2007 ISUZU KB P190 tow

Engine Mechanical – V6 Page 6A1–279
Page 6A1–279
8 Determine the connecting rod bearing clearance by
comparing the width of the flattened plastic
gauging (1) material at its widest point with the
graduation on the gauging mate rial container (2).
9 Compare the measurements with the specifications,
refer to 5 Specifications .
10 If the new bearings do not provide the correct crankshaft to connecting rod bearing clearance,
inspect the following:
11 Measure the crankshaft connecting rod journals for the correct specified size and ensure the correct new
bearings are being installed. If the crankshaft
connecting rod journals are in correctly sized, replace
or regrind the crankshaft. Crankshaft machining is
permitted and undersized bearings are available.
12 Measure the connecting rod bearing bore diameter to
ensure correct size. The connecting rod is not
machineable and the connecting rod must be
replaced if out of specification.
13 Clean the plastic gauging material from the connecting rod bearing journals using a soft lint-free
cloth.

Figure 6A1 – 498
Connecting Rod Final Assembly Procedure
1 Carefully guide the connecting rod away from the crankshaft connecting rod journal slightly to lubricate
the crankshaft connecting rod bearing journal.
2 Apply a liberal amount of clean engine oil to the crankshaft connecting rod bearing journal.
3 Guide the connecting rod to the crankshaft connecting rod journal.
4 Install the connecting rod end cap (1) on its original
connecting rod and ensure t he bearing lock tangs are
aligned on the same side of the rod.
CAUTION
• Do not lubricate the new connecting rod
bolts. The new bolts have a pre-applied
graphite lubricant. Applying lubricant to
the connecting rod bolts will effect the
clamp load when the connecting rod
bolts are tightened to the specified
torque. Incorrect clamp load can lead to
component failure and extensive engine
damage.
• Do not reuse the old connecting rod
bolts.

Figure 6A1 – 499
5 Install new connecting rod bolts into the connecting r od cap and tighten to the correct torque specification.
„ Connecting rod cap attaching bolt
torque specification:
Stage 1 .........................30.0 Nm
Stage 2 ........Loosen completely
Stage 3 .........................25.0 Nm
Stage 4 ..................110 degrees
NOTE
During and after installation, ensure each piston
is positioned correctly in the correct cylinder. The
locating arrow on the top of each piston must be
pointing toward the front of the engine.
6 Repeat these procedures for the rema ining piston/connecting rod assemblies.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–281
Page 6A1–281
4.6 Crankshaft and Main Bearings
1 Remove the engine assembly, refer to 4.1 Engine .
2 Remove both cylinder head assemblies, refer to 3.22 Cylinder Head Assembly.
3 Remove the oil pan assembly, refer to 4.2 Oil Pan and Oil Pump Suction Pipe Assembly .
4 Remove the piston and connecting rod assemblies, refer to 4.5 Pistons, Pins, Rings, Connecting Rods and Big-
end Bearings .
5 Remove the oil pump assembly, refer to 3.17 Oil Pump Assembly.
6 Remove the crankshaft rear oil seal and plate assembly, refer to 4.4 Crankshaft Rear Seal and Plate Assembly .
7 Remove the crankshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
Crankshaft End Play Measurement
1 Place a dial indicator at the end of the crankshaft nose.
2 Gently force the crankshaft towards the front and rear of the cylinder block with a lever while monitoring the
movement of the dial indicator.
3 The crankshaft endplay should not exceed specifications, refer to 5 Specifications.
4 If the specifications are ex ceeded, inspect the thrust bearing thrust outer diameter and the crankshaft thrust wall for
wear and/or excessive runout. Compare the va lues with the specifications, refer to 5 Specifications.
5 Replace the thrust bearing or crankshaft as required.
Remove
1 Remove the crankshaft bearing cap side bolts (3).
CAUTION
The crankshaft bearing cap outer bolts are
yield tightened during assembly and must
be replaced prior to reassembly. Crankshaft
bearing cap outer bolts that are not replaced
will not torque to the correct clamp load and
can lead to serious engine damage.
2 Remove the crankshaft bearing cap outer bolts (1).
3 Remove the crankshaft bearing cap inner bolts (2).

Figure 6A1 – 500

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ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–19

a Place a few drops of distilled water (between 21 and 29° C) onto the measuring window, then close the
plastic cover.
b Point the tester toward any light source, look into the eyepiece and check that the indicated reading is zero. If not, then re-calibrate the tester as detailed at the end of this Test Method, Calibrating the Tester.
2 Release the tip of the bulb pump from under the refractometer body. It is not necessary to remove the
complete pump from the tool.

