ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (C24SE) 6A-67

Coating sealing surfaces with Silicone Grease
Installation
1. Install water pump to cylinder block with new rubber O-ring.
2. Apply tension to toothed belt according to the corresponding operation.
3. Install coolant hoses.
4. Fill cooling system and bleed according to the corresponding operation.











Alternator
Removal
1. Remove ground cable from battery.
2. Remove cable connection from alternator and V-belt.
3. Remove alternator from retaining strap and lower fastening.

Installation
1. Install alternator by tightening firmly by hand.
2. Install V-belt and apply tension according to the corresponding operation.
3. Install cable connections to alternator.
4. Install ground cable to battery.





Starter
Removeal
1. Remove cable connections from starter.
2. Remove upper bolt of transmission side.
3. Remove lower bolt of engine side.

Tighten (Torque)
Starter to cylinder block:
Engine side - 51 N ⋅m (5.2 kgf ⋅m)
Transmission side - 75 N ⋅m (7.6 kgf ⋅m)

Starter support to cylinder block - 25 N ⋅m (2.5 kgf ⋅m)

Re-connect cables.

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6A-68 ENGINE MECHANICAL (C24SE)
V-belt Tension of Alternator



RTW 66ASH000101
Measure
Measure V-belt tension of alternator.
Permitted values for new V-belt are approx. 311-489N (31-50
kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.





Adjust
Adjust V-belt tension by loosening clamping bracket and lower
alternator bracket and moving alternator.

Tighten (Torque)
Clamping bracket to alternator - 35 N ⋅m (3.6 kgf ⋅m)
Lower alternator bracket - 25 N ⋅m (2.6 kgf ⋅m)

V-Belt Tension of Power Steering Pump
Measure
Measure V-belt tension of power steering pump. Permitted
values for new belt are approx. 578-712N (59-73 kgf) and 534-
667N (54-68 kgf) for used belt.
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.





Adjust
Adjust V-belt tension by loosening clamping bolt, lower pump
bracket, and adjusting nuts and moving steering pump.

Tighten (Torque)
Adjusting nuts - 18 N ⋅m (1.8 kgf ⋅m)
Clamping bolt - 25 N ⋅m (2.6 kgf ⋅m)
Lower pump bracket - 26 N ⋅m (2.6 kgf ⋅m)


V-Belt Tension of Air Conditioning Compressor
Measure
Measure V-belt tension of air conditioning compressor.
Permitted values for new V-belt are approx. 422N (43 kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-69


RTW 66ASH000201

Adjust
Adjust the A/C compressor V-belt (1) for adjustment of belt.
1. Loosen the tension pulley lock nut (2) and tension pulley adjusting bolt (3) of the tension pulley of the A/C
compressor V-belt (1) and bring the belt to free state.
2. Rotate the adjusting bolt (3) of A/C compressor adjust the belt (remove and fit).
• W hen replacing the belt, you must always replace both the belts.
3. After adjustments, tighten the lock nut (2) using the specified torque.
Tightening torque: 40 N ⋅m (4.1 kgf ⋅m)
• Finally, adjust the tension of A/C compressor V-belt.

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ISUZU KB P190 2007

6A-70 ENGINE MECHANICAL (C24SE)
FUEL INJECTION SYSTEM
MAP SENSOR



Removal
1. Disconnect the battery cable.
2. Disconnect the electrical connector from the sensor.
3. Remove the mounting bolts securing the sensor to the manifold.
4. Remove the sensor from the intake manifold.


Installation
1. Push MAP sensor into the manifold.
2. Install the mounting bolts and tighten them.
3. Connect electrical connector.
4. Connect the battery cable.









Pressure Regulator
Removal
1. Remove vacuum hose.
2. Remove fuel hoses.
3. Remove pressure regulator.

Installation
1. Install pressure regulator.
2. Install fuel hoses.
3. Install vacuum hoses.


ECM (Engine Control Module)
Removal

(2.4L)
1. Disconnect the ECM connector.
2. Remove the four hex bolts and nuts.
3. Remove the ECM from the ECM bracket on engine.



