2007 ISUZU KB P190 battery

Engine Mechanical – V6 Page 6A1–195

57 Unclip and remove the generator wiring harness
connector (1), Remove battery connection attaching
nut (4), and remove the battery harness cable (2)
from the connection stud.

Figure 6A1 – 345
58 Remove the generator attaching bolts (1, 2, and 4) three places, then remove the generator (3) from the
mounting bracket.
Figure 6A1 – 346
59 Remove the idler pulley attaching bolt and remove the idler pulley (1).
60 Remove the generator bracket attaching bolts, five places, and remove the generator mounting bracket
(2).
Figure 6A1 – 347

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–292

6 Torque Wrench Specifications
ATTENTION
„
„„
„
Fasteners must be replaced after loosening.



Fasteners either have micro encapsulated sealant applied or incorporate a mechanical thread lock and
should only be re-used once. If in doubt, replacement is recommended.

Oil Pan Drain Plug ................................................................................ 25.0 Nm
Oil Filter Adaptor Attaching Bolt ................................................ 20.0 – 26.0 Nm
Oil Level Indicator Tube Attaching Bolt........................................ 8.0 – 12.0 Nm
Accessory Drive Belt Idler Pulley Attaching Bolt................................... 50.0 Nm
Accessory Drive Belt Tensioner Attaching Bolt .................................... 50.0 Nm
Power Steering Reservoir Bracket Attaching Screw.............................. 9.0 Nm
Power Steering Pump Bracket Attaching Bolt ........................... 49.0 – 67.0 Nm
Upper Intake Manifold to Lower Intake Manifold Attaching Bolt ........... 23.0 Nm
Upper Intake Manifold to Cylinder Head Attaching Bolt........................ 23.0 Nm
Lower Intake Manifold to Cylinder Head Attaching Bolt........................ 23.0 Nm
Fuel Injector Wiring Harness Bracket Attaching bolt .............................. 9.0 Nm
Exhaust Manifold to Cylinder Head Attaching Bolt ..................... 17.0 - 23.0 Nm
Exhaust Manifold Heat Shield Attaching Bolt ............................... 8.0 - 12.0 Nm
Battery Harness Ground Terminal Attaching Nut ................................. 13.0 Nm
Camshaft Cover Attaching Bolt ................................................... 8.0 – 12.0 Nm
Engine Ground Connector Bolt............................................................. 10.0 Nm
Engine Wiring Harness Former Attaching Bolt .......................... 12.0 – 16.0 Nm
„ Crankshaft Balancer Assembly Attaching Bolt:
Stage 1 ..................................................................................... 90.0 –110.0 Nm
Stage 2 ....................................................................................................... 150 °
Engine Front Cover Assembly Attaching Bolt ............................ 20.0 – 26.0 Nm
Camshaft Intermediate Driveshaft Sprocket Attaching Bolt ....... 58.0 – 72.0 Nm
Secondary Timing Chain Guide Attaching Bolt.......................... 20.0 – 26.0 Nm
Secondary Timing Chain Shoe Attaching Bolt ........................... 20.0 – 26.0 Nm
Secondary Timing Chain Tensioner Attaching Bolt ................... 20.0 – 26.0 Nm
Primary Timing Chain Upper Guide Attaching Bolt.................... 20.0 – 26.0 Nm
Primary Timing Chain Tensioner Attaching Bolt ........................ 20.0 – 26.0 Nm
Oil Pump Assembly Attaching Bolt ............................................ 20.0 – 26.0 Nm
Camshaft Sprocket Attaching Bolt ............................................. 49.0 – 67.0 Nm
Exhaust Camshaft Sprocket Attaching Bolt ............................... 49.0 – 67.0 Nm
Camshaft Bearing Cap Attaching Bolt ......................................... 8.0 – 12.0 Nm
Cylinder Head Threaded Plug .............................................................. 31.0 Nm
„ Cylinder Head M11 Attaching Bolt:
Stage 1 ...................................................................................... 40.0 – 50.0 Nm
Stage 2 ....................................................................................................... 120 °
„ Cylinder Head M8 Attaching Bolt:
Stage 1 ...................................................................................... 12.0 – 18.0 Nm
Stage 2 ......................................................................................................... 60 °
Engine Mount Bracket to Cylinder Block Attaching Bolt ............ 43.0 – 57.0 Nm
Engine Mount to Bracket Attaching Nut ..................................... 70.0 – 90.0 Nm
Engine Mount to Frame Attaching Nut....................................... 44.0 – 60.0 Nm
Engine Lift Bracket Attaching Bolt .......................................... 58.0 – 72.0.0 Nm
Knock Sensor Attaching Nut................................................................. 23.0 Nm