Refer to 3.1 Service Notes in this
Section, for important safety items.
3 Carefully remove the coolant filler cap.
4 Insert the tube of the pump into the coolant, and then press the bulb to obtain a sample.
5 Bend the tube around and insert the end into the cover plate opening.
Figure 6B1 – 15
6 Press the pump bulb to deposit a few drops of coolant onto the measuring surface. Do not open the plastic cover when taking readings, as moisture evaporation will change the reading obtained.
7 Point the coolant tester toward any light source, looking into the eyepiece.
a The coolant protection reading is at the point where the dividing line between the light and
dark, crosses the scale.
b The scale for ethylene glycol (bold arrow) is the reference scale for either DEX-COOL®
long-life coolant or its equivalent, known as
Extended Life Anti-freeze Coolant conforming
to GM specification 6277M.
NOTE
The temperature scale is reversed from that of
a conventional thermometer. Below zero
readings are on the upper half of the scale.
8 A reading between – 30 and – 52 °C (corresponding
to a coolant concentration between 45 to 60%), is
satisfactory for the HFV6 engine cooling system.
Figure 6B1 – 16

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ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–63

4.5 Problems Not Requiring Disassembly of
Cooling System
1 Large obstructions blocking radiator or condenser airflow.
• Auxiliary oil coolers
• License plate
• Obstruction of radiator grille, for example, driving lights or mud
2 Loose, damaged or missing air chute side panels.
3 Missing or damaged air baffle.
4 Cracked or loose coolant recovery system hose.
5 Leaking heater component such as the heater core or water valve.
4.6 Problems Requiring Disassembly of Cooling System
1 Damaged cooling fan or faulty motor operation.
2 Pressure test cooling system.
3 Defective coolant pump.
• Eroded or broken impeller vanes
• Failed bearing or seal – check for shaft or bearing end play
4 Internally blocked radiator core.
5 Obstruction of coolant recovery system.
6 Internal system leaks.
• Head gaskets
• Cracked cylinder block
• Engine front cover
• Intake manifold gaskets
7 Blocked coolant passages in cylinder heads or block – remove cylinder heads and check.
4.7 Black Light and Dye Leak Diagnosis Method
It is strongly recommended that this diagnostic method be used to diagnose fluid leaks. This method is a proven and
reliable method that identifies the specific leak source.
The black light kit can be used for the leak detection of a number of fluids, when used with the appropriate tracer dye.
Examples are: Coolant, Engine Oil, Automatic Transmission Fluid and Air Conditioning Refrigerant (R134A).
The following is a summary of the steps involved in detecting a cooling system fluid leak using black light and dye:
1 Pour specified amount of dye into the cooling system via the coolant filler cap on the outlet housing. Refer 3.1 Service Notes in this Section.
2 Road test the vehicle under normal operating conditions.
3 Direct the light towards the suspect area. The fluid leak will appear as a brightly coloured path leading from the source.
4 Repair fluid leak and recheck to ensure that leak has been rectified.
5 Refer to the manufacturer’s directions when using this method.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 9


A small amount of fuel may be released when
connecting the fuel pressure gauge to the fuel
pressure test point. Cover the fittings with a
shop towel to absorb any fuel spillage before
connecting the fuel pressure gauge. After the
fuel pressure test procedure, place the soiled
towel in an approved container for disposal.
3 At the fuel pressure test point, remove the Schrader valve sealing cap.
4 Connect the fuel pressure gauge (1) (tool No. J 34730–1A) to the fuel gauge Schrader fitting
adapter (2) (tool No. AU453), then install to the fuel
pressure test port (3). W rap a shop towel around the
fitting while connecting the fuel pressure gauge to
avoid and/or capture any fuel spillage.
5 Route the bleed hose of the fuel gauge into an approved fuel container.


