ........................................................................................................................ ......................................... 54
Pressure Check ................................................................................................................. ................................... 55
3.2 Oil Filter Cartridge ............................................................................................................................................... 56
Replace ................................................................................................................................................................. 56
3.3 Oil Filter Adaptor............................................................................................................. ..................................... 57
Remove ................................................................................................................................................................. 57
Reinstall ................................................................................................................................................................ 57
3.4 Oil Level Indicator Tube ....................................................................................................... ............................... 58
Remove ............................................................................................................................................................ 58
Reinstall ........................................................................................................................................................... 58
3.5 Accessory Drive Belt ........................................................................................................... ................................ 59
RWD Vehicle ......................................................................................................................................................... 59
Remove ............................................................................................................................................................ 59
Reinstall ........................................................................................................................................................... 59
3.6 Accessory Drive Belt Idler Pulley .............................................................................................. ......................... 60
Remove ............................................................................................................................................................ 60
Reinstall ........................................................................................................................................................... 60
3.7 Accessory Drive Belt Tensioner Assembly ........................................................................................ ............... 61
Remove ............................................................................................................................................................ 61
Reinstall ........................................................................................................................................................... 61
3.8 Power Steering Pump Bracket .................................................................................................... ........................ 62
Remove ................................................................................................................................................................. 62
Reinstall ................................................................................................................................................................ 62
3.9 Upper Intake Manifold.......................................................................................................... ................................ 62
Remove ................................................................................................................................................................. 63
Disassemble ......................................................................................................................................................... 66
Clean ..................................................................................................................................................................... 66
Inspect .................................................................................................................................................................. 66
Reassemble .......................................................................................................................................................... 67
Reinstall ...................................................................................................................... .......................................... 67
3.10 Intake Manifold Assembly – Complete............................................................................................ ................... 68
Remove ................................................................................................................................................................. 68
Disassemble ......................................................................................................................................................... 72
Clean ..................................................................................................................................................................... 73
Inspect .................................................................................................................................................................. 73
Reassemble .......................................................................................................................................................... 74
Reinstall ...................................................................................................................... .......................................... 74
3.11 Exhaust Manifold Assembly ...................................................................................................... ......................... 75
Remove ................................................................................................................................................................. 75
Inspect .................................................................................................................................................................. 77
Reinstall ................................................................................................................................................................ 77
3.12 Camshaft Cover ................................................................................................................. .................................. 79
Remove ................................................................................................................................................................. 79
Clean and Inspect .............................................................................................................. .................................. 81

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–4

Reinstall ................................................................................................................................................................ 81
3.13 Crankshaft Balancer Assembly ................................................................................................... ....................... 84
Remove ................................................................................................................................................................. 84
Clean and Inspect .............................................................................................................. .................................. 85
Reinstall ................................................................................................................................................................ 85
3.14 Crankshaft Front Seal.......................................................................................................... ................................ 87
Replace ................................................................................................................................................................. 87
3.15 Front Cover Assembly........................................................................................................... .............................. 87
Remove ................................................................................................................................................................. 87
Disassemble ......................................................................................................................................................... 89
Clean ..................................................................................................................................................................... 90
Inspect .................................................................................................................................................................. 91
Reassemble .......................................................................................................................................................... 91
Reinstall ...................................................................................................................... .......................................... 92
3.16 Timing Chains, Tensioners, Shoes and Guides .................................................................................... ............ 94
Primary and Left-hand Secondary Timing Chain Installation ...................................................................... .... 94
Right-hand Secondary Timing Chain Installation ............................................................................................. 95
Remove ................................................................................................................................................................. 96
Right-hand Secondary Timing Chain.............................................................................................. .................. 96
Primary Timing Chain ..................................................................................................................................... 100
Left-hand Secondary Timing Chain ............................................................................................... ................. 102
Clean ................................................................................................................................................................... 105
Inspect ................................................................................................................................................................ 106
Timing Chains .................................................................................................................. .............................. 106
Camshaft Intermediate Driveshaft Sprockets ..................................................................................... ............ 106
Inlet and Exhaust Camshaft Sprocket ............................................................................................................ 106
Crankshaft Sprocket ....................................................................................................................................... 107
Primary Timing Chain Upper Guide............................................................................................... ................. 107
Primary Timing Chain Lower Guide................................................................................................................ 107
Primary Timing Chain Tensioner .................................................................................................................... 108
Left-hand Secondary Timing Chain Guide ......................................................................................... ............ 108
Left-hand Secondary Timing Chain Shoe....................................................................................................... 109
Left-hand Secondary Timing Chain Tensioner ..................................................................................... .......... 109
Right-hand Secondary Timing Chain Guide ................................................................................................... 110
Right-hand Secondary Timing Chain Shoe .................................................................................................... 110
Right-hand Secondary Timing Chain Tensioner.................................................................................... ......... 111
Reinstall .............................................................................................................................................................. 111
Left-hand Secondary Timing Chain Components.................................................................................... ....... 111
Primary Timing chain Components ................................................................................................................ 121
Right-hand Secondary Timing Chain Components ................................................................................... ..... 128
3.17 Oil Pump Assembly ........................................................................................................................................... 136
Remove ............................................................................................................................................................... 136
Disassemble ....................................................................................................................................................... 137
Clean ................................................................................................................................................................... 138
Inspect ................................................................................................................................................................ 139
Reassemble ........................................................................................................................................................ 141
Reinstall ...................................................................................................................... ........................................ 141
3.18 Camshaft Sprocket .............................................................................................................. .............................. 141
Remove ............................................................................................................................................................... 141
Right-hand Side................................................................................................................ .............................. 141
Left-hand Side ................................................................................................................................................ 144
Clean ................................................................................................................................................................... 146
Inspect ................................................................................................................................................................ 146
Reinstall ...................................................................................................................... ........................................ 147
3.19 Camshaft....................................................................................................................... ...................................... 147
Remove ............................................................................................................................................................... 147
Right-hand Side................................................................................................................ .............................. 147
Left-hand Side ................................................................................................................................................ 149
Clean ................................................................................................................................................................... 150
Inspect ................................................................................................................................................................ 150

