engine ISUZU KB P190 2007 Workshop Repair Manual

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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ISUZU KB P190 2007

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 6A1–9

• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.

1.2 Engine Components
Major Component Assemblies


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–10

Figure 6A1 – 2
Legend
1 Engine Assembly
2 Intake Manifold Assembly
3 Camshaft Cover Assembly, Left-hand
4 Camshaft Cover Assembly, Right-hand
5 Engine Front Cover Assembly
6 Oil Pan Assembly
7 Engine Flywheel
8 Engine Flywheel Bolt
9 Crankshaft Balancer
10 Crankshaft Balancer Bolt
11 Exhaust Manifold Gasket, Left-hand 12 Exhaust Manifold, Left-hand
13 Exhaust Manifold Heat Shield, Left-hand
14 Exhaust Manifold Heat Shield Bolt, Left-hand
15 Exhaust Manifold Gasket, Right-hand
16 Exhaust Manifold, Right-hand
17 Cylinder Head Exhaust Manifold Bolt
18 Exhaust Manifold Heat Shield, Right-hand
19 Exhaust Manifold Heat Shield Bolt, Right-hand
20 Ignition Coil Assembly
21 Ignition Coil Assembly Bolt
22 Spark Plug
Intake Manifold Assembly


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–11

Figure 6A1 – 3
Legend
1 PCV Hose
2 PCV Hose O-Ring Outer (larger)
3 PCV Hose O-Ring Inner (smaller)
4 Upper Intake Manifold
5 Lower Intake Manifold
6 Upper Intake Manifold Bolt – Long
7 Upper Intake Manifold Bolt – Short
8 Lower Intake Manifold to Upper Intake Manifold Guide Pin
9 Upper Intake Manifold to Lower Intake Manifold Gasket
10 Lower Intake Manifold to Cylinder Head Gasket
11 Lower Intake Manifold Bolt
12 Fuel Rail Bolt
13 Fuel Rail
14 Fuel Injector
15 Fuel Injector Retainer
16 Fuel Injector Upper O-ring 17 Fuel Injector Lower O-ring
18 Fuel Pressure Service Valve Cap
19 Fuel Pressure Service Valve
20 Ball Stud
21 Fuel Injector Wiring Harness
22 Throttle Body
23 Throttle Body Bolt
24 Throttle Body Gasket
25 Throttle Body Engine Wiring Harness Clip
26 EVAP Purge Solenoid
27 EVAP Purge Solenoid Bolt
28 EVAP Purge Solenoid Tube
29 EVAP Purge Solenoid Bracket
30 BARO Sensor Bolt
31 BARO Sensor
32 BARO Sensor O-Ring

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Engine Mechanical – V6 Page 6A1–12

Engine Front Cover

Figure 6A1 – 4
Legend
1 Engine Front Cover Locating Pin
2 Engine Front Cover Bolt, M10
3 Engine Front Cover
4 Engine Front Cover Gasket
5 Engine Front Cover Bolt, M8
6 Engine Front Cover Seal
7 Coolant Pump Assembly
8 Coolant Pump Bolt
9 Coolant Pump Gasket 10 Coolant Pump Pulley
11 Coolant Pump Pulley Bolt
12 Crankshaft Balancer
13 Crankshaft Balancer Bolt
14 Camshaft Position Sensor
15 Camshaft Position Sensor O-ring
16 Camshaft Position Sensor Bolt
17 Camshaft Position Actuator Solenoid Valve Seal


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–13

Camshaft Timing Components

Figure 6A1 – 5
Legend
1 Crankshaft Sprocket
2 Lower Primary Timing Chain Guide
3 Primary Timing Chain Tensioner
4 Primary Timing Chain Tensioner Bolt
5 Lower Primary Timing Chain Guide Bolt
6 Primary Timing Chain
7 Upper Primary Timing Chain Guide
8 Upper Primary Timing Chain Guide Bolt
9 Camshaft Intermediate Driveshaft Sprocket Bolt
10 Primary Timing Chain Tensioner Gasket
11 Camshaft Intermediate Driveshaft Sprocket, Left-hand
12 Camshaft Intermediate Driveshaft Sprocket, Right-hand
13 Secondary Timing Chain, Left-hand
14 Secondary Timing Chain Guide, Left-hand
15 Secondary Timing Chain Guide Bolt, Left-hand
16 Secondary Timing Chain Shoe, Left-hand
17 Secondary Timing Chain Shoe Bolt, Left-hand 18 Secondary Timing Chain Tensioner, Left-hand
19 Secondary Timing Chain Tensioner Bolt, Left-hand
20 Secondary Timing Chain Tensioner Gasket, Left-hand
21 Secondary Timing Chain, Right-hand
22 Secondary Timing Chain Guide, Right-hand
23 Secondary Timing Chain Guide Bolt, Right-hand
24 Secondary Timing Chain Shoe, Right-hand
25 Secondary Timing Chain Shoe Bolt, Right-hand
26 Secondary Timing Chain Tensioner, Right-hand
27 Secondary Timing Chain Tensioner Bolt, Right-hand
28 Secondary Timing Chain Tensioner Gasket, Right-hand
29 Exhaust Camshaft Sprocket, Left-hand
30 Intake Camshaft Sprocket, Left-hand
31 Camshaft Sprocket Bolt
32 Exhaust Camshaft Sprocket, Right-hand
33 Intake Camshaft Sprocket, Right-hand

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–14

Camshaft Cover Assembly

Figure 6A1 – 6
Legend
1 Camshaft Cover, Left-hand
2 Camshaft Cover Gasket, Left-hand
3 Camshaft Cover, Right-hand
4 Camshaft Cover Gasket, Right-hand
5 Camshaft Cover Spark Plug Port Seal
6 Camshaft Cover Bolt
7 Camshaft Cover Bolt Insulator
8 Ignition Coil Bolt Thread Insert
9 Oil Fill Cap 10 Oil Fill O-Ring
11 Camshaft Cover PCV Fitting, Left-hand
12 Camshaft Cover PCV Fitting Orifice, Right-hand
13 Oil Fill Tube
14 Camshaft Cover PCV Fitting O-Ring, Left-hand
15 Ignition Coil
16 Ignition Coil Bolt
17 Spark Plug


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Engine Mechanical – V6 Page 6A1–15

Cylinder Head Assembly

Figure 6A1 – 7
Legend
1 Cylinder Head, Left-hand
2 Cylinder Head, Right-hand
3 Cylinder Head Gasket, Left-hand
4 Cylinder Head Gasket, Right-hand
5 Cylinder Head Bolt
6 Cylinder Head Front Bolt
7 Cylinder Head Coolant Hole Threaded Plug
8 Spark Plug Sleeve
9 Cylinder Head Oil Gallery Expansion Plug
10 Exhaust Valve
11 Intake Valve
12 Valve Rocker Arm Assembly
13 Hydraulic Valve Lash Adjuster Assembly
14 Valve Stem Oil Seal 15 Valve Spring
16 Valve Spring Cap
17 Valve Stem Key
18 Cylinder Head Camshaft Front Thrust Bearing Cap
19 Camshaft Oil Seal Ring
20 Exhaust Camshaft
21 Intake Camshaft, Left-hand (bank 2)
22 Intake Camshaft, Right-hand (bank 1)
23 Exhaust Camshaft, Right-hand (bank 1)
24 Cylinder Head Camshaft Cap – Intermediate
25 Cylinder Head Camshaft Cap Bolt
26 Cylinder Head Oil Galley Check Valve
27 Engine Coolant Temperature Sensor

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ISUZU KB P190 2007