2007 ISUZU KB P190 steering rack

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

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–3
Page 6A1–3
Definition ..................................................................................................................... .....................................62
Diagnostic Aids................................................................................................................................................. 62
Test Description ............................................................................................................... ................................62
Diagnostic Table............................................................................................................... ................................62
Drive Belt Excessive Wear ...................................................................................................... ............................64
Definition ..................................................................................................................... .....................................64
Diagnostic Aids................................................................................................................................................. 64
Test Description ............................................................................................................... ................................64
Diagnostic Table............................................................................................................... ................................64
Accessory Drive Belt Tensioner Diagnosis ....................................................................................... ................65
Diagnostic Table............................................................................................................... ................................65
3 Minor Service Operations ....................................................................................................... .............66
3.1 Engine Oil ..................................................................................................................... ........................................66
Check.................................................................................................................................................................... 66
Replace ........................................................................................................................ .........................................67
Pressure Check ................................................................................................................. ...................................68
3.2 Oil Filter Cartridge ........................................................................................................... ....................................69
Replace ........................................................................................................................ .........................................69
3.3 Oil Filter Adaptor............................................................................................................. .....................................70
Remove ................................................................................................................................................................. 70
Reinstall ................................................................................................................................................................ 70
3.4 Oil Level Indicator Tube ...................................................................................................................................... 71
Remove ................................................................................................................................................................. 71
Reinstall ................................................................................................................................................................ 71
3.5 Accessory Drive Belt ........................................................................................................................................... 72
RWD Vehicle ......................................................................................................................................................... 72
Remove ............................................................................................................................................................72
Reinstall ...................................................................................................................... .....................................73
3.6 Accessory Drive Belt Idler Pulley .............................................................................................. .........................74
Remove ................................................................................................................................................................. 74
Reinstall ................................................................................................................................................................ 74
3.7 Accessory Drive Belt Tensioner Assembly ........................................................................................ ...............75
Remove ................................................................................................................................................................. 75
Reinstall ................................................................................................................................................................ 75
3.8 Power Steering Pump Bracket .................................................................................................... ........................76
Remove ................................................................................................................................................................. 76
Reinstall ................................................................................................................................................................ 76
3.9 Upper Intake Manifold .......................................................................................................... ...............................77
Remove ................................................................................................................................................................. 77
Disassemble ......................................................................................................................................................... 80
Clean..................................................................................................................................................................... 80
Inspect ........................................................................................................................ ..........................................81
Reassemble .......................................................................................................................................................... 81
Reinstall ................................................................................................................................................................ 82
3.10 Intake Manifold Assembly – Complete............................................................................................ ...................83
Remove ................................................................................................................................................................. 83
Disassemble ......................................................................................................................................................... 87
Clean..................................................................................................................................................................... 88
Inspect ........................................................................................................................ ..........................................88
Reassemble .......................................................................................................................................................... 89
Reinstall ................................................................................................................................................................ 89
3.11 Exhaust Manifold Assembly ...................................................................................................... .........................91
Remove ................................................................................................................................................................. 91
Inspect ........................................................................................................................ ..........................................93
Reinstall ................................................................................................................................................................ 93
3.12 Camshaft Cover ................................................................................................................. ..................................94
Remove ................................................................................................................................................................. 94
Clean and Inspect .............................................................................................................. ..................................96

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–48
Page 6A1–48
2.18 Engine Oil Leak Diagnosis
Introduction
It is important to correctly identify the source of an engine oil leak. For example, a power steering fluid leak or spillage
during servicing can travel across the va lley area of the engine and run-out the weep hole, which is located at the back of
the cylinder block. Failure to correctly identify the source of an engine oil leak can lead to unnecessary replacement of
engine components.
Most fluid leaks can be repaired by repairi ng or replacing the faulty component or resealing the gasket surface. However,
once a leak is identified it is im portant to determine and repair the c ause as well as the leak itself.
Locating and Identifying the Leak
Inspect the leaking fluid and determine whet her it is engine oil, transmission fluid, power steering fluid, brake fluid or
some other fluid. If unsure of the source of the leaking lubricant, a quick check of fluid levels should indicate where the
fluid is coming from, as one or more fluid level should be low.
Visual Inspection
Once the type of leaking fluid has been determined, a visual inspection of the affected system should be performed.
When performing the visual inspection:
1 Bring the vehicle to the normal operating temperature.
2 Park the vehicle over a large s heet of paper or other clean surface.
3 Leave the vehicle idling for 2-3 minut es, then check for dripping fluid.
4 If required, identify the type of fluid leak ing and the approximate location of the leak.
5 Visually inspect the suspected area. A small mirror may assist viewing areas that are difficult to see normally.
6 Check for leaks at all sealing surfaces and fittings.
7 Check for any cracked or damaged components.
8 If the leak cannot be located, completely clean the entire engine and surrounding components, drive the vehicle at
normal operating temperature for several k ilometres and then repeat Steps 3 to 8.
9 If the leak still cannot be located, proceed with either the Powder Method or Black Light and Dye Method as
outlined below.
Powder Method
1 Completely clean the entir e engine and surrounding components.
2 Apply an aerosol type powder (e.g. f oot powder) to the suspected area.
3 Operate the vehicle at normal operating temperature and at varying speeds for several kilometres.
4 Identify the source of the leak from the discoloration of the powder around the suspect components.
5 If required, use a small mirror to assist in vi ewing areas that are difficult to see normally.
6 Refer to Possible Causes for Engine Oil Leaks in this Section, and repair or replace components as required.
Black Light and Dye Method
A black light and die kit Tool No. J28428-E or a commercially av ailable equivalent is available to technicians to aid in
engine oil leak diagnosis. When using a black light and die kit fo r the first time, it is recommended the technician read the
manufacturers instructions prior to using the kit.
1 Add the specified amount of dye, as per manufacturers instructions, into the engine or suspected source of the oil
leak.
2 Operate the vehicle at normal operating temperature and at varying speeds for several kilometres.
3 With the vehicle parked on a flat leve l surface, aim the black light at the suspected component/s. The dyed fluid will
appear as a yellow path leading to the oil leak source
4 Refer to Possible Causes for Engine Oil Leaks in this Section, and repair or replace components as required.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–76
Page 6A1–76
3.8 Power Steering Pump Bracket
Remove
1 Remove the power steering pump and reservoir, refer to Section 3B Steering.
2 Remove the three bolts (1), (3) and (4) attaching t he power steering pump bracket (5) to the engine block.
3 Remove the power steering pump bracket.