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–5

Camshaft Visual Inspection ............................................................................................................................ 150
Camshaft Measurement ........................................................................................................... ...................... 151
Reinstall .............................................................................................................................................................. 153
Right-hand Side................................................................................................................ .............................. 153
Left-hand Side ................................................................................................................................................ 155
3.20 Rocker Arm..................................................................................................................... .................................... 158
Remove ............................................................................................................................................................... 158
Clean and Inspect .............................................................................................................. ................................ 158
Reinstall .............................................................................................................................................................. 159
3.21 Stationary Hydraulic Lash Adjuster ............................................................................................. .................... 160
Remove ............................................................................................................................................................... 160
Clean and Inspect .............................................................................................................. ................................ 160
Reinstall .............................................................................................................................................................. 161
3.22 Cylinder Head Assembly ......................................................................................................... .......................... 161
Remove ............................................................................................................................................................... 161
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... .............. 161
Left-hand Side (Bank 2) Cylinder Head .......................................................................................................... 162
Disassemble ....................................................................................................................................................... 163
Clean ................................................................................................................................................................... 166
Inspect ................................................................................................................................................................ 167
Visual Inspection .............................................................................................................. .............................. 167
Cylinder Head Measurement...................................................................................................... .................... 167
Valve Spring Inspection and Measurement ........................................................................................ ............ 169
Valve and Seat Grinding ................................................................................................................................ 170
Assemble ............................................................................................................................................................ 174
Reinstall .............................................................................................................................................................. 177
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... .............. 177
Left-hand Side (Bank 2) Cylinder Head .......................................................................................................... 178
3.23 Engine Mounts and Brackets ............................................................................................................................ 181
Remove .......................................................................................................................................................... 181
Engine Mount Location .......................................................................................................... ........................... 182
Inspect ................................................................................................................................................................ 182
Reinstall .............................................................................................................................................................. 183
4 Major Service Operations ....................................................................................................... ...........184
4.1 Engine Removal ................................................................................................................................................. 184
Remove .......................................................................................................................................................... 185
Disassemble................................................................................................................................................... 197
Reassemble ................................................................................................................................................... 198
Reinstall ......................................................................................................................................................... 198
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ........... 198
Remove .......................................................................................................................................................... 198
Disassemble................................................................................................................................................... 200
Clean .............................................................................................................................................................. 200
Inspect............................................................................................................................................................ 201
Reassemble ................................................................................................................................................... 201
Reinstall ......................................................................................................................................................... 202
4.3 Flexplate Assembly ............................................................................................................. .............................. 203
Remove ............................................................................................................................................................... 203
Clean ................................................................................................................................................................... 204
Inspect ................................................................................................................................................................ 204
Reinstall ...................................................................................................................... ........................................ 205
4.4 Crankshaft Rear Seal and Plate Assembly ........................................................................................ .............. 205
Remove ............................................................................................................................................................... 205
Reinstall .............................................................................................................................................................. 207
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 208
Remove ............................................................................................................................................................... 208
Disassemble ....................................................................................................................................................... 211
Clean and Inspect .............................................................................................................. ................................ 212

