engine coolant ISUZU KB P190 2007 Workshop Repair Manual

6B-10 ENGINE COOLING (4JK1/4JJ1)
5. Radiator Upper Hose.






RTW 56FSH000101
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of clamp shall be directed to horizontal.
c. Replenish the engine coolant.
6. Install the engine cover.


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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-11
Thermostat
Read this Section carefully before performing any
removal and installation procedure. This Section gives
you important points as well as the order of operation.
Be sure that you understand everything in this Section
before you begin.

Removal
1. Remove the engine cover.
2. Radiator Upper Hose a. Partially drain the engine coolant.
b. Remove the radiator upper hose.
c. Remove the engine harness clip.






RTW 56FSH000101
3. W ater Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from outlet pipe.
b. Loosen the fixing bolt and remove the wate
r
outlet bolt.
4. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.




RTW 56BSH000101
Legend
1. Front
2. Thermostat
3. Jiggle Valve

Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Operating Test of Thermostat
1. Completely submerge the thermostat in water.
2. Heat the water.Stir the water constantly to avoid direct heat being applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C (°F)
85 (185)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature °C (°F)
100 (212)
Valve Lift At Fully Open Position mm (in)
10 (0.39)


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6B-12 ENGINE COOLING (4JK1/4JJ1)







MFW 41CSH001401
Legend
1. W ooden Piece
2. Agitating Rod

Installation
1. Thermostat
Install the thermostat.
Mount the jiggle valve with the valve facing engine front.




RTW 56BSH000101
Legend
1. Front
2. Thermostat
3. Jiggle Valve


2. W ater Outlet Pipe.
a. Install the water outlet pipe with new gasket to the thermostat housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque: 25 N·m (2.5 kg·m /18 lb ft)
c. Connect the turbocharger-cooling pipe to outlet pipe.
d. Install the engine harness clip.
3. Radiator Upper Hose.






RTW 56FSH000101
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of the clamp should be directed to the horizontal side.
c. Replenish the engine coolant.
4. Install the engine cover.

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-15
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure: 93.3 - 122.7 kPa (0.95 - 1.25 kg / cm
2 / 13.5 -
17.8 psi)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
Valve opening vacuum: 1.96 - 4.91 kPa (0.02 - 0.05 kg / cm
2 / 0.28 - 0.71
psi)



110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:
• Leakage from the radiator.
• Leakage from the coolant pump.
• Leakage from the water hoses.
• Check the rubber hoses for swelling.



110RS005


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6B-16 ENGINE COOLING (4JK1/4JJ1)
Installation
1. Install radiator assembly (6) with hose, taking care
not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (9) and secure the radiator.
3. Connect reserve tank hose (1).
4. Install lower fan guide (4).
5. Connect radiator inlet hose and outlet hose (3) to the engine.
6. Install the engine cover.
7. Connect oil cooler hose to automatic transmission.
8. Connect battery ground cable.



RTW 76BMH000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket


9. Pour engine coolant up to filler neck of radiator,
and up to MAX mark of reserve tank.
Important operation (in case of 100% engine coolant change) procedure for filling with engine
coolant.







RTW 76BSH000101
Engine coolant change
Refer to change procedure for Draining and Refilling
Cooling System in this section.

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6C-28 FUEL SYSTEM (4JK1/4JJ1)
Removal
1. Partially drain the engine coolant.
Refer to drain procedure for engine cooling in this manual.
2. Remove the radiator upper hose.





RTW 56FSH000101
3. Remove the fan guide.




RTW 46BSH000101
Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling Fan.




RTW 56ASH025401
5. Remove the A/C compressor drive belt.
6. Remove the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut

7. Remove the battery.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-37
24. Install the A/C compressor.




RTW 56ASH004201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor

Tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
25. Install the battery.
26. Install the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut


Tighten the nut and bolt to the specified torque.
Bolt Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
Nut Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
27. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure fo
r
Heating and air conditioning in this manual.
28. Install the cooling fan.
29. Install the fan guide.
30. Install the radiator upper hose.
31. Replenish the engine coolant.

Fuel Supply Pump Relearn Procedure
The ECM goes through a fuel supply pump learn
procedure to fine tune the current supplied to the fuel
rail pressure (FRP) regulator. This learning process in
only performed when the engine is idling.
1. Install the scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Supply Pump Learn Reset with the scan tool.
4. Observe the Supply Pump Status parameter with the scan tool. Confirm the scan tool indicates Not
Learn.
5. Start the engine and let idle until engine coolant temperature (ECT) reads 149°F (65°C) or highe
r
while observing Supply Pump Status parameter
with the scant tool. The scan tool changes status
Not Learn > Learning > Learned.
6. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.