Figure 6A1 – 33
Reinstall
Reinstallation of the power steering pump and pump bracket is the reverse of the removal procedure, noting the
following:
1 Hand start the bolts before tightening.
2 Tighten the bolts to the co rrect torque specification.
Power steering pump bracket
attaching bolt torque specification ......................22.0 Nm



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–104
Page 6A1–104
3.15 Front Cover Assembly
Remove
1 Drain the engine coolant, refer to Section 6B1 Engine Cooling.
2 Remove the water outlet pipe and coolant pump assembly, refer to Section 6B1 Engine Cooling:
3 Remove the camsha ft covers, refer to 3.12 Camshaft Cover .
4 Remove the crankshaft bal ancer assembly, refer to 3.13 Crankshaft Balancer Assembly .
5 Disconnect the purge vent hose from the water outlet pipe.
NOTE
Do not disconnect the power steering pipes or
drain the power steering fluid.
6 Remove the power steering pump reservoir mounting bracket, refer to 3.8 Power Steering Pump Bracket.
7 Remove the camshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
NOTE
Do not disconnect the A/C compressor pipes.

8 Remove the bolt (2), 22 places, attaching the front cover assembly (1).

CAUTION
Only use the prise points and a bolt in the
jackscrew hole to remove the engine front
cover.

9 Loosely install a 10 x 1.5 mm bolt in the jackscrew hole (1).

10 Using the prise points (2) located at the edge of the
front cover and the jackscrew, shear the RTV sealant.
Figure 6A1 – 83






Figure 6A1 – 84

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–218
Page 6A1–218
Left-hand Side (Bank 2) Cylinder Head
1 Remove the intake manifold assembly, refer to 3.10 Intake Manifold Assembly – Complete .
2 Remove the exhaust manifold, refer to 3.11 Exhaust Manifold Assembly.
3 Remove the power steering reservoi r and pump mounting brackets, refer to 3.8 Power Steering Pump Bracket.
NOTE
Do not disconnect the power steering pipes
and/or hoses.
4 Remove the oil filter adapter upper bolt. NOTE
Do not remove the oil filter adapter.
5 Remove the engine coolant temper ature (ECT) sensor, refer to Section 6C1-3 Engine Management – V6 – Service
Operations .
6 Remove engine harness ground terminal attach ing bolt from cylinder head, refer to Section 8A Electrical Body &
Chassis .
7 Remove the left-hand bank secondary timing chain, refer to 3.16 Timing Chains, Tensioners, Shoes and Guides.
8 Remove the camshaft position actuators, refer to 3.18 Camshaft Sprocket.
9 Remove the front M8 (1) cylinder head attaching bolt, two places.
10 Remove the cylinder head attaching bolt (2), eight places.
11 Remove the cylinder head (3).


Figure 6A1 – 367
12 Remove and discard the cylinder head gasket (1).


Figure 6A1 – 368

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–248
Page 6A1–248
50 Unplug the connector from the oil level sensor (1).
51 Remove the attaching bolt (2) holding the ground cable to the engine block.


Figure 6A1 – 429
52 Remove the accessory drive belt using a socket wrench (1), to reduce tension rotate the drive belt
tensioner (2) clockwise, then while holding the
tensioner in the reduced tens ion position, remove the
accessory drive belt (3).


Figure 6A1 – 430
53 Remove the power steering pump bolts (two places),
remove the pump (1) from the mounting bracket and
disconnect the power steering hoses (two places)
from the pump body.

NOTE
Plug the open ends of the power steering hoses
to prevent the ingre ss of contaminants.

Figure 6A1 – 431

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–249
Page 6A1–249
54 Remove the power steering pump bracket mounting
bolts (three places) then remove the pump bracket
(1).

Figure 6A1 – 432
55 Release the lower radiator hose clamp (1) and remove the lower hose from the coolant pipe (2).

Figure 6A1 – 433
56 Release the upper radiator hose clamp (1) and remove the upper hose from the coolant pipe (2).

Figure 6A1 – 434

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007