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–7

Engine Block Right-hand Deck Face................................................................................................................ 279
Engine Front Cover............................................................................................................................................ 280
Upper Intake Manifold Top ...................................................................................................... .......................... 281
Upper Intake Manifold Front .................................................................................................... ......................... 282
Upper Intake Manifold Rear............................................................................................................................... 283
Lower Intake Manifold Top ................................................................................................................................ 284
Oil Pan Front ...................................................................................................................................................... 285
Oil Pan Rear........................................................................................................................................................ 286
Oil Pan Bottom ................................................................................................................. .................................. 287
5 Specifications .....................................................................................................................................288
6 Torque Wrench Specifications................................................................................................... .......292
7 Special Tools ......................................................................................................................................294

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–10

Figure 6A1 – 2
Legend
1 Engine Assembly
2 Intake Manifold Assembly
3 Camshaft Cover Assembly, Left-hand
4 Camshaft Cover Assembly, Right-hand
5 Engine Front Cover Assembly
6 Oil Pan Assembly
7 Engine Flywheel
8 Engine Flywheel Bolt
9 Crankshaft Balancer
10 Crankshaft Balancer Bolt
11 Exhaust Manifold Gasket, Left-hand 12 Exhaust Manifold, Left-hand
13 Exhaust Manifold Heat Shield, Left-hand
14 Exhaust Manifold Heat Shield Bolt, Left-hand
15 Exhaust Manifold Gasket, Right-hand
16 Exhaust Manifold, Right-hand
17 Cylinder Head Exhaust Manifold Bolt
18 Exhaust Manifold Heat Shield, Right-hand
19 Exhaust Manifold Heat Shield Bolt, Right-hand
20 Ignition Coil Assembly
21 Ignition Coil Assembly Bolt
22 Spark Plug
Intake Manifold Assembly


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–14

Camshaft Cover Assembly

Figure 6A1 – 6
Legend
1 Camshaft Cover, Left-hand
2 Camshaft Cover Gasket, Left-hand
3 Camshaft Cover, Right-hand
4 Camshaft Cover Gasket, Right-hand
5 Camshaft Cover Spark Plug Port Seal
6 Camshaft Cover Bolt
7 Camshaft Cover Bolt Insulator
8 Ignition Coil Bolt Thread Insert
9 Oil Fill Cap 10 Oil Fill O-Ring
11 Camshaft Cover PCV Fitting, Left-hand
12 Camshaft Cover PCV Fitting Orifice, Right-hand
13 Oil Fill Tube
14 Camshaft Cover PCV Fitting O-Ring, Left-hand
15 Ignition Coil
16 Ignition Coil Bolt
17 Spark Plug


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–15

Cylinder Head Assembly

Figure 6A1 – 7
Legend
1 Cylinder Head, Left-hand
2 Cylinder Head, Right-hand
3 Cylinder Head Gasket, Left-hand
4 Cylinder Head Gasket, Right-hand
5 Cylinder Head Bolt
6 Cylinder Head Front Bolt
7 Cylinder Head Coolant Hole Threaded Plug
8 Spark Plug Sleeve
9 Cylinder Head Oil Gallery Expansion Plug
10 Exhaust Valve
11 Intake Valve
12 Valve Rocker Arm Assembly
13 Hydraulic Valve Lash Adjuster Assembly
14 Valve Stem Oil Seal 15 Valve Spring
16 Valve Spring Cap
17 Valve Stem Key
18 Cylinder Head Camshaft Front Thrust Bearing Cap
19 Camshaft Oil Seal Ring
20 Exhaust Camshaft
21 Intake Camshaft, Left-hand (bank 2)
22 Intake Camshaft, Right-hand (bank 1)
23 Exhaust Camshaft, Right-hand (bank 1)
24 Cylinder Head Camshaft Cap – Intermediate
25 Cylinder Head Camshaft Cap Bolt
26 Cylinder Head Oil Galley Check Valve
27 Engine Coolant Temperature Sensor

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ISUZU KB P190 2007