2007 ISUZU KB P190 oil

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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
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.

BACK TO CHAPTER INDEX
TO MODEL INDEX
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

BACK TO CHAPTER INDEX
TO MODEL INDEX
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

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 6A1–4
Page 6A1–4
Reinstall ................................................................................................................................................................ 97
3.13 Crankshaft Balancer Assembly ................................................................................................... .....................100
Remove ............................................................................................................................................................... 100
Clean and Inspect .............................................................................................................. ................................101
Reinstall .............................................................................................................................................................. 101
3.14 Crankshaft Front Seal.......................................................................................................... ..............................103
Replace ........................................................................................................................ .......................................103
3.15 Front Cover Assembly........................................................................................................... ............................104
Remove ............................................................................................................................................................... 104
Disassemble ....................................................................................................................................................... 105
Clean................................................................................................................................................................... 106
Inspect ........................................................................................................................ ........................................107
Reassemble ........................................................................................................................................................ 107
Reinstall .............................................................................................................................................................. 108
3.16 Timing Chains, Tensioners, Shoes and Guides .................................................................................... ..........110
Primary and Left-hand Secondary Timing Chain Installation ...................................................................... ..110
Excluding MY 06 Update .......................................................................................................... .......................110
MY06 Update .................................................................................................................... .............................111
Right-hand Secondary Timi ng Chain Installation ........................................................................................... 112
Excluding MY06 Update .......................................................................................................... .......................112
MY06 Update .................................................................................................................... .............................113
Remove ............................................................................................................................................................... 114
Right-hand Secondary Timing Chain.............................................................................................. ................114
Primary Timi ng Chain ........................................................................................................... ..........................118
Left-hand Secondary Timing C hain ............................................................................................... .................120
Clean................................................................................................................................................................... 123
Inspect ........................................................................................................................ ........................................124
Timing Chains .................................................................................................................. ..............................124
Camshaft Intermedi ate Sprockets .................................................................................................................. 124
Inlet and Exhaust Camshaft Sprocket ............................................................................................ ................124
Crankshaft Sprocket ....................................................................................................................................... 125
Primary Timing Chain Upper Guide............................................................................................... .................125
Primary Timing C hain Lower Guide............................................................................................... .................125
Primary Timing C hain Tensioner ................................................................................................. ...................126
Left-hand Secondary Ti ming Chain Guide ......................................................................................... ............126
Left-hand Secondary Ti ming Chain Shoe.......................................................................................... .............127
Left-hand Secondary Timi ng Chain Tensioner ..................................................................................... ..........127
Right-hand Sec ondary Timing Chain Guide ................................................................................................... 128
Right-hand Secondary Timing Chain Shoe ......................................................................................... ...........128
Right-hand Se condary Timing Chain Tensioner .................................................................................... .........129
Reinst all .............................................................................................................................................................. 130
Left-hand Secondary Timing Chain Components – Excluding MY06 Update ................................................ 130
Left-hand Secondary Timing Chain Components – MY06 Update ................................................................. 139
Primary Timing Chain Components – Excluding MY06 Update ..................................................................... 149
Primary Timing Chain Components – MY06 Update .................................................................................. ....156
Right-hand Secondary Timing Chain Components – Excluding MY06 Update .............................................. 164
Right-hand Secondary Timing Chain Components – MY06 Update............................................................... 171
3.17 Oil Pump Assembly .............................................................................................................. .............................180
Remove ............................................................................................................................................................... 180
Disassemble ....................................................................................................................................................... 181
Clean................................................................................................................................................................... 182
Inspect ........................................................................................................................ ........................................183
Reassemble ........................................................................................................................................................ 185
Reinstall .............................................................................................................................................................. 185
3.18 Camshaft Sprocket – Excluding MY06 Update ................................................................................................ 186
Remove ............................................................................................................................................................... 186
Right-hand Side................................................................................................................ ..............................186
Left-hand Side ................................................................................................................................................ 189
Clean................................................................................................................................................................... 191
Inspect ........................................................................................................................ ........................................191