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–45
Page 6A1–45
2.15 Engine Compression Test
A compression pressure test of the engine cylinders determines the condition of the rings, the valves and the head
gasket.
Preliminary Steps
1 Ensure the battery is fully charged.
2 Remove the spark plugs from all cylinders, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
NOTE
DTCs will set when the fuel system or the ignition
system is disabled and the engine is cranked.
Disregard DTCs that set under this condition.
3 Disable the fuel system by removi ng the fuel pump relay, refer to Section 8A Electrical Body & Chassis .
4 Start the engine to use any resi dual fuel from the fuel lines.
4 Disable the ignition coils by removing fuses 34 and 35, refer to Section 8A Electrical Body & Chassis .
5 Using Tech 2, command the throttle plate to wide open throttle.
Engine Cylinder Compression Test
1 Install the compression tester to cylinder number 1.
2 While observing the compression tester reading, turn t he ignition to the START position for several seconds and
then allow the ignition to return to the ON position.
3 Record the highest compression reading obtained.
4 Repeat the engine compression test for each cylinder.
Test Result Evaluation
Normal engine compression pressure builds quickly and evenly to over 965 kPa. In addition, the lowest reading of an
engine cylinder should not be less than 70 per cent of the highest reading. If any cylinder fails the compression test,
adding 15 ml of engine oil to the suspected cylinder may help isolate the following fault condition.
1 A fault condition in the piston rings will produce the following result:
• A low compression on the first engine cycle
• The compression tends to build-up with the succeeding engine rotation.
• The compression improves with the addition of engine oil.
2 A fault condition in an intake or exhaus t valve will produce the following result:
• A low compression on the first engine cycle
• The compression does not build with the succeeding engine rotation.
• The compression does not improve with the addition of engine oil.
3 A fault condition in the cylinder head gasket will produce the following result:
• A low compression on the first engine cycle
• The compression does not build with the succeeding engine rotation.
• The compression does not improve with the addition of engine oil.
• The suspected cylinders are pos itioned adjacent to each other.
• The engine oil may be contaminated with engine coolant.
• The engine coolant may be cont aminated with engine oil.
Once the fault has been identified, refe r to the relevant service procedure and reinstall the removed components.
Using Tech 2, clear DTCs.

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Engine Mechanical – V6 Page 6A1–46
Page 6A1–46
2.16 Cylinder Leakage Test
A leakage test may be performed to measure cylinder/combustion chamber leakage. High cylinder leakage may indicate
one or more of the following:
• worn or burnt valves,
• broken valve springs,
• stuck valve lifters,
• incorrect valve lash/adjustment,
• damaged piston,
• worn piston rings,
• worn or scored cylinder bore,
• damaged cylinder head gasket,
• cracked or damaged cylinder head, or
• cracked or damaged engine block.

