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