Figure 6C – 5

After connecting the fuel pressure gauge and
pressurising the fuel system, inspect for fuel
leaks at the fuel pressure gauge and the fuel
pressure test point.
6 Either: Using Tech 2, enable the fuel pump to pressurise the fuel system, refer to 0C Tech 2. Inspect for fuel leaks at the
fuel pressure gauge and fuel pressure test point, then bleed the air from the fuel pressure gauge.
or: Reinstall the fuel pump relay and fuel pump fuse, then open the fuel gauge bleed valve (4) to bleed the air from the
fuel pressure gauge, refer to Figure 6C – 5.
7 Remove and place the soiled shop towel in an approved container.
Test
1 Start the engine and record the fuel pressure.
2 Turn the ignition switch off.
3 If required, perform any tests and/or diagnostic procedures:
• For the fuel system leak test, refer to 3.3 Fuel Leak Test.
• For the fuel injector leak-down test (for vehicles fitted with a V6 engine, refer to 6C1-3 Engine Management –
V6 – Service Operations.
4 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
Removal
1 Turn the ignition switch off.
2 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 10


After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing the fuel lines or connections. Cover
the fittings with a shop towel before
disconnecting. This catches any leaking fuel.
Place the soiled towel in an approved
container when disconnection is completed.
3 W rap a shop towel around the fuel pressure test point to absorb any fuel spillage.
4 Remove the fuel pressure gauge and drain any fuel remaining in the fuel pressure gauge into an approved fuel container.
5 Remove the soiled shop towel and place in an approved container.
6 Repressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
7 Road-test the vehicle and check for correct operation.
3.3 Fuel Leak Test

After installing any fuel system component
and before starting the engine, check the fuel
system for leaks.
NOTE
For the fuel injector leak-down test (for vehicles
fitted with a V6 engine), refer to 6C1-3 Engine
Management – V6 – Service Operations.
1 Turn the ignition switch on for two seconds.
2 Turn the ignition switch off for 10 seconds.
3 Turn the ignition switch on.
4 Check for fuel leaks, particularly at points marked z (that is, quick-connect fittings, fuel rails, fuel injectors,
Schrader valve and evaporative emission control canister purge solenoid, refer to Figure 6C – 6.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 12


A small amount of fuel may be released when
pressing on the Schrader valve. Cover the
fitting with a shop towel to absorb any fuel
spillage before removing the Schrader valve
sealing cap. Place the soiled towel in an
approved container for disposal.
7 At the fuel pressure test point (2), remove the Schrader valve sealing cap (1), refer to Figure 6C – 7.

Figure 6C – 7
Legend
1 Schrader Valve Sealing Cap
2 Pressure Test Point 3 Schrader Valve

Wear safety glasses when performing the fuel
pressure relief procedure.
8 Place a shop towel around the Schrader valve to soak up the expelled petrol.
9 Use a small screwdriver to press the Schrader valve down (3).
10 Remove the soiled shop towel and place in an approved container.
Repressurise
1 Reinstall the fuel pump relay and fuel pump fuse.
2 Perform the following procedure to inspect for leaks at the fuel pressure test point: a Turn the ignition switch on for two seconds.
b Turn the ignition switch off for 10 seconds.
c Turn the ignition switch on.
d Check for leaks at the fuel pressure test point.
3 Tighten the fuel filler cap.
4 Start the engine and recheck for leaks.
5 Reinstall the Schrader valve sealing cap.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 27

4.6 Evaporative Emission Control Canister
Remove
1 Raise the vehicle on a hoist to give access to the evaporative emission control canister, located above the spare
wheel , refer to 0A General Information.
2 Disconnect the evaporative emission control canister purge line (3) by using the following procedure:
a Grasp both sides of the quick-connect fitting. Twist the connector 1/4 turn in each direction in
order to loosen any dirt within the quick-connect
fitting.

Wear safety glasses when using compressed
air. Do not blow compressed air onto any
body part.
b Using compressed air, blow any dirt out of the quick-connect fitting.
c Grasp the quick-connect fitting and push it towards the canister.
d Squeeze the quick-connect fitting to release the retaining tabs, then pull back on the connector to
remove the canister purge line from the canister.
Figure 6C – 28
3 Disconnect the fuel tank vent line (4) by using the following procedure:
a Grasp both sides of the quick-connect fitting. Twist the connector 1/4 turn in each direction in
order to loosen any dirt within the quick-connect
fitting.

Wear safety glasses when using compressed
air. Do not blow compressed air onto any
body part.
b Using compressed air, blow any dirt out of the quick connect fitting.
c Grasp the quick-connect fitting and push it towards the canister.
d Squeeze the quick-connect fitting to release the retaining tabs, then pull back on the connector to
remove the tank vent line from the canister.
Figure 6C – 29

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ISUZU KB P190 2007