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