Part of the Isuzu 6HK1 engine documentation.
This is the Isuzu 6HK1 diesel engine Workshop Manual, an Interim Tier 4 compatible reference running 963 pages. It is delivered as a downloadable PDF you can open on a phone, tablet or computer, or print by section for the workshop.
Coverage spans the whole common-rail engine: a service information guide, maintenance information and primary specifications, functional inspection of the starting, fuel, air intake and EGR systems, symptom diagnosis, and a deep set of DTC diagnostics from P0016 through the P2xxx and Uxxxx series. The mechanical section covers the cylinder head, block, crankshaft, and flywheel, and an Electronic Troubleshooting Manual adds the engine wiring diagrams, location diagrams, and connector list.
With it you can diagnose DPD regeneration faults, chase injector coil and common-rail pressure codes, sort a boost or VNT problem, and carry out a full mechanical overhaul with Isuzu's own specifications.
Other edition of this manual
What's Inside This Isuzu 6HK1 Manual
| System | Pages | Key Topics |
|---|---|---|
| Service Information Guide | 6-25 | Contents Included in Service Information, Plastic Gauge, Recommended Liquid Gasket, Thread Locking Adhesive Agent |
| Maintenance Information | 26-94 | Primary Specifications, Function, Structure, And Operation, Maintenance Precautions, Introduction to Trouble Diagnosis |
| Functional Inspection | 95-112 | Starting System Check, Fuel System Check, Air Intake System Check, Exhaust System Check, EGR Control System Check, Glow Control System Check, Dpd Control System Check |
| Symptom Diagnosis | 113-128 | Dpd System Manual Regeneration Frequently, Dpd System Regeneration Long Time, Engine Start Failure, Engine Stalling, Engine Hunching, Rough Idling, Excessive White Smoke in the Exhaust Gas, Excessive Black Smoke in the Exhaust Gas |
| DTC Information | 129-228 | DTC P0016 - P0093, DTC Descriptions, DTC Mapping Table |
| Engine Control | 229-350 | Table of Contents, DTC Diagnostics, DTC P0016 - Crankshaft/Camshaft Correlation, DTC P0045 - Turbocharger Boost Control, DTC P0087 - Fuel Rail Pressure Too Low, DTC Diagnostics: P01xx - P04xx Series, DTC Diagnostics: P05xx - P1xxx Series, DTC Diagnostics: P2xxx - Uxxxx Series |
| Mechanical | 351-734 | Idle Gear, Flywheel and Housing, Oil Pan, Crankshaft Seals, Cylinder Head Cover, Cylinder Head Assembly, Cylinder Block, DTC Mapping Table |
| Fuel System | 735-780 | Injector, Suction Control Valve, Relief Valve, Fuel Filter, Fuel Filter Element, Fuel Filter Pressure Sensor |
| Cooling System | 781-806 | Water Pump Assembly, Drive Belt, Thermostat, Overheat Switch, Engine Coolant Temperature Sensor |
| Lubrication | 807-884 | Oil Port Cover, Oil Pump Assembly, Disassembly |
| Induction (Turbocharger) | 885-900 | Boost Temperature Sensor, Turbocharger Assembly, Imt Sensor, Boost Sensor, Intercooler |
| Exhaust and Dpd | 901-916 | Dpd Assembly, Exhaust Differential Pressure Sensor, Exhaust Gas Temperature Sensor |
| Emission Control Devices | 917-926 | EGR Valve |
| Electrical | 927-964 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Boost pressure (DTC P0234 setting condition) | 300 kPa {3 kgf/cm2 / 44 psi} or higher for 5 seconds or longer | p. 159 |
| Actual common rail pressure (DTC P0093 setting condition) | 15 MPa {153 kgf/cm2 / 2175 psi} or lower for 3 seconds or longer | p. 138 |
| Injector harness intermediate connector resistance | 2.0 Ω | p. 258 |
| Compression Pressure (Specified Value) | 3240.0 kPa | p. 109 |
| Compression Pressure (Limit) | 2260.0 kPa | p. 109 |
| Valve Clearance (Intake & Exhaust, Cold) | 0.4 mm | p. 28 |
| Cylinder Bore | 115 mm | p. 28 |
| Lubrication Oil Amount | 36.0 to 46.0 L | p. 28 |
| Thermostat Opening Temperature (without jiggle valve) | 82 °C | p. 28 |
| Glow Plug Standard Current | 3.5 A | p. 28 |
| Cylinder Head Cover Bolt Torque | 13 N·m | p. 77 |
| M14 Cylinder Head Bolt Torque (Step 1) | 98 N·m | p. 389 |
