Isuzu KB P190. Service manual - part 620

Engine Mechanical – V6 

Page 6A1–1 

 

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

 

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 .............................................................................................................................................. 9

 

Major Component Assemblies.............................................................................................................................. 9

 

Intake Manifold Assembly ................................................................................................................................... 10

 

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.......................................................................................................................................... 20

 

1.4

 

Engine Construction............................................................................................................................................ 21

 

Cylinder Block...................................................................................................................................................... 21

 

Cylinder Heads..................................................................................................................................................... 21

 

Crankshaft ............................................................................................................................................................ 22

 

Pistons, Pins and Connecting Rods .................................................................................................................. 22

 

Camshaft Drive System ....................................................................................................................................... 22

 

1.5

 

Engine Lubrication System................................................................................................................................. 24

 

Lubrication Description....................................................................................................................................... 24

 

1.6

 

Service Notes ....................................................................................................................................................... 24

 

Cleanliness and Care........................................................................................................................................... 24

 

Replacing Engine Gaskets .................................................................................................................................. 24

 

Re-Using Gaskets and Applying Sealants........................................................................................................ 24

 

Separating Components................................................................................................................................... 24

 

Cleaning Gasket Surfaces................................................................................................................................ 24

 

Assembling Components ................................................................................................................................. 25

 

Use of Room Temperature Vulcanising and Anaerobic Sealer........................................................................ 25

 

Room Temperature Vulcanising Sealer............................................................................................................ 25

 

Anaerobic Sealer.............................................................................................................................................. 25

 

Pipe Joint Compound ....................................................................................................................................... 26

 

Separating Parts .................................................................................................................................................. 26

 

Tools and Equipment .......................................................................................................................................... 26

 

Fasteners .............................................................................................................................................................. 27

 

Clamp Load ...................................................................................................................................................... 27

 

Torque Angle and Torque to Yield Fasteners................................................................................................... 27

 

2

 

Diagnosis ..............................................................................................................................................28

 

2.1

 

Engine Diagnosis................................................................................................................................................. 28

 

2.2

 

Symptoms............................................................................................................................................................. 28

 

Strategy Based Diagnosis................................................................................................................................... 28

 

Engine Mechanical – V6 

Page 6A1–2 

 

Visual / Physical Inspection ................................................................................................................................ 28

 

Intermittent ........................................................................................................................................................... 28

 

2.3

 

Engine Misfire without Internal Engine Noises ................................................................................................. 29

 

2.4

 

Engine Misfire with Abnormal Internal Lower Engine Noises.......................................................................... 30

 

2.5

 

Engine Misfire with Abnormal Valve Train Noise.............................................................................................. 31

 

2.6

 

Engine Misfire with Coolant Consumption ........................................................................................................ 31

 

2.7

 

Engine Misfire with Excessive Oil Consumption .............................................................................................. 31

 

2.8

 

Engine Noise on Start-up, but only Lasting a Few Seconds............................................................................ 31

 

2.9

 

Upper Engine Noise, Regardless of Engine Speed........................................................................................... 33

 

2.10

 

Lower Engine Noise, Regardless of Engine Speed .......................................................................................... 34

 

2.11

 

Engine Noise Under Load ................................................................................................................................... 35

 

2.12

 

Engine Will Not Crank – Crankshaft Will Not Rotate ........................................................................................ 35

 

2.13

 

Coolant in Combustion Chamber ....................................................................................................................... 37

 

Definition .............................................................................................................................................................. 37

 

2.14

 

Coolant in Engine Oil........................................................................................................................................... 37

 

Definition .............................................................................................................................................................. 37

 

2.15

 

Engine Compression Test................................................................................................................................... 38

 

Preliminary Steps................................................................................................................................................. 38

 

Engine Cylinder Compression Test ................................................................................................................... 38

 

Test Result Evaluation......................................................................................................................................... 38

 

2.16

 

Cylinder Leakage Test ......................................................................................................................................... 39

 

2.17

 

Engine Oil Consumption Diagnosis ................................................................................................................... 39

 

Definition .............................................................................................................................................................. 39

 

2.18

 

Engine Oil Leak Diagnosis .................................................................................................................................. 40

 

Introduction .......................................................................................................................................................... 40

 

Locating and Identifying the Leak ...................................................................................................................... 40

 

Visual Inspection ................................................................................................................................................. 40

 

Powder Method .................................................................................................................................................... 40

 

Black Light and Dye Method ............................................................................................................................... 40

 

Possible Causes for Engine Oil Leaks............................................................................................................... 41

 

2.19

 

