Isuzu KB P190. Manual — part 715

Engine Mechanical – V6

Page 6A1–83

Page 6A1–83

3.10 Intake Manifold Assembly – Complete

The intake manifold comprises of an upper and lower section. Some service procedures only require the removal of the
upper intake manifold (e.g. fuel injector/spark plug servicing), while other service procedures require the removal of both
the upper and lower manifold as a complete assembly (e.g. cylinder head/s). If only the upper intake manifold needs to
be removed, refer to

3.9 Upper Intake Manifold

.

Remove

Disconnection of the battery affects

certain vehicle electronic systems. Refer to

1.1 WARNING, CAUTION and NOTES

before

disconnecting the battery.

1

Depressurise the fuel system.

2

Disconnect the battery negative terminal.

3

Remove the air intake duct (1) and hose (2), refer to

Section 6C1-3 Engine Management – V6 – Service
Operations

.

Figure 6A1 – 43

Engine Mechanical – V6

Page 6A1–84

Page 6A1–84

4

Retract the throttle body wiring connector lock (3).

5

While pressing the connector latch in the direction of
the arrow (4), disconnect the throttle body wiring
connector.

6

Disconnect the throttle body connector wiring harness
from its retaining clip (5).

7

Remove the main wiring harness retainer pin (6) from
the intake manifold by pushing from the front to the
rear using a suitable piece of 5 mm steel rod (or an
Allen key).

The following precautions must be followed
when disconnecting the throttle body wiring
connector:
• Do not use any mechanical device such

as a screwdriver to disengage the
harness connector (1) from the throttle
body (2).

• When retracting the throttle wiring

connector lock (3), take care not to
disengage the lock from the connector.

• Do not pull on the connector wires.
• Take care not to break the barbed

harness retainer pin (6) while removing
the harness retainer from the intake
manifold.

• Should the pin be broken, then it is vital

that a new harness retainer is fitted to the
wiring harness shield. If not, the harness
will foul the engine drive belt.

Figure 6A1 – 44

8

Disconnect the brake booster hose (1), from the upper
intake manifold:

Figure 6A1 – 45

Engine Mechanical – V6

Page 6A1–85

Page 6A1–85

9

Disconnect the wiring harness connector from the
barometric (BARO) pressure sensor (1).

Figure 6A1 – 46

10

Disconnect the PCV tube connector (1) from the
upper intake manifold assembly.

Figure 6A1 – 47

11

Disconnect the fuel feed hose from the fuel rail (1).

12

Pull out the release bar (2) (broad arrow) of the fuel
injector harness wiring connector (3).

13

Disconnect the fuel injector harness wiring connector
from the fuel injector wiring harness (4).

Plug the fuel feed hose opening after
removal to prevent dirt and other
contaminants from entering the fuel system.

Figure 6A1 – 48

Engine Mechanical – V6

Page 6A1–86

Page 6A1–86

14

Remove the wiring harness connector (2) from the
EVAP valve (1).

15

Disconnect the quick connect (3) from the rear of the
EVAP valve, as follows:

a

Squeeze the two barbed lugs together, push the quick
connect into the valve, then pull out to separate the
connection.

b

Plug both open ends to prevent the entry of foreign
matter.

Figure 6A1 – 49

16

Remove the bolt (3) attaching the EVAP valve and the
fuel injector wiring harness connector mounting
bracket to the upper intake manifold assembly.

17

Move the EVAP valve and the fuel injector wiring
harness connector mounting bracket clear of the
upper intake manifold assembly.

18

Disconnect the PCV fresh air tube (1) from its upper
intake manifold mounting clip (2).

Figure 6A1 – 50

19

Remove the four long (1) bolts (165 mm) securing the
complete intake manifold to the cylinder heads.

20

Remove the two short (2) bolts (45 mm) securing the
lower intake manifold to the cylinder heads.

Do not loosen nor remove the short bolts (

8)

(70 mm) holding the upper intake manifold to
the lower. These bolts are at the front left
and rear right of the upper intake manifold.

Figure 6A1 – 51