ISUZU KB P190 2007 Workshop Repair Manual

Engine Mechanical – V6 Page 6A1–4
Page 6A1–4
Reinstall ................................................................................................................................................................ 97
3.13 Crankshaft Balancer Assembly ................................................................................................... .....................100
Remove ............................................................................................................................................................... 100
Clean and Inspect .............................................................................................................. ................................101
Reinstall .............................................................................................................................................................. 101
3.14 Crankshaft Front Seal.......................................................................................................... ..............................103
Replace ........................................................................................................................ .......................................103
3.15 Front Cover Assembly........................................................................................................... ............................104
Remove ............................................................................................................................................................... 104
Disassemble ....................................................................................................................................................... 105
Clean................................................................................................................................................................... 106
Inspect ........................................................................................................................ ........................................107
Reassemble ........................................................................................................................................................ 107
Reinstall .............................................................................................................................................................. 108
3.16 Timing Chains, Tensioners, Shoes and Guides .................................................................................... ..........110
Primary and Left-hand Secondary Timing Chain Installation ...................................................................... ..110
Excluding MY 06 Update .......................................................................................................... .......................110
MY06 Update .................................................................................................................... .............................111
Right-hand Secondary Timi ng Chain Installation ........................................................................................... 112
Excluding MY06 Update .......................................................................................................... .......................112
MY06 Update .................................................................................................................... .............................113
Remove ............................................................................................................................................................... 114
Right-hand Secondary Timing Chain.............................................................................................. ................114
Primary Timi ng Chain ........................................................................................................... ..........................118
Left-hand Secondary Timing C hain ............................................................................................... .................120
Clean................................................................................................................................................................... 123
Inspect ........................................................................................................................ ........................................124
Timing Chains .................................................................................................................. ..............................124
Camshaft Intermedi ate Sprockets .................................................................................................................. 124
Inlet and Exhaust Camshaft Sprocket ............................................................................................ ................124
Crankshaft Sprocket ....................................................................................................................................... 125
Primary Timing Chain Upper Guide............................................................................................... .................125
Primary Timing C hain Lower Guide............................................................................................... .................125
Primary Timing C hain Tensioner ................................................................................................. ...................126
Left-hand Secondary Ti ming Chain Guide ......................................................................................... ............126
Left-hand Secondary Ti ming Chain Shoe.......................................................................................... .............127
Left-hand Secondary Timi ng Chain Tensioner ..................................................................................... ..........127
Right-hand Sec ondary Timing Chain Guide ................................................................................................... 128
Right-hand Secondary Timing Chain Shoe ......................................................................................... ...........128
Right-hand Se condary Timing Chain Tensioner .................................................................................... .........129
Reinst all .............................................................................................................................................................. 130
Left-hand Secondary Timing Chain Components – Excluding MY06 Update ................................................ 130
Left-hand Secondary Timing Chain Components – MY06 Update ................................................................. 139
Primary Timing Chain Components – Excluding MY06 Update ..................................................................... 149
Primary Timing Chain Components – MY06 Update .................................................................................. ....156
Right-hand Secondary Timing Chain Components – Excluding MY06 Update .............................................. 164
Right-hand Secondary Timing Chain Components – MY06 Update............................................................... 171
3.17 Oil Pump Assembly .............................................................................................................. .............................180
Remove ............................................................................................................................................................... 180
Disassemble ....................................................................................................................................................... 181
Clean................................................................................................................................................................... 182
Inspect ........................................................................................................................ ........................................183
Reassemble ........................................................................................................................................................ 185
Reinstall .............................................................................................................................................................. 185
3.18 Camshaft Sprocket – Excluding MY06 Update ................................................................................................ 186
Remove ............................................................................................................................................................... 186
Right-hand Side................................................................................................................ ..............................186
Left-hand Side ................................................................................................................................................ 189
Clean................................................................................................................................................................... 191
Inspect ........................................................................................................................ ........................................191

