engine ISUZU KB P190 2007 Workshop Repair Manual

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 â‹…m (1.0 kgf â‹…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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6A-72 ENGINE MECHANICAL (C24SE)






Crank Position Sensor
Removal
1. Remove crank position sensor.

Installation
1. Install crank position sensor.


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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 â‹…m (3.1 kgf â‹…m)
W hen re-using, insert oxygen sensor.


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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 â‹…m (3.1 kgf â‹…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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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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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 â‹…m (2.5
kgf â‹…m) - use.



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ENGINE MECHANICAL (C24SE) 6A-77
TECHNICAL DATA
SOHC Gasoline Engine C24SE

Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.

Engine Oil Quality
It is important that the following API and CCMC classes are
used:


Engines Single and multigrade oils Easy run oils
Petrol API-SF/CC, SF/CD, SG/CC,
SG/CD, CCMC/G4 API-SF/CC, SF/CD, SG/CD
CCMC-G5/PD2




Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.

Disposal.
Observe the relevant national regulations when disposing of
used oil.


Engine Oil Filling Quantities

Engine Model Initial filling
(litres) Filling quantity
with filter change* (litres) MIN to MAX
(litres)
2.4L 4.80 4.25 1.00
*Up to mark "MAX" on oil dipstick




Oil Pump
Backlash 0.1 to 0.2mm
Gaps in gears opposite housing 0.03 to 0.1mm
Oil pressure at idle speed Engine at operating temperature (>70°C oil and
approx. 80 °C coolant)
450 - 500 kpa
Oil drain plug M14 × 1.5


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6A-78 ENGINE MECHANICAL (C24SE)
Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 8


Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10
°
°°
°
C
Quantity in litres Up to-20
°
°°
°
C
Quantity in litres Up to-30
°
°°
°
C
Quantity in litres Up to-40
°
°°
°
C
Quantity of litres
(in litres) Water (80%) An ti -
Freeze (20%) Water
(66%) An ti -
Freeze (34%) Water
(56%) An ti -
Freeze (44%) Water
(48%) An ti -
Freeze (52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8


Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm


Radiator cap

Boiling point 123°C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)


Thermostat

Start of opening 92°C
Fully opened 107°C
Type Bypassed


Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W /O catalytic converter system)
*** Ignition timing adjustment not possible.

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ENGINE MECHANICAL (C24SE) 6A-79
Adjustment Values/Checking Values

Valve clearance Inlet Hydraulic valve lash adjustment
Outlet No adjustment necessary

Spark plugs - electrode gap 1.0 ∼ 1.1mm

Compression The difference in compression
between the individual cylinders
in the engine must not exceed
100 kPa (1 bar).

Pressure loss The pressure loss of an engine
in perfect condition per cylinder
is not more than max. 25%
























Cylinder Head
Cylinder Head Gasket
Thickness - installed mm 1.2

Valve seat width at cylinder head
inlet mm 1.0 to 1.5
outlet mm 1.7 to 2.2

Valve stem play inlet mm 0.018 to 0.052
outlet mm 0.038 to 0.072

Permissible valve stem to cone runout
inlet mm 0.03
outlet mm 0.33

Overall height of cylinder head
(Sealing surface to sealing surface) mm 95.5 ± 0.25

Installation height
inlet and
outlet valves mm 17.85 to 18.25
dimension "A" Distance Gauge
5-8840-2596-0

Installation height valve guide mm 83.50 to 83.80

Sealing surface peak-to-valley height mm max. 0.025


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