2007 ISUZU KB P190 engine oil

Engine Mechanical – V6 Page 6A1–290

Valve Spring Installed Height – Closed................................................................... 35.000 mm
Valve Spring Installed Height – Open ..................................................................... 24.000 mm
Valve Spring Load – Closed ................................................................................. 247 – 273 N
Valve Spring Load – Open.................................................................................... 598 – 662 N
Valve Spring Diameter – Inside Top ........................................................ 12.200 – 12.700 mm
Valve Spring Diameter – Outside Top ..................................................... 18.000 – 20.500 mm
Valve Spring Diameter – Inside Bottom ................................................... 17.950 – 18.450 mm
Valve Spring Diameter – Outside Bottom ............................................................... 26.000 mm
Valve Spring Coil Thickness ........................................................................ 3.250 – 3.900 mm
Valve Spring Total Number of Coils ..................................................................................... 7.1
Camshaft
Camshaft Bearing Inside Diameter – Front Number 1 ............................. 35.000 – 35.020 mm
Camshaft Bearing Inside Diameter – Middle & Rear Number 2 - 4.......... 27.000 – 27.020 mm
Camshaft End Play ...................................................................................... 0.045 – 0.215 mm
Camshaft Journal Diameter – Front Number 1 ........................................ 34.936 – 34.960 mm
Camshaft Journal Diameter – Middle & Rear Number 2 - 4..................... 26.936 – 26.960 mm
Camshaft Journal Out-of-round ................................................................................ 0.006 mm
Camshaft Journal to Bore Clearance ........................................................... 0.040 – 0.084 mm
Camshaft Runout – Front & Rear Number 1 and 4 ................................................... 0.025 mm
Camshaft Runout – Middle Number 2 and 3............................................................ .0.050 mm
Camshaft Lobe Duration – Exhaust (@ 0.150 mm Lift) .................................................... 238 °
Camshaft Lobe Duration – Intake (@ 0.150 mm Lift)........................................................ 237 °
Camshaft Lobe Height – Exhaust ................................................................................. 6.6 mm
Camshaft Lobe Height – Intake .................................................................................... 6.5 mm
Camshaft Lobe Overlap (@ 0.150 mm Lift) ..................................................... -5 ° (no overlap)
Valve Opens – Exhaust .........................................................................................229 ° BTDC
Valve Opens – Intake ...............................................................................................14 ° ATDC
Centre-line – Exhaust .............................................................................................111 ° BTDC
Centre-line – Intake ................................................................................................132 ° ATDC
Valve Closes – Exhaust ..............................................................................................9 ° ATDC
Valve Closes – Intake ............................................................................................252 ° ATDC
Valve Lift – Exhaust .................................................................................................... 10.8 mm
Valve Lift – Intake ....................................................................................................... 10.8 mm
Oil Pump
Type........................................................................................................................... ...Gerotor
Gear Diameter – Outer ............................................................................ 87.095 – 87.175 mm
Gear Bore Depth...................................................................................... 15.565 – 15.600 mm
Gear Bore Diameter................................................................................. 87.275 – 87.325 mm
Gear Thickness........................................................................................ 15.511 – 15.536 mm
Gear to Cover Clearance ............................................................................. 0.030 – 0.085 mm
Gear to Housing Clearance ......................................................................... 0.100 – 0.230 mm
Inner Gear Tip Clearance ............................................................................ 0.075 – 0.180 mm
Crankshaft Clearance to Housing ................................................................ 0.040 – 0.130 mm
Inner Gerotor Hub Diameter .................................................................... 53.310 – 53.335 mm
Housing Hub Diameter ............................................................................ 53.380 – 53.420 mm
Inner Gerotor Hub Clearance to Housing .................................................... 0.045 – 0.110 mm
Lubrication System
Oil Type .................................................................................................................. SAE 5 W 30
Oil Capacity – with Filter ................................................................................................... 6. 5 L
Oil Pressure – Minimum at idle ......................................................................................69 kPa
Oil Pressure – Minimum at 2000 r.p.m. .......................................................................138 kPa

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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 6A1–293