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–5
Page 6A1–5
Reinstall .............................................................................................................................................................. 192
3.19 Camshaft Sprocket – MY06 Update ................................................................................................ ..................193
Remove ............................................................................................................................................................... 193
Right-hand Side................................................................................................................ ..............................193
Left-hand Side ................................................................................................................................................ 196
Clean................................................................................................................................................................... 199
Inspect ........................................................................................................................ ........................................199
Reinstall .............................................................................................................................................................. 200
3.20 Camshaft ............................................................................................................................................................ 201
Remove ............................................................................................................................................................... 201
Right-hand Side................................................................................................................ ..............................201
Left-hand Side ................................................................................................................................................ 203
Clean................................................................................................................................................................... 204
Inspect ........................................................................................................................ ........................................205
Camshaft Visual Inspection ..................................................................................................... .......................205
Camshaft Meas urement ................................................................................................................................. 205
Reinstall .............................................................................................................................................................. 207
Right-hand Side................................................................................................................ ..............................207
Left-hand Side ................................................................................................................................................ 210
3.21 Rocker Arm......................................................................................................................................................... 213
Remove ............................................................................................................................................................... 213
Clean and Inspect .............................................................................................................. ................................213
Reinstall .............................................................................................................................................................. 214
3.22 Stationary Hydraulic Lash Adjuster ............................................................................................. ....................215
Remove ............................................................................................................................................................... 215
Clean and Inspect .............................................................................................................. ................................215
Reinstall .............................................................................................................................................................. 216
3.23 Cylinder Head Assembly ......................................................................................................... ..........................217
Remove ............................................................................................................................................................... 217
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............217
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................218
Disassemble ....................................................................................................................................................... 219
Clean................................................................................................................................................................... 222
Inspect ........................................................................................................................ ........................................222
Visual Inspection .............................................................................................................. ..............................222
Cylinder Head Measurement.......................................................................................................................... 223
Valve Spring Inspection and Measurement ........................................................................................ ............225
Valve and Seat Grinding ........................................................................................................ ........................225
Assemble ....................................................................................................................... .....................................230
Reinstall .............................................................................................................................................................. 233
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............233
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................234
3.24 Engine Mounts and Brackets ..................................................................................................... .......................236
Remove ............................................................................................................................................................... 236
Engine Mount Location ..................................................................................................................................... 237
Inspect ........................................................................................................................ ........................................237
Reinstall .............................................................................................................................................................. 238
4 Major Service Operations ....................................................................................................... ...........239
4.1 Engine Re moval ................................................................................................................. ................................239
Remove ............................................................................................................................................................... 240
Disassemble ....................................................................................................................................................... 252
Reassemble ........................................................................................................................................................ 253
Reinstall .............................................................................................................................................................. 253
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ...........254
Remove ............................................................................................................................................................... 254
Disassemble ....................................................................................................................................................... 255
Clean................................................................................................................................................................... 255
Inspect ........................................................................................................................ ........................................256

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–7
Page 6A1–7
Left-hand Cylinder Head Intake Face ............................................................................................ ...................324
Left-hand Cylinder H ead Exhaust Face ........................................................................................... ................325
Left-hand Cylinder H ead Rear Face .............................................................................................. ...................326
Right-hand Cylinder Head Camshaft Cover Face ................................................................................... ........327
Right-hand Cylinder Head Front Face............................................................................................ ..................328
Right-hand Cylinder Head Intake Face ........................................................................................... .................329
Right-hand Cylinder He ad Exhaust Face .......................................................................................... ...............330
Right-hand Cylinder Head Rear Face ............................................................................................. ..................331
Engine Block Front ............................................................................................................................................ 332
Engine Block Left-hand Side .................................................................................................... ........................333
Engine Block Ri ght-hand Side ................................................................................................... .......................334
Engine Block Rear .............................................................................................................. ...............................335
Engine Block Bottom......................................................................................................................................... 336
Engine Block Left-hand Deck Face ............................................................................................... ...................337
Engine Block Righ t-hand Deck Face.............................................................................................. ..................338
Engine Front Cover............................................................................................................. ...............................339
Upper Intake Manifold Top ...................................................................................................... ..........................340
Upper Intake Mani fold Front .................................................................................................... .........................341
Upper Intake Ma nifold Rear..................................................................................................... ..........................342
Lower Intake Ma nifold Top...................................................................................................... ..........................343
Oil Pan Front .................................................................................................................. ....................................344
Oil Pan Rear........................................................................................................................................................ 345
Oil Pan Bottom ................................................................................................................................................... 346
5 Specifications .....................................................................................................................................347
6 Torque Wrench Specifications................................................................................................... .......351
7 Special Tools .................................................................................................................. ....................353

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007