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ENGINE MECHANICAL (C24SE) 6A-71
Installation

(2.4L)
1. Install the ECM to the ECM bracket on engine.
2. Tighten the four screws to the bracket.
3. Connect the connector.









ECT
Removal
1. Remove wiring harness plug and coolant temperature sensor.

Tighten (Torque)
Temperature sensor to intake pipe - 10 N ⋅m (1.0 kgf ⋅m)
W iring harness plug to temperature sensor

Inspection
Coolant level








Idle Air Control (IAC) Valve
Removal
1. Remove wiring harness plug, hose clamps and idle speed adjuster.

Installation
1. Install idle speed adjuster, hose clamps and wiring harness plug.







Ignition Coil
Removal
1. Remove 2 bolts, plug and ignition coil.

Installation
1. Install ignition coil, plug and bolts.


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ISUZU KB P190 2007

6A-72 ENGINE MECHANICAL (C24SE)






Crank Position Sensor
Removal
1. Remove crank position sensor.

Installation
1. Install crank position sensor.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-73
FUEL INJECTOR




Removal
Caution: To reduce the risk of fire and personal injury, it is
necessary to relieve the fuel system pressure before
servicing the fuel system components.

Caution: After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel lines
or connections. Reduce the chance of personal injury by
covering the fuel line fitting with a shop towel before
disconnecting the fittings. The towel will absorb any fuel
that may leak out. When the disconnect is completed,
place the towel in an approved container.

1. Depressurize the fuel system.
2. Disconnect the fuel inlet.
3. Disconnect the fuel return line.
4. Remove the fuel rail from the intake manifold.
5. Remove the fuel injector from the fuel rail by disengaging claws.

Installation
1. Install the fuel injector to the fuel rail by engaging claws.
2. Install the fuel rail to the intake manifold.
3. Connect the fuel return line firmly.
4. Connect the fuel supply line firmly.





Knock sensor
Removal
1. Remove fixing bolts.
2. Disconnect the connector at the other side.


Tighten (Torque)
Oxygen sensor in exhaust pipe - 30N ⋅m (3.1 kgf ⋅m)
W hen re-using, insert oxygen sensor.


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ISUZU KB P190 2007

6A-74 ENGINE MECHANICAL (C24SE)




Oxygen Sensor (If applicable)
Removal
1. Remove wiring harness plug.
2. Remove oxygen sensor from the front exhaust pipe.


Tighten (Torque)
Oxygen sensor in exhaust pipe - 30 N ⋅m (3.1 kgf ⋅m)









Throttle Valve Position Sensor
Removal
1. Remove wiring harness connector.
2. Remove throttle valve position sensor.

Installation
1. Install throttle valve position sensor.
2. Install wiring harness connector.


Accelerator Pedal and Cable
Removal
1. Remove pad stopper from pedal stop bolt.





Installation
1. Install pad stopper.

Inspection
Ensure that accelerator pedal is fully in idle position and
accelerator level at engine is in closed position.

Pull outer sleeve of accelerator cable towards pedal and check
that clip on sleeve is in slot nearest to grommet.

Reposition clip if necessary, and check that full throttle and idle
positions are obtained at engine lever.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-75


RTW 46JSH000101









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

Removal
(2.4L)
1. Remove air cleaner cover and air cleaner element.
2. Remove air intake nose.
3. Remove lower air cleaner.
4. Remove mud guard.
5. Remove front fender cover.
6. Remove outside air intake duct.


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




130RW 002




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

Installation
(2.4L)
1. Install outside air intake duct.
2. Install front fender cover.
3. Install mud guard.
4. Install lower air cleaner.
5. Install air intake hose.
6. Install air cleaner element and air cleaner cover.


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ISUZU KB P190 2007

6A-76 ENGINE MECHANICAL (C24SE)









Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).

Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)

Tighten (Torque)
Spark plug with thread bush into cylinder head - 25N ⋅m (2.5
kgf ⋅m) - use.



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ISUZU KB P190 2007