2007 ISUZU KB P190 torque

Engine Mechanical – V6 Page 6A1–27
Page 6A1–27
Use of Room Temperature Vulcanising and Anaerobic Sealer
CAUTION
A number of sealant types are commonly
used in engines. Examples are; room
temperature vulcanising (RTV) sealer,
anaerobic gasket eliminator sealer, and
anaerobic thread sealant and pipe joint
compound. The correct type of sealant and
amount must be used in the specified location
to prevent oil leaks. Do not interchange the
different types of sealers.
Room Temperature Vulcanising Sealer
• Room temperature vulcanising (RTV) s ealant hardens when exposed to air. This type of sealer is used where two
non-rigid parts (such as the intake manifold and the engine block) are assembled together.
• Do not use RTV sealant in areas where extreme temper atures are experienced. These areas include the exhaust
manifold, head gasket, or other surfaces w here a gasket eliminator is specified.
• Follow all safety recommendations and di rections that are on the container.
• To remove the sealant or the gasket mate rial, refer to Replacing Engine Gaskets.
• Apply RTV to a clean surface. Use a bead size as specified in the service procedure. Run the bead to the inside of
any bolt holes. Do not allow the sealer to enter any bli nd threaded holes, as it may prevent the bolt from clamping
correctly or cause damage when the bolt is tightened.
• Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
Anaerobic Sealer
• Anaerobic gasket eliminator or thread sealant, hardens in t he absence of air. This type sealer is used where two
rigid parts (such as castings) are assembled together, w here fasteners are subjected to vibration, or where the
holes are not blind. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts
were probably assembled using a gasket eliminator.
• Follow all safety recommendations and di rections that are on the container.
• To remove the sealant or the gasket mate rial, refer to Replacing Engine Gaskets.
• Apply a continuous bead of gasket eliminator to one flange or on the bolt/stud thread. All surfaces must be clean
and dry.
• Spread the sealer evenly to achieve a uniform coating on the sealing surface.
• Do not allow the sealer to enter any blind threaded holes as it may prevent the bolt from clamping correctly or
cause damage when tightened.
CAUTION
Anaerobic sealed joints that are partially
tightened and allowed to cure more than five
minutes may result in incorrect shimming and
sealing of the joint.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
• After correctly tightening the fasteners, remove t he excess sealer from the outside of the joint.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–28
Page 6A1–28
Pipe Joint Compound
• Pipe joint compound is a pliable sealer that does not comp letely harden. This type of sealer is used where two non-
rigid parts (such as pressed steel and ma chined surfaces) are assembled together.
• Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include the
exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
• Follow all safety recommendations and di rections that are on the container.
• To remove the sealant or the gasket mate rial, refer to Replacing Engine Gaskets.
• Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run
the bead to the inside of any bolt holes. Do not allow the s ealer to enter any blind threaded holes as it may prevent
the bolt from clamping correctly or caus e component damage when the bolt is tightened.
• Apply a continuous bead of pipe joint compound to one seali ng surface. Sealing surfaces to be resealed must be
clean and dry.
• Tighten the bolts to the correct torque specification. Do not over-tighten.
Separating Parts
CAUTION
Many internal engine components will
develop specific wear patterns on their
friction surfaces. When disassembling the
engine, internal components must be
separated, marked and organised in a way to
ensure reinstallation in their original location
and position.
Separate, mark, or organise the following components:
• Piston and the piston pin.
• Piston to the specific cylinder bore.
• Piston rings to the specific piston.
• Connecting rod to the crankshaft journal.
• Connecting rod to the bearing cap.
• Crankshaft main and connecting rod bearings.
• Camshaft and rocker arms.
• Rocker arms and stationary hydraulic lash adjusters to cylinder head location.
• Valve to the valve guide.
• Valve spring and shim to the cylinder head location.
• Engine block main bearing cap location and direction.
• Oil pump drive and driven gears.
Tools and Equipment
Special tools are listed and illustrated throughout this Section with a complete listing at the end, refer to 7 Special Tools.
These tools (or their equivalents) are specially designed to quickly and safely accomplish the operations for which they
are intended. The use of these special tools will also minimise possible damage to engine components. Some precision
measuring tools are required for inspec tion of certain critical components. A commercially available torque wrench and
torque angle wrench, Tool No. EN-7115 are required for the correct tightening of various fasteners.
To correctly service the engine assembly, the following items should be readily available:
• Approved eye protection and safety gloves.
• A clean, well-lit, work area.
• A suitable parts cleaning tank.
• A compressed air supply.
• Trays or storage containers to keep parts and fasteners organised.
• An adequate set of hand tools.
• Approved engine repair stand.
• An approved engine lifting device that will adequatel y support the weight of the components.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–29
Page 6A1–29
Fasteners
Fasteners are central to the reliable operation of an engine.
Whenever any bolt or any other threaded component is
removed, allow the engine to cool (inset A) before
attempting fastener removal.
Because of the greater the rmal expansion of aluminium,
bolt threads will change dimensi on to a greater extent when
hot with this material (inset B) when compared to cast iron.
If a bolt or other threaded com ponent is removed before the
engine is allowed to cool to at least 50 ° C, threads could be
pulled from the cylinder block or cylinder head.
Do not use impact tools to remove bolts during engine
disassembly. While this may be common practice with cast
iron engine components, use of thes e tools is more likely to
pull the aluminium threads in the cylinder block or head of
this engine.