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–5
Page 6A1–5
Reinstall .............................................................................................................................................................. 192
3.19 Camshaft Sprocket – MY06 Update ................................................................................................ ..................193
Remove ............................................................................................................................................................... 193
Right-hand Side................................................................................................................ ..............................193
Left-hand Side ................................................................................................................................................ 196
Clean................................................................................................................................................................... 199
Inspect ........................................................................................................................ ........................................199
Reinstall .............................................................................................................................................................. 200
3.20 Camshaft ............................................................................................................................................................ 201
Remove ............................................................................................................................................................... 201
Right-hand Side................................................................................................................ ..............................201
Left-hand Side ................................................................................................................................................ 203
Clean................................................................................................................................................................... 204
Inspect ........................................................................................................................ ........................................205
Camshaft Visual Inspection ..................................................................................................... .......................205
Camshaft Meas urement ................................................................................................................................. 205
Reinstall .............................................................................................................................................................. 207
Right-hand Side................................................................................................................ ..............................207
Left-hand Side ................................................................................................................................................ 210
3.21 Rocker Arm......................................................................................................................................................... 213
Remove ............................................................................................................................................................... 213
Clean and Inspect .............................................................................................................. ................................213
Reinstall .............................................................................................................................................................. 214
3.22 Stationary Hydraulic Lash Adjuster ............................................................................................. ....................215
Remove ............................................................................................................................................................... 215
Clean and Inspect .............................................................................................................. ................................215
Reinstall .............................................................................................................................................................. 216
3.23 Cylinder Head Assembly ......................................................................................................... ..........................217
Remove ............................................................................................................................................................... 217
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............217
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................218
Disassemble ....................................................................................................................................................... 219
Clean................................................................................................................................................................... 222
Inspect ........................................................................................................................ ........................................222
Visual Inspection .............................................................................................................. ..............................222
Cylinder Head Measurement.......................................................................................................................... 223
Valve Spring Inspection and Measurement ........................................................................................ ............225
Valve and Seat Grinding ........................................................................................................ ........................225
Assemble ....................................................................................................................... .....................................230
Reinstall .............................................................................................................................................................. 233
Right-hand Side (Bank 1) Cylinder Head ......................................................................................... ..............233
Left-hand Side (Bank 2) Cylinder Head .......................................................................................... ................234
3.24 Engine Mounts and Brackets ..................................................................................................... .......................236
Remove ............................................................................................................................................................... 236
Engine Mount Location ..................................................................................................................................... 237
Inspect ........................................................................................................................ ........................................237
Reinstall .............................................................................................................................................................. 238
4 Major Service Operations ....................................................................................................... ...........239
4.1 Engine Re moval ................................................................................................................. ................................239
Remove ............................................................................................................................................................... 240
Disassemble ....................................................................................................................................................... 252
Reassemble ........................................................................................................................................................ 253
Reinstall .............................................................................................................................................................. 253
4.2 Oil Pan and Oil Pump Suction Pipe Assembly ..................................................................................... ...........254
Remove ............................................................................................................................................................... 254
Disassemble ....................................................................................................................................................... 255
Clean................................................................................................................................................................... 255
Inspect ........................................................................................................................ ........................................256

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–6
Page 6A1–6
Reassemble ........................................................................................................................................................ 257
Reinstall .............................................................................................................................................................. 257
4.3 Flexplate Assembly ............................................................................................................. ..............................259
Remove ............................................................................................................................................................... 259
Clean................................................................................................................................................................... 259
Inspect ........................................................................................................................ ........................................260
Reinstall .............................................................................................................................................................. 260
4.4 Crankshaft Rear Seal and Plate Assembly ........................................................................................ ..............262
Remove ............................................................................................................................................................... 262
Reinstall .............................................................................................................................................................. 263
4.5 Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 265
Remove ............................................................................................................................................................... 265
Disassemble ....................................................................................................................................................... 268
Clean and Inspect .............................................................................................................. ................................269
Piston Cleaning Procedure...................................................................................................... .......................269
Piston Inspection Procedure .................................................................................................... ......................269
Piston Measurement ............................................................................................................. .........................270
Piston Ring Measurement ........................................................................................................ ......................271
Connecting Rod Cleaning Procedure .............................................................................................. ...............272
Connecting Rod Visual Inspection Procedure ..................................................................................... ...........272
Connecting Rod Meas urement Procedure ........................................................................................... ..........272
Reasse mble ........................................................................................................................................................ 274
Piston and Piston Pin ..................................................................................................................................... 274
Piston Ring .................................................................................................................... .................................275
Connecting Rod Bearing ................................................................................................................................ 276
Reinstall .............................................................................................................................................................. 277
Piston Connecting Rod and Connecting Rod Bearing Inst allation .................................................................. 277
Connecting Rod Bearing Clearance Measurement Procedure....................................................................... 278
Connecting Rod Final Assembly Procedure ........................................................................................ ...........279
4.6 Crankshaft and Ma in Bearings ................................................................................................... ......................281
Crankshaft End Play Measurement ................................................................................................ ..................281
Remove ............................................................................................................................................................... 281
Crankshaft Bearing............................................................................................................. ............................283
Clean and Inspect .............................................................................................................. ................................283
Crankshaft and Main Bearing Cleaning ........................................................................................... ...............283
Crankshaft and Main Bear ing Visual Inspection .................................................................................. ...........284
Crankshaft Main B earing Inspection............................................................................................. ..................285
Crankshaft M easurement ......................................................................................................... ......................286
Reinstall .............................................................................................................................................................. 288
Crankshaft Bearing Installation Procedure ...................................................................................... ...............288
Crankshaft Main Bearing Clearance Measurement .................................................................................. ......289
Crankshaft Final Instal lation Procedure........................................................................................ ..................291
4.7 Cylinder Block ................................................................................................................. ...................................293
Disassemble ....................................................................................................................................................... 293
Clean................................................................................................................................................................... 297
Inspect ........................................................................................................................ ........................................297
Visual Inspection .............................................................................................................. ..............................297
Measuring Cylinder Bore Diameter ............................................................................................... .................297
Measuring Cylinder Bore Taper.................................................................................................. ....................298
Measuring Cylinder Bo re Out-of-Round ........................................................................................... ..............298
Deck Flatness Inspection ............................................................................................................................... 298
Reassemble ........................................................................................................................................................ 299
4.8 Thread Repairs ................................................................................................................................................... 303
General Information ............................................................................................................ ...............................303
General Thread Repair .......................................................................................................... ............................304
Main Bearing Cap Bolt Hole Thread Repair ....................................................................................... ..............310
Cylinder Head Bolt Hole Thread Repair .......................................................................................... .................315
4.9 Thread Repair Specifications................................................................................................... .........................322
Left-hand Cylinder Head Camshaft Cover Face .................................................................................... ..........322
Left-hand Cylinder H ead Front Face ............................................................................................. ...................323