Power Steering High Pressure Line Attaching Bolt ..................... 8.0 – 12.0 Nm
Power Steering High Pressure Line Flare Nut ........................... 25.0 – 35.0 Nm
Steering Gear Housing Mounting Nut:
Stage 1 ................................................................................................. 60.0 Nm
Stage 2 ................................................................................................40° – 50°
Oil Suction Pipe Attaching Bolt ............................................................. 10.0 Nm
Crankshaft Oil Deflector Attaching bolt................................................. 10.0 Nm
Oil Level Sensor ................................................................................... 20.0 Nm
Oil Pan to Cylinder Block Attaching Bolt .................................... 20.0 – 26.0 Nm
Oil Pan to Crankshaft Rear Oil Seal Housing Attaching Bolt ........ 8.0 - 12.0 Nm
„ Flexplate Attaching Bolt:
Stage 1 ...................................................................................... 26.0 – 34.0 Nm
Stage 2 ......................................................................................................... 45 °
Crankshaft Rear Oil Seal Housing Attaching Bolt........................ 8.0 – 12.0 Nm
„ Connecting Rod Cap Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ................................................................................ Loosen Completely
Stage 3 ................................................................................................. 25.0 Nm
Stage 4 ....................................................................................................... 110 °
Crankshaft Bearing Cap Remover Nut ................................................. 11.0 Nm
„ Crankshaft Main Bearing Cap Inboard Attaching Bolt:
Stage 1 ................................................................................................. 20.0 Nm
Stage 2 ......................................................................................................... 80 °
„ Crankshaft Main Bearing Cap Outboard Attaching Bolt:
Stage 1 ................................................................................................. 15.0 Nm
Stage 2 ....................................................................................................... 110 °
„ Crankshaft main Bearing Cap Side Attaching Bolt:
Stage 1 ................................................................................................. 30.0 Nm
Stage 2 ......................................................................................................... 60 °
Cylinder Block Threaded Plug .................................................... 27.0 - 35.0 Nm
Oil Jet Attaching Bolt ................................................................... 8.0 – 12.0 Nm

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–295

Tool Number Illustration Description
EN-46109
Engine Front Cover / Oil Pan / Crankshaft Rear Oil Seal
Housing Installation Guide Pins
Used to align the engine front cover/oil pan/crankshaft rear oil
seal housing during engine assembly.
EN-46110
On-vehicle Valve Spring Compressor
Used to remove valve springs with the cylinder heads
assembled to the cylinder block.
EN-46111
Crankshaft Rotation Socket
Used to rotate the crankshaft during engine overhaul.
EN-46112
Timing Chain Tensioner Retraction Springs
Used to retain the timing chain tensioner plunger within the
tensioner bore during assembly of timing chains to engine.
EN-46114
Engine Lift Brackets
Used in conjunction with commercially available lifting
equipment to lift engine.
EN-46116
Valve Stem Seal Remover / Installer
Used to remove/install the valve stem seals.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–296

Tool Number Illustration Description
EN-46117
Valve Stem Key Remover / Installer
Used in conjunction with J-8062 or EN-46110 to remove and
reinstall the valve stem keys.
EN-46119
Off-vehicle Valve Spring Compressor Adaptor
Used in conjunction with J-8062 to remove valve springs with
the engine disassembled.
EN-46120 and
J-42096

Valve Guide Reamer
Used to oversize valve guides prior to the installation of new
oversized valves.
EN-46121
Connecting Rod Guide Pin Set
Used to guide connecting rods onto the crankshaft journals
and prevent damage to the cylinder bores, journal faces and
piston cooling jets during engine assembly procedures.
EN-46122
Oil Control Valve Check Ball Remover / Installer
EN-7115 Torque Angle W rench
Used to accurately tighten fasteners when an angle torque is
required.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–297

Tool Number Illustration Description
J-29184
Crankshaft Front Oil Seal Installer

J-36648-A
Oil Pressure Gauge Adaptor
j-41816 three legged puller

J-41818
Main Bearing Cap Removal Tool
Used in conjunction with J-6125-1B to remove the main
bearing caps from the cylinder block during engine
disassembly procedures.
J-41998-B
Crankshaft Balancer Installer
J-42385-2000

Thread Insert Kit
Used to repair damaged threads during engine overhaul.
J-42385-700
High Feature Thread Repair Kit
Used to repair damaged threads during engine overhaul.

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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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