lock ISUZU KB P190 2007 Workshop Repair Manual

E N G IN E SPEED C O NTR O L S Y STEM ( C 24SE) 6 H-1
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT S
YSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

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ISUZU KB P190 2007

6H-2 ENGINE SPEED CONTROL SYSTEM (C24SE)
Accelerator Pedal Control Cable


RHD MODEL


RTW 46HLF000501

Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from
accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in indirection an arro
w
90 °.



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ISUZU KB P190 2007

4. Remove the accelerator control cable from the
throttle.





LHD MODEL

RTW 46AMH000101

Inspection
Check the following items and replace the control
cable if any abnormality is found.
• The control cable should move smoothly.
• The control cable should not be bent or kinked.
• The control cable should not be damage o
r
corrosion.
Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam o
f
engine.
3. Install accelerator control cable to accelerato
r
bracket.
1) Rotate the ratchet ring in direction an arrow 90 °
until both white marking are aligned.
2) Confirm marking of outer cap must be uppe
r
side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
EN
GIN E SPEED CONTR O L SY STEM (C 24SE) 6H-3

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ISUZU KB P190 2007

6J-2 INDUCTION

Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


RTW 46JSH000101










Air Cleaner Filter
NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.

Removal
1. Remove positive ventilation hose connector.
2. Remove intake air temperature sensor.
3. Remove mass air flow sensor.
4. Remove air cleaner duct assembly.
5. Remove air cleaner element.

Inspection
Check the air cleaner filter for damage or dust clogging.
Replace if it is damaged, or clean if it is clogged.



Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–1

6A1
Engine Mechanical – V6
ATTENTION
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

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Engine Mechanical – V6 Page 6A1–6

Piston Cleaning Procedure............................................................................................................................. 212
Piston Inspection Procedure .................................................................................................... ...................... 213
Piston Measurement ...................................................................................................................................... 213
Piston Ring Measurement ........................................................................................................ ...................... 214
Connecting Rod Cleaning Procedure .............................................................................................. ............... 215
Connecting Rod Visual Inspection Procedure ..................................................................................... ........... 215
Connecting Rod Measurement Procedure ........................................................................................... .......... 216
Reassemble ........................................................................................................................................................ 217
Piston and Piston Pin ..................................................................................................................................... 217
Piston Ring ..................................................................................................................................................... 218
Connecting Rod Bearing ......................................................................................................... ....................... 219
Reinstall .............................................................................................................................................................. 220
Piston Connecting Rod and Connecting Rod Bearing Installation.................................................................. 220
Connecting Rod Bearing Clearance Measurement Procedure....................................................................... 22 1
Connecting Rod Final Assembly Procedure ................................................................................................... 222
4.6 Crankshaft and Main Bearings ......................................................................................................................... 223
Crankshaft End Play Measurement ................................................................................................ .................. 223
Remove ............................................................................................................................................................... 223
Crankshaft Bearing............................................................................................................. ............................ 225
Clean and Inspect .............................................................................................................. ................................ 225
Crankshaft and Main Bearing Cleaning ........................................................................................... ............... 225
Crankshaft and Main Bearing Visual Inspection .................................................................................. ........... 226
Crankshaft Main Bearing Inspection............................................................................................................... 227
Crankshaft Measurement ............................................................................................................................... 228
Reinstall .............................................................................................................................................................. 230
Crankshaft Bearing Installation Procedure ...................................................................................... ............... 230
Crankshaft Main Bearing Clearance Measurement.................................................................................. ...... 231
Crankshaft Final Installation Procedure.......................................................................................................... 233
4.7 Cylinder Block .................................................................................................................................................... 234
Disassemble ....................................................................................................................................................... 234
Clean ................................................................................................................................................................... 238
Inspect ................................................................................................................................................................ 239
Visual Inspection .............................................................................................................. .............................. 239
Measuring Cylinder Bore Diameter ............................................................................................... ................. 239
Measuring Cylinder Bore Taper...................................................................................................................... 239
Measuring Cylinder Bore Out-of-Round ........................................................................................... .............. 239
Deck Flatness Inspection ............................................................................................................................... 240
Reassemble ........................................................................................................................................................ 240
4.8 Thread Repairs ................................................................................................................................................... 244
General Information ............................................................................................................ ............................... 244
General Thread Repair.......................................................................................................... ............................. 246
Main Bearing Cap Bolt Hole Thread Repair ....................................................................................... .............. 251
Cylinder Head Bolt Hole Thread Repair ........................................................................................................... 257
4.9 Thread Repair Specifications............................................................................................................................ 263
Left-hand Cylinder Head Camshaft Cover Face .................................................................................... .......... 263
Left-hand Cylinder Head Front Face ................................................................................................................ 264
Left-hand Cylinder Head Intake Face ............................................................................................................... 265
Left-hand Cylinder Head Exhaust Face........................................................................................... ................. 266
Left-hand Cylinder Head Rear Face ................................................................................................................. 267
Right-hand Cylinder Head Camshaft Cover Face ................................................................................... ........ 268
Right-hand Cylinder Head Front Face.............................................................................................................. 269
Right-hand Cylinder Head Intake Face............................................................................................................. 270
Right-hand Cylinder Head Exhaust Face .......................................................................................... ............... 271
Right-hand Cylinder Head Rear Face ............................................................................................................... 272
Engine Block Front ............................................................................................................................................ 273
Engine Block Left-hand Side .................................................................................................... ........................ 274
Engine Block Right-hand Side ................................................................................................... ....................... 275
Engine Block Rear ............................................................................................................................................. 276
Engine Block Bottom............................................................................................................ ............................. 277
Engine Block Left-hand Deck Face ............................................................................................... ................... 278