1 Disconnect the battery ground negative cable.
2 Remove the spark plugs from all cylinders, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
3 Rotate the crankshaft to place the piston in the cyli nder being tested at top dead centre (TDC) of the compression
stroke.
4 Install a commercially available cylinder head leak down tester into the spark plug hole.
NOTE
If required, hold the crankshaft balancer bolt to
prevent the engine from rotating.
5 Apply shop air pressure to the cylinder head leak dow n tester and adjust according to the manufacturers
instructions.
6 Record the cylinder leakage value. Cylinder leakage t hat exceeds 25 percent is considered excessive and may
require component service. In excessive leakage situations, inspect for the following conditions:
• air leakage sounds at the throttle body or air inlet duct that may indicate a worn or burnt intake valve or a
broken valve spring,
• air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken
valve spring,
• air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston
rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder
head, or
• air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7 Perform the leakage test on the rema ining cylinders and record the values.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–70
Page 6A1–70
3.3 Oil Filter Adaptor
Remove

Disconnection of the battery affects
certain vehicle electronic systems, refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Disconnect the battery negative terminal.
2 Disconnect the wiring harness connecto r from the oil pressure sender.

3 Remove the oil filter adaptor attaching bolts (2), four
places.
4 Remove the oil filter adaptor and discard the gasket (3).
5 Clean the surfaces of t he adaptor and cylinder block.

• Do not use a screwdriver or similar to
prise the oil filter adapter from the engine
as damage to the sealing surface may
occur.
• If required, use a rubber mallet to tap the
oil filter adapter to loosen the
components prior to separating.
Tapping should be done at bends,
corners or reinforced areas to prevent
distortion of parts.
Figure 6A1 – 27
Reinstall
Reinstallation of the oil filter adaptor is the reverse of the remo val procedure, noting the following:
1 A new gasket must be used.
2 Loosely install the oil filter adaptor attaching bolts, then tighten all fast eners to the correct torque specification.
Oil filter adaptor attaching bolt
torque specificatio n ...................................20.0- 26.0 Nm

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–77
Page 6A1–77
3.9 Upper Intake Manifold
The intake manifold comprises of an upper and lower section. Some service procedures only require the removal of the
upper intake manifold (e.g. fuel injector/spark plug servicing), while other servic e procedures require the removal of both
the upper and lower manifold as a complete assembly (e .g. cylinder head/s). If the complete assembly needs to be
removed, refer to 3.10 Intake Manifold Assembly – Complete .
Remove

Disconnection of the battery affects
certain vehicle electronic systems. Refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Disconnect the battery negative terminal.
2 Remove the air intake duct (1) and hose (2), refer to
Section 6C1-3 Engine Management – V6 – Service
Operations .

Figure 6A1 – 34

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–83
Page 6A1–83
3.10 Intake Manifold Assembly – Complete
The intake manifold comprises of an upper and lower section. Some service procedures only require the removal of the
upper intake manifold (e.g. fuel injector/spark plug servicing), while other servic e procedures require the removal of both
the upper and lower manifold as a complete assembly (e.g . cylinder head/s). If only the upper intake manifold needs to
be removed, refer to 3.9 Upper Intake Manifold .
Remove

Disconnection of the battery affects
certain vehicle electronic systems. Refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Depressurise the fuel system.
2 Disconnect the battery negative terminal.
3 Remove the air intake duc t (1) and hose (2), refer to
Section 6C1-3 Engine Management – V6 – Service
Operations .


Figure 6A1 – 43

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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 vehicle electronic systems, refer to
1.1 WARNING, CAUTION and NOTES before
disconnecting the battery.
1 Disconnect the battery negative terminal.
2 Remove the oxygen sensor harness connector (1) from the retaining bracket.
3 Disconnect the oxygen sensor wiring harness connector from the engine wiring harness connector
(2).
4 Unclip the oxygen sensor wiring harness retaining clip and move aside.
5 For the left-hand side: Remove the oil level indicator tube.
6 Raise the front of the vehicle and place on stands,
refer to Section 0A General Information .
7 Working from under the vehicle, remove the two exhaust manifold to exhaust pipe flange nuts, refer to
Section 6F Exhaust System - V6 .
Figure 6A1 – 56
8 Remove the three bolts attaching the exhaust manifold outer heat shield (1) to the exhaust manifold
(2).

Figure 6A1 – 57

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ISUZU KB P190 2007