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–7
Page 6A1–7
Left-hand Cylinder Head Intake Face ............................................................................................ ...................324
Left-hand Cylinder H ead Exhaust Face ........................................................................................... ................325
Left-hand Cylinder H ead Rear Face .............................................................................................. ...................326
Right-hand Cylinder Head Camshaft Cover Face ................................................................................... ........327
Right-hand Cylinder Head Front Face............................................................................................ ..................328
Right-hand Cylinder Head Intake Face ........................................................................................... .................329
Right-hand Cylinder He ad Exhaust Face .......................................................................................... ...............330
Right-hand Cylinder Head Rear Face ............................................................................................. ..................331
Engine Block Front ............................................................................................................................................ 332
Engine Block Left-hand Side .................................................................................................... ........................333
Engine Block Ri ght-hand Side ................................................................................................... .......................334
Engine Block Rear .............................................................................................................. ...............................335
Engine Block Bottom......................................................................................................................................... 336
Engine Block Left-hand Deck Face ............................................................................................... ...................337
Engine Block Righ t-hand Deck Face.............................................................................................. ..................338
Engine Front Cover............................................................................................................. ...............................339
Upper Intake Manifold Top ...................................................................................................... ..........................340
Upper Intake Mani fold Front .................................................................................................... .........................341
Upper Intake Ma nifold Rear..................................................................................................... ..........................342
Lower Intake Ma nifold Top...................................................................................................... ..........................343
Oil Pan Front .................................................................................................................. ....................................344
Oil Pan Rear........................................................................................................................................................ 345
Oil Pan Bottom ................................................................................................................................................... 346
5 Specifications .....................................................................................................................................347
6 Torque Wrench Specifications................................................................................................... .......351
7 Special Tools .................................................................................................................. ....................353

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–8
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 wa ter 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 m anufactured from powdered
metal and the rod cap is separ ated during the manufacturing
process using the fractured me thod. This creates a stronger,
visually seamless rod to cap union.
Figure 6A1 – 1
MY06 Update
Throughout this Section, reference is made to 'MY06 Update' or 'Excluding MY06 Update'.
Vehicles manufactured post 14th Marc h 2007 are fitted with an updated version of the HFV6 engine. This engine
features a different timing chain, and as a result different sprocket teeth. This change also introduces the use of a new
special tool to assist in the serviceab ility of replacing the engine timing components.
All service procedures and descriptions specific to this update variation are qualified as 'MY06 Update'.
1.1 WARNING, CAUTION and NOTES
This Section contains various WARNING S, CAUTIONS and NOTE statements that y ou must observe carefully to reduce
the risk of death or injury during servic e, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operat ional faults. WARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of a ll 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 WARNING, 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 reco mmended manner. WARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from o ccurring, but not all hazards can be foreseen.
WARNING defined
A WARNING statement immediately precedes an operating procedure or maint enance practice which, if not correctly
followed, could result in death or injury . A WARNING statement alerts you to ta ke necessary action or not to take a
prohibited action. If a WARNING 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 prec edes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equi pment, 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,

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–9
Page 6A1–9
• 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,
• 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 tool s or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediatel y precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characte ristics 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 performi ng a procedure in the recommended manner, and / or
Present information that gives the tec hnician the benefit of past experience in accomplishing a procedure with greater
ease.


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–10
Page 6A1–10
1.2 Engine Components
Major Component Assemblies

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

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–11
Page 6A1–11
Intake Manifold Assembly

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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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–12
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
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 Sprocket Bolt
10 Primary Timing Chain Tensioner Gasket
11 Camshaft Intermediate Sprocket, Left-hand
12 Camshaft Intermediate 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 Chai n Tensioner, Right-hand
27 Secondary Timing Chain Tensioner Bolt, Right-hand
28 Secondary Timing Chain T ensioner 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