Isuzu KB P190. Manual - part 621

 

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Isuzu KB P190. Manual - part 621

 

 

Engine Mechanical – V6 

Page 6A1–5 

 

Camshaft Visual Inspection............................................................................................................................ 150

 

Camshaft Measurement ................................................................................................................................. 151

 

Reinstall .............................................................................................................................................................. 153

 

Right-hand Side.............................................................................................................................................. 153

 

Left-hand Side ................................................................................................................................................ 155

 

3.20

 

Rocker Arm......................................................................................................................................................... 158

 

Remove ............................................................................................................................................................... 158

 

Clean and Inspect .............................................................................................................................................. 158

 

Reinstall .............................................................................................................................................................. 159

 

3.21

 

Stationary Hydraulic Lash Adjuster ................................................................................................................. 160

 

Remove ............................................................................................................................................................... 160

 

Clean and Inspect .............................................................................................................................................. 160

 

Reinstall .............................................................................................................................................................. 161

 

3.22

 

Cylinder Head Assembly................................................................................................................................... 161

 

Remove ............................................................................................................................................................... 161

 

Right-hand Side (Bank 1) Cylinder Head ....................................................................................................... 161

 

Left-hand Side (Bank 2) Cylinder Head.......................................................................................................... 162

 

Disassemble ....................................................................................................................................................... 163

 

Clean ................................................................................................................................................................... 166

 

Inspect ................................................................................................................................................................ 167

 

Visual Inspection ............................................................................................................................................ 167

 

Cylinder Head Measurement.......................................................................................................................... 167

 

Valve Spring Inspection and Measurement.................................................................................................... 169

 

Valve and Seat Grinding ................................................................................................................................ 170

 

Assemble ............................................................................................................................................................ 174

 

Reinstall .............................................................................................................................................................. 177

 

Right-hand Side (Bank 1) Cylinder Head ....................................................................................................... 177

 

Left-hand Side (Bank 2) Cylinder Head.......................................................................................................... 178

 

3.23

 

Engine Mounts and Brackets............................................................................................................................ 181

 

Remove.......................................................................................................................................................... 181

 

Engine Mount Location ..................................................................................................................................... 182

 

Inspect ................................................................................................................................................................ 182

 

Reinstall .............................................................................................................................................................. 183

 

4

 

Major Service Operations ..................................................................................................................184

 

4.1

 

Engine Removal ................................................................................................................................................. 184

 

Remove.......................................................................................................................................................... 185

 

Disassemble................................................................................................................................................... 197

 

Reassemble ................................................................................................................................................... 198

 

Reinstall ......................................................................................................................................................... 198

 

4.2

 

Oil Pan and Oil Pump Suction Pipe Assembly ................................................................................................ 198

 

Remove.......................................................................................................................................................... 198

 

Disassemble................................................................................................................................................... 200

 

Clean.............................................................................................................................................................. 200

 

Inspect............................................................................................................................................................ 201

 

Reassemble ................................................................................................................................................... 201

 

Reinstall ......................................................................................................................................................... 202

 

4.3

 

Flexplate Assembly ........................................................................................................................................... 203

 

Remove ............................................................................................................................................................... 203

 

Clean ................................................................................................................................................................... 204

 

Inspect ................................................................................................................................................................ 204

 

Reinstall .............................................................................................................................................................. 205

 

4.4

 

Crankshaft Rear Seal and Plate Assembly ...................................................................................................... 205

 

Remove ............................................................................................................................................................... 205

 

Reinstall .............................................................................................................................................................. 207

 

4.5

 

Pistons, Pins, Rings, Connecting Rods and Big-end Bearings ..................................................................... 208

 

Remove ............................................................................................................................................................... 208

 

Disassemble ....................................................................................................................................................... 211

 

Clean and Inspect .............................................................................................................................................. 212

 

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....................................................................... 221

 

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

 

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

 

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 WARNINGS, 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. WARNINGS, 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 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 recommended manner. WARNING, CAUTION and NOTE statements are 
designed to help prevent these hazards from occurring, but not all hazards can be foreseen. 

WARNING defined 

A WARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly 
followed, could result in death or injury. A WARNING statement alerts you to take 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 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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