Figure 6A1 – 19
Clamp Load
When torque is applied to a fa stener, the fastener stretches
and the joint compresses. The force developed in the
fastener due to its stretch is called tension (C), while the
force applied to the joint is called clamp load (B).
As shown, only a small portion of the applied torque (A) is
transferred to the clamp load (inset 1). Friction under the
bolt head (inset 3) and in the threads (inset 2) absorbs
much of the applied torque (A). Typically, only 10% (inset 1)
of the torque is available to develop stretch (or tension) in
the fastener and clamp load in the joint.
Therefore, a slight variation in friction in the thread or under
the bolt head, results in a wide variation in the clamp load
applied to the joint.

Figure 6A1 – 20
Torque Angle and Torque to Yield Fasteners
The torque angle method of applying torque to a fastener has been developed to overcome the effects of friction
variation in fastener applications.
The application of the torque angle method does not always mean the fastener has to be replaced after loosening. It is
only when the fastener has been angle tightened to the extent the yield point has been exceeded, that the fastener must
be replaced.
Examples are the main bearing caps that are angle tightened but the bolts can be re-used, whereas the M11 cylinder
head bolts that are torque to yield fasteners, must be replaced after loosening.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–40
Page 6A1–40
2.10 Lower Engine Noise, Regardless of
Engine Speed
NOTE
A cold piston knock which disappears in
approximately 1.5 minutes from start up should
be considered acceptable. A cold engine knock
usually disappears when t he specific cylinder’s
secondary ignition circuit is grounded out during
diagnosis.
A light rattle/tapping noise may indicate a valve train/upper engine concern, while a low rumble/knocking may indicate a
crankshaft, piston or lower engine concern.
Cause Correction
Low oil pressure. 1 Perform an oil pressure test, refer to 2.19 Engine Oil
Pressure Diagnosis.
2 Repair or replace the engine oil pump as required, refer to 3.17 Oil Pump Assembly.
Worn accessory drive components.
Abnormalities such as severe cracking, bumps, stretching
or missing areas on an accessory drive belt and/or
misalignment of accessory drive system components. Inspect the accessory drive system, repair or replace
components as required, refer to 3.5 Accessory Drive Belt.
Loose or damaged crankshaft balancer and pulley
assembly. Repair or replace the crankshaft balancer and pulley
assembly as required, refer to 3.13 Crankshaft Balancer
Assembly.
Detonation or spark knock. Confirm the correct operation of the ignition system, refer to
6C1-2 Engine Management – V6 – Diagnostics.
Loose torque converter bolts. Inspect and tighten the torque converter bolts to the correct
torque specification, refer to 7C4 Automatic Transmission –
4L60E – On-vehicle Servicing.
Loose or damaged flexplate. Repair or replace the flexplate as required, refer to 4.3
Flexplate Assembly.
Oil pump suction pipe loos e, damaged or restricted.
Clean, inspect and repair/replace the oil pump suction pipe
as required, refer to 4.2 O il Pan and Oil Pump Suction Pipe
Assembly.
Excessive piston-to-cylinder bore clearance. Inspect the piston and cylinder bore and repair/replace
components as required, refer to 4.5 Pistons, Pins, Rings,
Connecting Rods and Big-end Bearings and 4.7 Cylinder
Block.
Excessive connecting rod bearing clearance. Inspect the connecting rod, crankshaft and bearings and
repair/replace components as required, refer to 4.5
Pistons, Pins, Rings, Connecting Rods and Big-end
Bearings and 4.6 Crankshaft and Main Bearings.
Excessive piston pin to bore clearance. Inspect the pistons and pins and repair/replace components
as required, refer to 4.5 Pistons, Pins, Rings, Connecting
Rods and Big-end Bearings.
Excessive crankshaft main bearing clearance. Inspect the crankshaft, cylinder block journals, main
bearings and main bearing caps and repair/replace
components as required, refer to 4.6 Crankshaft and Main
Bearings and 4.7 Cylinder Block.
Incorrect piston, pin and c onnecting rod installation.
Pistons must be installed with the mark or dimple facing the
front of the engine. Piston pi ns must be centred in the
piston pin bore. Confirm the pistons, pins and
connecting rods are installed
correctly and repair if required, refer to 4.5 Pistons, Pins,
Rings, Connecting Rods and Big-end Bearings.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–41
Page 6A1–41
2.11 Engine Noise Under Load
NOTE
A cold piston knock which disappears in
approximately 1.5 minutes from start up, should
be considered acceptable. A cold engine knock
usually disappears when t he specific cylinder’s
secondary ignition circuit is grounded out during
diagnosis.
A light rattle/tapping noise may indicate a valve train/upper engine concern, while a low rumble/knocking may indicate a
crankshaft, piston or lower engine concern.
Cause Correction
Low oil pressure. 1 Perform an oil pressure test, refer to 2.19 Engine Oil
Pressure Diagnosis.
2 Repair or replace the engine oil pump as required, refer to 3.17 Oil Pump Assembly.
Detonation or spark knock. Confirm the correct operation of the ignition system, refer to
6C1-2 Engine Management – V6 – Diagnostics.
Loose torque converter bolts. Inspect and tighten the torque converter bolts to the correct
torque specification, refer to 7C1 Automatic – 4L60E –
General Information – 4L60E – General Information.
Cracked flexplate. Replace the flywheel/flex-plate as required, refer to
4.3 Flexplate Assembly.
Excessive connecting rod bearing clearance. Inspect the connecting rod, crankshaft and bearings and
repair/replace components as required, refer to
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end
Bearings and 4.6 Crankshaft and Main Bearings.
Excessive crankshaft bearing clearance Inspect the crankshaft, cylinder block journals, main
bearings and main bearing caps and repair/replace
components as required, refer to 4.6 Crankshaft and Main
Bearings and 4.7 Cylinder Block.

