Isuzu KB P190. Manual - part 694

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. 

Engine Mechanical – V6 

Page 6A1–298 

 

Tool Number 

Illustration 

Description 

J-45027 

 

Tensioner Tool 

Used to reset the timing chain tensioner plunger. 

J-6125-1B 

 

Slide Hammer 

Used in conjunction with J-41818 to remove the main bearing 
caps from the cylinder block during engine disassembly. 

J-8062 

 

Valve Spring Compressor 

Used in conjunction with EN-46119 to remove valve springs 
with the engine disassembled. 

J-8087 

 

Cylinder Bore Gauge 

Commercial equivalent also available 

 

Engine Mechanical – V6 

Page 6A1–1 

 

Page 6A1–1 

Section 6A1  

Engine Mechanical – V6 

A T T E N T I O N  

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, CAUTION 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 Cover 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 Drive 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 Components................................................................................................................................... 26

 

Cleaning Gasket Surfaces................................................................................................................................ 26

 

Assembling Components ................................................................................................................................. 26

 

Use of Room Temperature Vulcanising and Anaerobic Sealer........................................................................ 27

 

Room Temperature Vulcanising 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 Fasteners................................................................................................... 29

 

2

 

Diagnosis ..............................................................................................................................................30

 

2.1

 

Engine Diagnosis................................................................................................................................................. 30

 

2.2

 

Symptoms ............................................................................................................................................................ 31

 

Strategy Based Diagnosis................................................................................................................................... 31

 

Engine Mechanical – V6 

Page 6A1–2 

 

Page 6A1–2 

Visual / Physical Inspection ................................................................................................................................ 31

 

Intermittent ........................................................................................................................................................... 31

 

2.3

 

Engine Misfire without Internal Engine Noises ................................................................................................. 32

 

2.4

 

Engine Misfire with Abnormal Internal Lower Engine Noises.......................................................................... 34

 

2.5

 

Engine Misfire with Abnormal Valve Train Noise.............................................................................................. 35

 

2.6

 

Engine Misfire with Coolant Consumption ........................................................................................................ 36

 

2.7

 

Engine Misfire with Excessive Oil Consumption .............................................................................................. 37

 

2.8

 

Engine Noise on Start-up, but only Lasting a Few Seconds............................................................................ 38

 

2.9

 

Upper Engine Noise, Regardless of Engine Speed........................................................................................... 39

 

2.10

 

Lower Engine Noise, Regardless 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 Combustion 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 Pressure 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