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Engine Mechanical – V6 Page 6A1–7

Engine Block Right-hand Deck Face................................................................................................................ 279
Engine Front Cover............................................................................................................................................ 280
Upper Intake Manifold Top ...................................................................................................... .......................... 281
Upper Intake Manifold Front .................................................................................................... ......................... 282
Upper Intake Manifold Rear............................................................................................................................... 283
Lower Intake Manifold Top ................................................................................................................................ 284
Oil Pan Front ...................................................................................................................................................... 285
Oil Pan Rear........................................................................................................................................................ 286
Oil Pan Bottom ................................................................................................................. .................................. 287
5 Specifications .....................................................................................................................................288
6 Torque Wrench Specifications................................................................................................... .......292
7 Special Tools ......................................................................................................................................294

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–8

1 General Information
The HFV6 engine features a closed vee, deep skirt die cast aluminium cylinder block with cast iron cylinder liners,
internally balanced crankcase, full length water jackets and six bolt main bearing caps.
The cylinders are arranged in two banks of three with a 60 degree included angle between the two banks.
The right-hand bank of cylinders consists of number 1-3-5
cylinders and the left-hand bank of cylinders consists of
number 2-4-6.
The engine firing order is 1-2-3-4-5-6.
Each aluminium cylinder head is fitted with hardened valve
seats and four valves per cylinder: two intake and two
exhaust.
The valves are operated by two camshafts (DOHC) per
cylinder bank, one each for intake and exhaust valves.
The crankshaft is manufactured from forged steel. A reluctor
wheel is pressed in place onto the rear of the crankshaft for
the crankshaft position sensor.
The connecting rods are manufactured from powdered
metal and the rod cap is separated during the manufacturing
process using the fractured method. This creates a stronger,
visually seamless rod to cap union.
Figure 6A1 – 1
1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–17

Engine Block Assembly

Figure 6A1 – 9
Legend
1 Piston and Connecting Rod Assembly
2 Crankshaft Bearing Cap
3 Crankshaft Bearing Thrust Cap
4 Crankshaft Bearing Cap Inboard Bolt
5 Crankshaft Bearing Cap Outboard Bolt
6 Crankshaft Bearing Cap Side Bolt, Short
7 Crankshaft Bearing Cap Side Bolt, Long
8 Engine Block Oil Gallery Expansion Plug, 10 mm
9 Crankshaft
10 Crankshaft Sprocket Locating Pin
11 Crankshaft Upper Bearing
12 Crankshaft Lower Bearing
13 Crankshaft Upper Thrust Bearing #3 14 Engine Block Oil Gallery Expansion Plug, 14 mm
15 Engine Block Oil Gallery Threaded Plug, 14 mm
16 Engine Block Coolant Drain Threaded Plug, 14 mm
17 Engine Block Oil Gallery Threaded Plug, 20 mm
18 Engine Block Core Coolant Expansion Plug, 34.3 mm
19 Transaxle Locating Pin
20 Crankshaft Rear Oil Seal Housing Assembly
21 Crankshaft Rear Oil Seal Housing Assembly Bolt
22 Oil Pan Locating Pin
23 Cylinder Head Locating Pin
24 Piston Oil Nozzle
25 Piston Oil Nozzle Bolt

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Engine Mechanical – V6 Page 6A1–20

Oil Filter Assembly
Legend
1 Oil Filter Gasket
2 Oil Filter Adapter
3 Oil Filter Adapter Bolt
4 Oil Filter Element
Figure 6A1 – 12
1.3 Engine Serial Number
The engine serial number is located on the machined pad
(1) at the left-hand rear of the cylinder block.
The following is a breakdown of the engine serial number,
using an example of 10H7E H051230001:
• 10 = Component ID (i.e. 10 = Assembly)
• H7E = Engine Broadcast Code
• H = Assembly Plant Code
• 05 = Build Year
• 123 = Julian Date
• 0001 = Four Digit Daily Sequence Number
Figure 6A1 – 13

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