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Engine Mechanical – V6 Page 6A1–42
Page 6A1–42
2.12 Engine Will Not Crank – Crankshaft Will
Not Rotate
Cause Correction
Seized accessory drive system component. 1 Remove the accessory drive belt, refer to
3.5 Accessory Drive Belt.
2 Rotate the crankshaft by hand at the balancer pulley or flywheel.
3 Repair or replace accessory drive system components as required.
Hydraulically locked cylinder caused by:
• coolant in cylinder,
• oil in cylinder, or
• fuel in cylinder. 1 Remove the spark plugs and check for fluid, refer to
6C1-3 Engine Management – V6 – Service
Operations.
2 Inspect for broken head gasket/s.
3 Inspect for cracked engine block or cylinder head.
4 Inspect for sticking fuel injector.
5 Repair or replace components as required.
Seized torque converter. 1 Remove the torque converter bolts, refer to 7C1
Automatic – 4L60E – General Information – 4L60E –
General Information.
2 Rotate the crankshaft by hand at the balancer pulley or flywheel.
3 Repair or replace torque converter as required.
Material in cylinder bore, caused by:
• broken valve,
• broken piston or ring, or
• dirt or foreign matter entry during engine assembly
procedure. 1 Clean and inspect the cylinder for damaged
components and or foreign matter, refer to 4.7
Cylinder Block.
2 Repair or replace components as required.
Seized crankshaft or connecting rod bearings. Inspect and repair or replace crankshaft, connecting rod
and bearings as required, refer to 4.5 Pistons, Pins, Rings,
Connecting Rods and Big-end Bearings and 4.6
Crankshaft and Main Bearings.
Bent or broken connecting rod. Inspect and repair or replace connecting rod and bearings
as required, refer to 4.5 Pistons, Pins, Rings, Connecting
Rods and Big-end Bearings.
Bent or broken crankshaft. Inspect and repair or replace crankshaft and bearings as
required, refer to 4.6 Crankshaft and Main Bearings.
Seized or broken camshaft. 1 Inspect and replace camshafts as required, refer to
3.19 Camshaft.
2 Inspect camshaft journals and cam caps on cylinder head and repair or replace components as required,
refer to 3.22 Cylinder Head Assembly.
Seized or broken camshaft timing components. 1 Inspect the crankshaft, idler, intake camshaft and
exhaust camshaft sprockets.
2 Inspect the timing chains.
3 Inspect the guides.
4 Inspect the tensioners.
5 Repair or replace components as required, refer to 3.16 Timing Chains, Tensioners, Shoes and Guides.
Seized or broken valve train components. 1 Inspect the stationary hydraulic lash adjusters, refer
to 3.21 Stationary Hydraulic Lash Adjuster.
2 Inspect the rocker arms, re fer to 3.20 Rocker Arm.
3 Inspect the Valves Refer to 3.22 Cylinder Head Assembly.
4 Inspect the valve springs, refer to 3.22 Cylinder Head Assembly.
5 Repair or replace components as required.