Engine Oil Pressure Diagnosis........................................................................................................................... 42

 

2.20

 

Accessory Drive Belt Diagnosis ......................................................................................................................... 42

 

Tension Check ..................................................................................................................................................... 42

 

Inspect .................................................................................................................................................................. 42

 

Drive Belt Chirp.................................................................................................................................................... 43

 

Definition .......................................................................................................................................................... 43

 

Diagnostic Aids................................................................................................................................................. 43

 

Test Description ............................................................................................................................................... 43

 

Diagnostic Table............................................................................................................................................... 44

 

Drive Belt Squeal ................................................................................................................................................. 45

 

Definition .......................................................................................................................................................... 45

 

Diagnostic Aids................................................................................................................................................. 45

 

Test Description ............................................................................................................................................... 45

 

Diagnostic Table............................................................................................................................................... 46

 

Drive Belt Whine .................................................................................................................................................. 46

 

Definition .......................................................................................................................................................... 46

 

Diagnostic Aids................................................................................................................................................. 46

 

Test Description ............................................................................................................................................... 46

 

Diagnostic Table............................................................................................................................................... 47

 

Drive Belt Rumble ................................................................................................................................................ 47

 

Definition .......................................................................................................................................................... 47

 

Diagnostic Aids................................................................................................................................................. 48

 

Test Description ............................................................................................................................................... 48

 

Diagnostic Table............................................................................................................................................... 48

 

Drive Belt Vibration.............................................................................................................................................. 49

 

Definition .......................................................................................................................................................... 49

 

Diagnostic Aids................................................................................................................................................. 49

 

Test Description ............................................................................................................................................... 49

 

Diagnostic Table............................................................................................................................................... 50

 

Drive Belt Falls Off............................................................................................................................................... 50

 

Engine Mechanical – V6 

Page 6A1–3 

 

Definition .......................................................................................................................................................... 50

 

Diagnostic Aids................................................................................................................................................. 50

 

Test Description ............................................................................................................................................... 50

 

Diagnostic Table............................................................................................................................................... 51

 

Drive Belt Excessive Wear .................................................................................................................................. 51

 

Definition .......................................................................................................................................................... 51

 

Diagnostic Aids................................................................................................................................................. 52

 

Test Description ............................................................................................................................................... 52

 

Diagnostic Table............................................................................................................................................... 52

 

Accessory Drive Belt Tensioner Diagnosis ....................................................................................................... 52

 

Diagnostic Table............................................................................................................................................... 52

 

3

 

Minor Service Operations ....................................................................................................................53

 

3.1

 

Engine Oil ............................................................................................................................................................. 54

 

Check .................................................................................................................................................................... 54

 

Replace ................................................................................................................................................................. 54

 

Pressure Check.................................................................................................................................................... 55

 

3.2

 

Oil Filter Cartridge ............................................................................................................................................... 56

 

Replace ................................................................................................................................................................. 56

 

3.3

 

Oil Filter Adaptor.................................................................................................................................................. 57

 

Remove ................................................................................................................................................................. 57

 

Reinstall ................................................................................................................................................................ 57

 

3.4

 

Oil Level Indicator Tube ...................................................................................................................................... 58

 

Remove............................................................................................................................................................ 58

 

Reinstall ........................................................................................................................................................... 58

 

3.5

 

Accessory Drive Belt ........................................................................................................................................... 59

 

RWD Vehicle......................................................................................................................................................... 59

 

Remove............................................................................................................................................................ 59

 

Reinstall ........................................................................................................................................................... 59

 

3.6

 

Accessory Drive Belt Idler Pulley ....................................................................................................................... 60

 

Remove............................................................................................................................................................ 60

 

Reinstall ........................................................................................................................................................... 60

 

3.7

 

Accessory Drive Belt Tensioner Assembly ....................................................................................................... 61

 

Remove............................................................................................................................................................ 61

 

Reinstall ........................................................................................................................................................... 61

 

3.8

 

Power Steering Pump Bracket............................................................................................................................ 62

 

Remove ................................................................................................................................................................. 62

 

Reinstall ................................................................................................................................................................ 62

 

3.9

 

Upper Intake Manifold.......................................................................................................................................... 62

 

Remove ................................................................................................................................................................. 63

 

Disassemble ......................................................................................................................................................... 66

 

Clean ..................................................................................................................................................................... 66

 

Inspect .................................................................................................................................................................. 66

 

Reassemble .......................................................................................................................................................... 67

 

Reinstall ................................................................................................................................................................ 67

 

3.10

 

Intake Manifold Assembly – Complete............................................................................................................... 68

 