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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-3
Specifications
Temperature vs Resistance
Engine Coolant Temperature vs. Resistance
Intake Air Temperature vs. Resistance
Fuel Temperature vs. Resistance
Altitude vs Barometric Pressure
° C °FOhms
Temperature vs. Resistance Value (Approximately)
110 230 160
100 212 200 90 194 260
80 176 350
70 158 470
60 140 640
50 122 880
40 104 1250
30 86 1800
20 68 2650
10 50 4000 0 32 6180
-10 14 9810
-20 -4 16000
-30 -22 27000
° C °FOhms
Temperature vs. Resistance Value (Approximately)
90 194 240
80 176 320
70 158 430
60 140 590
50 122 810
40 104 1150
30 86 1650
20 68 2430
10 50 3660
0325650
-10 14 8970
-20 -4 14700
° C °FOhms
Temperature vs. Resistance Value (Approximately) 110 230 140
100 212 180
90 194 24080 176 310
70 158 420
60 140 580
50 122 810
40 104 1150
30 861660
20 682450
10 503700
03 2574 0
-10 149160
-20 -415000
-30 -2225400
Altitude Measured in Meters (m) Altitude Measured
in Feet (ft) Barometric
Pressure
Measured in
Kilopascals (kPa)
Determine your altitude by contacting a local weather station or by using another reference source.
4267 14000 56 - 64
3962 13000 58 - 66
3658 12000 61 - 69
3353 11000 64 - 72
3048 10000 66 - 74
2743 900069 - 77
2438 800071 - 79
2134 700074 - 82
1829 600077 - 85
1524 500080 - 88
1219 400083 - 91
914 300087 - 98
610 200090 - 98
305 100094 - 102
0 0 Sea Level 96 - 104
-305 -1000101 - 105
°
C °FO hm s
Temperature vs. Resistance Value (Approximately)

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-5
P0093 227 AAA Fuel System Leak Detected
P0101 92 A -- Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A AA Mass Air Flow Sensor Circuit Low Input
P0103 91 A AA Mass Air Flow Sensor Circuit High Input
P0107 32 A A- Manifold Absolute Pressure Sensor Circuit Low Input
P0108 32 A A- Manifold Absolute Pressure Sensor Circuit High Input
P0112 22 A AA Intake Air Temperature Sensor Circuit Low
P0113 22 A AA Intake Air Temperature Sensor Circuit High
P0116 23 A --Engine Coolant Temperature Sensor Circuit Range/
Performance
P0117 23 A AA Engine Coolant Temperature Sensor Circuit Low
P0118 23 A AA Engine Coolant Temperature Sensor Circuit High
P0122 43 B AA Throttle Position Sensor Circuit Low
P0123 43 B AA Throttle Position Sensor Circuit High
P0182 211 A AA Fuel Temperature Sensor Circuit Low
P0183 211 A AA Fuel Temperature Sensor Circuit High
P0192 245 A AA Fuel Rail Pressure Sensor Circuit Low
P0193 245 A AA Fuel Rail Pressure Sensor Circuit High
P0201 271 A AA Injector Circuit Open - Cylinder 1
P0202 272 A AA Injector Circuit Open - Cylinder 2
P0203 273 A AA Injector Circuit Open - Cylinder 3
P0204 274 A AA Injector Circuit Open - Cylinder 4
P0217 542 D DD Engine Coolant Over Temperature Condition
P0219 543 C AA Engine Overspeed Condition
P0231 69 C AA Fuel Pump Secondary Circuit Low
P0232 69 C AA Fuel Pump Secondary Circuit High
P0234 42 A A- Turbocharger Overboost Condition
P0299 65 A A- Turbocharger Underboost
P0335 15 A AA Crankshaft Position Sensor Circuit
P0336 15 A AA Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 C AA Camshaft Position Sensor Circuit
P0341 14 C AA Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C AA Glow Plug Circuit
P0401 93 A -- EGR Flow Insufficient Detected
P0403 37 B AA EGR Control Circuit
P0404 45 A AA EGR Control Circuit Range/ Performance
P0405 44 B AA EGR Sensor Circuit Low
P0406 44 B AA EGR Sensor Circuit High
P0500 25 A AA Vehicle Speed Sensor
DTC
Flash
Code DTC Type
DTC Descriptor
Euro 4
Specification Except Euro 4
Specification
(High Output) Except Euro 4
Specification (Standard Output)

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6E-16 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Gauges
RTW76EXF004701
Fuel
consumption
signal
output
11 676
8
7 5 B-56
C-107 8 B-24
17
0.3
BLK/
YEL
0.5
YEL
0.5
YEL
0.5
YEL
0.5
BLK
0.85
BLK 6
7 0.5
BLK/
YEL 0.5
BLK/
YEL
0.5
BLK/
YEL 0.5
BLK/
YEL 0.5
BLK/
YEL
0.5
BLK/
YEL 0.5
BLK
0.85
BLK
0.85
BLK
0.85
BLK
0.85
BLK 0.5
BLK
0.5
BLK0.5
WHT
0.5
BLK/
RED
0.3
BLK/
RED
20
13
23 0.3
YEL/
RED
0.3
YEL/
RED 0.5
YEL/
BLK
0.5
YEL/
BLK
0.5
YEL/
RED 0.5
YEL/
BLK
0.5
GRN/
RED
ECM(27)
ECM(26) 0.3
BLK/
RED
0.5
BLK/
RED
4
20.3
ORN/
WHT
0.5
ORN/
WHT
Fuel
tank
sender
unit
10 C-94
TCM
Engine
speed
signal
inputTCM
7 C-94
62 C-58 A/T
Engine
speed
signal
output
33 IP
cluster
70 B-23
B-24
B-23
H-18
H-4
12
5
H-9
F-2
F-2
3
22 E-41
31
H-4
2 H-6
H-4 M/T
A/T 4WD
A/T 2WD
10
H-15
E-10
E-10 4
C-58
ECT
sensor
VSS
E-44
E-44
1
2 3
C-14
Meter
10A
Fuse/
relay
box
(Cabin) Speedometer
Fuel gaugeEngine coolant
temperature gauge
Tachometer Multi display
ECM
Signal
ECM
+B VSS
signal
output

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