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Engine Mechanical – V6 Page 6A1–54
Page 6A1–54
Diagnostic Table
Step Action Yes No
1
Did you review the information provided in 2.2 Symptoms, and
perform the required inspections. Go to Step 2 Go to
2.2 Symptoms
2 Confirm the customer compla int. Is there a chirping noise?
Go to Step 3 Refer to Diagnostic
Aids in this Section
3 1 Remove the drive belt, refer to 3.5 Accessory Drive Belt.
2 Operate the engine for no more than 40 seconds.
Does the chirping noise still exist? Accessory drive
system OK.
Go to 2.2
Symptoms, and
restart the diagnosis
of the noise Go to Step 4
4
Inspect for severe pilling, i.e. in excess of 33% of the belt groove
depth.
Do the belt grooves have pilling? Go to Step 5 Go to Step 6
5 Clean the drive belt pulleys with a wire brush.
Are the belt pulleys clean? Go to Step 15 Go to Step 6
6 Inspect for misalignment of the pulleys.
Are the pulleys misaligned? Go to Step 7 Go to Step 8
7 Replace or repair misaligned pulleys.
Did you complete the repair? Go to Step 15 —
8
Inspect for any bent or damaged accessory drive component
mounting brackets.
Did you find any bent or damaged brackets? Go to Step 9 Go to Step 10
9 Replace or repair any bent or damaged Brackets. Did you complete the repairs? Go to Step 15 —
10 Inspect for missing, loose or incorrect fasteners.
Did you find any missing, loose or incorrect fasteners? Go to Step 11 Go to Step 12
11
Tighten any loose fasteners to the to rque specification as provided in
provided in 6. Torque Wrench Specifications.
Replace any incorrect or missing fasteners.
Did you complete the repairs? Go to Step 15 —
12 Inspect for a bent pulley.
Did you find any bent pulleys? Go to Step 13 Go to Step 14
13 Replace bent pulleys as required.
Did you complete the repair? Go to Step 15 —
14 Replace the accessory drive belt, re
fer to 3.5 Accessory Drive Belt.
Did you complete the repair? Go to Step 15 —
15
Reinstall the accessory drive belt and operate the system to confirm
the repair.
Did you correct the chirp noise? Accessory drive
system OK Go to 2.2
Symptoms, and
restart the diagnosis

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Engine Mechanical – V6 Page 6A1–61
Page 6A1–61
Step Action Yes No
6 Inspect for incorrect, loose, missing or damaged fasteners.
Did you find any incorrect, loose, missing or damaged fasteners? Go to Step 7 Go to Step 8
7
Tighten any loose fasteners to the corre ct torque specification, refer to
6 Torque Wrench Specifications.
Replace any incorrect or missing fasteners.
Did you complete the repairs? Go to Step 10 —
8
Inspect the coolant pump for a bent shaft, refer to 6B1 Engine Cooling
– V6.
Did you find and repair a bent coolant pump shaft? Go to Step 10 Go to Step 9
9
Inspect for bent, cracked or damaged accessory drive component
mounting brackets.
Did you find and repair any bent brackets? Go to Step 10 Refer to Diagnostic
Aids in this Section
10 If required, reinstall the accessory drive belt and operate the system to
confirm the repair.
Did you correct the vibration? Accessory drive
system OK Refer to Diagnostic
Aids in this Section

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