Remove ................................................................................................................................................................. 68

 

Disassemble ......................................................................................................................................................... 72

 

Clean ..................................................................................................................................................................... 73

 

Inspect .................................................................................................................................................................. 73

 

Reassemble .......................................................................................................................................................... 74

 

Reinstall ................................................................................................................................................................ 74

 

3.11

 

Exhaust Manifold Assembly ............................................................................................................................... 75

 

Remove ................................................................................................................................................................. 75

 

Inspect .................................................................................................................................................................. 77

 

Reinstall ................................................................................................................................................................ 77

 

3.12

 

Camshaft Cover ................................................................................................................................................... 79

 

Remove ................................................................................................................................................................. 79

 

Clean and Inspect ................................................................................................................................................ 81

 

Engine Mechanical – V6 

Page 6A1–4 

 

Reinstall ................................................................................................................................................................ 81

 

3.13

 

Crankshaft Balancer Assembly .......................................................................................................................... 84

 

Remove ................................................................................................................................................................. 84

 

Clean and Inspect ................................................................................................................................................ 85

 

Reinstall ................................................................................................................................................................ 85

 

3.14

 

Crankshaft Front Seal.......................................................................................................................................... 87

 

Replace ................................................................................................................................................................. 87

 

3.15

 

Front Cover Assembly......................................................................................................................................... 87

 

Remove ................................................................................................................................................................. 87

 

Disassemble ......................................................................................................................................................... 89

 

Clean ..................................................................................................................................................................... 90

 

Inspect .................................................................................................................................................................. 91

 

Reassemble .......................................................................................................................................................... 91

 

Reinstall ................................................................................................................................................................ 92

 

3.16

 

Timing Chains, Tensioners, Shoes and Guides ................................................................................................ 94

 

Primary and Left-hand Secondary Timing Chain Installation .......................................................................... 94

 

Right-hand Secondary Timing Chain Installation ............................................................................................. 95

 

Remove ................................................................................................................................................................. 96

 

Right-hand Secondary Timing Chain................................................................................................................ 96

 

Primary Timing Chain..................................................................................................................................... 100

 

Left-hand Secondary Timing Chain ................................................................................................................ 102

 

Clean ................................................................................................................................................................... 105

 

Inspect ................................................................................................................................................................ 106

 

Timing Chains ................................................................................................................................................ 106

 

Camshaft Intermediate Driveshaft Sprockets ................................................................................................. 106

 

Inlet and Exhaust Camshaft Sprocket ............................................................................................................ 106

 

Crankshaft Sprocket....................................................................................................................................... 107

 

Primary Timing Chain Upper Guide................................................................................................................ 107

 

Primary Timing Chain Lower Guide................................................................................................................ 107

 

Primary Timing Chain Tensioner .................................................................................................................... 108

 

Left-hand Secondary Timing Chain Guide ..................................................................................................... 108

 

Left-hand Secondary Timing Chain Shoe....................................................................................................... 109

 

Left-hand Secondary Timing Chain Tensioner ............................................................................................... 109

 

Right-hand Secondary Timing Chain Guide ................................................................................................... 110

 

Right-hand Secondary Timing Chain Shoe .................................................................................................... 110

 

Right-hand Secondary Timing Chain Tensioner............................................................................................. 111

 

Reinstall .............................................................................................................................................................. 111

 

Left-hand Secondary Timing Chain Components........................................................................................... 111

 

Primary Timing chain Components ................................................................................................................ 121

 

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

 

3.17

 

Oil Pump Assembly ........................................................................................................................................... 136

 

Remove ............................................................................................................................................................... 136

 

Disassemble ....................................................................................................................................................... 137

 

Clean ................................................................................................................................................................... 138

 

Inspect ................................................................................................................................................................ 139

 

Reassemble ........................................................................................................................................................ 141

 

Reinstall .............................................................................................................................................................. 141

 

3.18

 

Camshaft Sprocket ............................................................................................................................................ 141

 

Remove ............................................................................................................................................................... 141

 

Right-hand Side.............................................................................................................................................. 141

 

Left-hand Side ................................................................................................................................................ 144

 

Clean ................................................................................................................................................................... 146

 

Inspect ................................................................................................................................................................ 146

 

Reinstall .............................................................................................................................................................. 147

 

3.19

 

Camshaft............................................................................................................................................................. 147

 

Remove ............................................................................................................................................................... 147

 

Right-hand Side.............................................................................................................................................. 147

 

Left-hand Side ................................................................................................................................................ 149

 

Clean ................................................................................................................................................................... 150

 

Inspect ................................................................................................................................................................ 150