Isuzu KB P190. Manual - part 695

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

 

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 MY06 Update................................................................................................................................. 110

 

MY06 Update ................................................................................................................................................. 111

 

Right-hand Secondary Timing Chain Installation ........................................................................................... 112

 

Excluding MY06 Update................................................................................................................................. 112

 

MY06 Update ................................................................................................................................................. 113

 

Remove ............................................................................................................................................................... 114

 

Right-hand Secondary Timing Chain.............................................................................................................. 114

 

Primary Timing Chain..................................................................................................................................... 118

 

Left-hand Secondary Timing Chain ................................................................................................................ 120

 

Clean ................................................................................................................................................................... 123

 

Inspect ................................................................................................................................................................ 124

 

Timing Chains ................................................................................................................................................ 124

 

Camshaft Intermediate Sprockets .................................................................................................................. 124

 

Inlet and Exhaust Camshaft Sprocket ............................................................................................................ 124

 

Crankshaft Sprocket....................................................................................................................................... 125

 

Primary Timing Chain Upper Guide................................................................................................................ 125

 

Primary Timing Chain Lower Guide................................................................................................................ 125

 

Primary Timing Chain Tensioner .................................................................................................................... 126

 

Left-hand Secondary Timing Chain Guide ..................................................................................................... 126

 

Left-hand Secondary Timing Chain Shoe....................................................................................................... 127

 

Left-hand Secondary Timing Chain Tensioner ............................................................................................... 127

 

Right-hand Secondary Timing Chain Guide ................................................................................................... 128

 

Right-hand Secondary Timing Chain Shoe .................................................................................................... 128

 

Right-hand Secondary Timing Chain Tensioner............................................................................................. 129

 

Reinstall .............................................................................................................................................................. 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

 

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 Measurement ................................................................................................................................. 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 Removal ................................................................................................................................................. 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

 

Engine Mechanical – V6 

Page 6A1–6 

 

Page 6A1–6 

Reassemble ........................................................................................................................................................ 257

 

Reinstall .............................................................................................................................................................. 257

 

4.3

 

Flexplate Assembly ........................................................................................................................................... 259

 

Remove ............................................................................................................................................................... 259

 

Clean ................................................................................................................................................................... 259

 

Inspect ................................................................................................................................................................ 260

 

Reinstall .............................................................................................................................................................. 260

 

4.4

 

Crankshaft Rear Seal and Plate Assembly ...................................................................................................... 262

 

Remove ............................................................................................................................................................... 262

 

Reinstall .............................................................................................................................................................. 263

 

4.5

 

Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 265

 

Remove ............................................................................................................................................................... 265

 

Disassemble ....................................................................................................................................................... 268

 

Clean and Inspect .............................................................................................................................................. 269

 

Piston Cleaning Procedure............................................................................................................................. 269

 

Piston Inspection Procedure .......................................................................................................................... 269

 

Piston Measurement ...................................................................................................................................... 270

 

Piston Ring Measurement .............................................................................................................................. 271

 

Connecting Rod Cleaning Procedure ............................................................................................................. 272

 

Connecting Rod Visual Inspection Procedure ................................................................................................ 272

 

Connecting Rod Measurement Procedure ..................................................................................................... 272

 

Reassemble ........................................................................................................................................................ 274

 

Piston and Piston Pin ..................................................................................................................................... 274

 

Piston Ring ..................................................................................................................................................... 275

 

Connecting Rod Bearing ................................................................................................................................ 276

 

Reinstall .............................................................................................................................................................. 277

 

Piston Connecting Rod and Connecting Rod Bearing Installation.................................................................. 277

 

Connecting Rod Bearing Clearance Measurement Procedure....................................................................... 278

 

Connecting Rod Final Assembly Procedure ................................................................................................... 279

 

4.6

 

Crankshaft and Main Bearings ......................................................................................................................... 281

 

Crankshaft End Play Measurement .................................................................................................................. 281

 

Remove ............................................................................................................................................................... 281

 

Crankshaft Bearing......................................................................................................................................... 283

 

Clean and Inspect .............................................................................................................................................. 283

 

Crankshaft and Main Bearing Cleaning.......................................................................................................... 283

 

Crankshaft and Main Bearing Visual Inspection ............................................................................................. 284

 

Crankshaft Main Bearing Inspection............................................................................................................... 285

 

Crankshaft Measurement ............................................................................................................................... 286

 

Reinstall .............................................................................................................................................................. 288

 

Crankshaft Bearing Installation Procedure ..................................................................................................... 288

 

Crankshaft Main Bearing Clearance Measurement........................................................................................ 289

 

Crankshaft Final Installation Procedure.......................................................................................................... 291

 

4.7

 

Cylinder Block.................................................................................................................................................... 293

 

Disassemble ....................................................................................................................................................... 293

 

Clean ................................................................................................................................................................... 297

 

Inspect ................................................................................................................................................................ 297

 

Visual Inspection ............................................................................................................................................ 297

 

Measuring Cylinder Bore Diameter ................................................................................................................ 297

 

Measuring Cylinder Bore Taper...................................................................................................................... 298

 

Measuring Cylinder Bore Out-of-Round ......................................................................................................... 298

 

Deck Flatness Inspection ............................................................................................................................... 298

 

Reassemble ........................................................................................................................................................ 299

 

4.8

 

Thread Repairs................................................................................................................................................... 303

 

General Information........................................................................................................................................... 303

 

General Thread Repair ...................................................................................................................................... 304

 

Main Bearing Cap Bolt Hole Thread Repair ..................................................................................................... 310

 

Cylinder Head Bolt Hole Thread Repair ........................................................................................................... 315

 

4.9

 

Thread Repair Specifications............................................................................................................................ 322

 

Left-hand Cylinder Head Camshaft Cover Face .............................................................................................. 322

 

Left-hand Cylinder Head Front Face ................................................................................................................ 323