radiator cap ISUZU KB P190 2007 Workshop User Guide

ENGINE COOLING 6B – 17
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 kPa (psi) 93.3
∼
∼∼
∼122.7 (13.5
∼
∼∼
∼17.8)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the center 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.





110RS006

Valve opening vacuum kPa (psi) 1.96 ∼
∼∼
∼ 4.91 (0.28 ∼
∼∼
∼ 0.71)


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 (28.5 psi)
with a cap tester:
• Leakage from the radiator
• Leakage from the coolant pump
• Leakage from the water hoses

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS

Main Data and Specifications ............................. 6B-2
General Description............................................ 6B-3 Coolant Flow ................................................... 6B-3
W ater Pump .................................................... 6B-4
Thermostat ...................................................... 6B-4
Radiator ........................................................... 6B-5
Antifreeze Solution .......................................... 6B-5
Diagnosis............................................................ 6B-6
Draining and Refilling Cooling System ............... 6B-7
W ater Pump ....................................................... 6B-8 Removal .......................................................... 6B-8
Inspection and Repair ..................................... 6B-9
Installation ....................................................... 6B-9
Thermostat ......................................................... 6B-11 Removal .......................................................... 6B-11
Inspection and Repair ..................................... 6B-11
Operating Test of Thermostat ......................... 6B-11
Installation ....................................................... 6B-12

Radiator .............................................................. 6B-13 Radiator and Associated Parts........................ 6B-13
Removal .......................................................... 6B-14
Inspection and Repair ..................................... 6B-15
Radiator Cap ................................................... 6B-15
Radiator Core .................................................. 6B-15
Flushing the Radiator ...................................... 6B-15
Cooling System Leakage Check ..................... 6B-15
Installation ....................................................... 6B-16
Engine Coolant Change .................................. 6B-16
Fan Clutch with Cooling Fan .............................. 6B-17 Inspection and Repair ..................................... 6B-17
Special Tools................................................... 6B-18

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ISUZU KB P190 2007

6B-2 ENGINE COOLING (4JK1/4JJ1)
Main Data and Specifications
Description Item
M/T A/T
Cooling system
W ater pump type
Pump to crankshaft speed ratio (To 1)
Delivery volume lit (US/UK gal)/min
Pump speed at 5600 rpm
W ater temperature at 30 °C (86 °F)
Pump bearing type

Thermostat type
Valve initial opening temperature °C ( °F)
Valve full opening temperature °C ( °F)
Valve lift at fully open position mm (in) Engine coolant forced circulation
Centrifugal impeller type 1.25
240 (63.1/53.3)

Double row shaft
W ax pellet with jiggle valve 85 (185)
100 (212) 10 (0.39)
Radiator Tube type corrugated
Heat radiation capacity kW (kcal/h) 93 (80.2)
Heat radiation area m2 (ft2) 11.63 (125.2)
Radiator front area m2 (ft2) 0.28 (3)
Radiator dry weight N (kg/lb) 52 53
Radiator cap valve opening pressure kPa (kg/cm2/psi) 93.3 - 122.7 (0.95 - 1.25/13.5 - 17.8)
Engine coolant capacity lit (U.S pint) 4.0 (8.5) 4.0 (8.5)
Engine coolant total capacity lit (U.S pint) 8.7 (18.4) 8.6 (18.2)


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ENGINE COOLING (4JK1/4JJ1) 6B-5
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of the coolant, the radiator is
fitted with a cap in which the valve is operated at 93.3 -
122.7 kPa (0.95 - 1.25 kg / cm
2 / 13.5 - 17.8 psi)
pressure. (No oil cooler provided for M/T)




RTW 56BSH000301
Antifreeze Solution
NOTE:
Antifreeze solution + W ater = Total cooling system
capacity.
Total Cooling System Capacity Lit
(US / UK gal) (US pint)
M/T 8.7 (2.3/1.9) (18.4)
A/T 8.6 (2.3/1.9) (18.2)
See section 0B MAINTENANCE AND LUBRICATION .







F06RW 005

NOTE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a
1:1 solution (50% antifreeze and 50% water).



RTW 76BSH000201


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6B-6 ENGINE COOLING (4JK1/4JJ1)
Diagnosis
Engine Cooling Trouble
Condition Possible Cause Correction
Low Engine Coolant level Replenish
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature
sensor Repair or replace
Clogged radiator
Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of
improper engine oil Replenish or change oil
Clogged exhaust system
Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position
sensor circuit Repair or replace
Engine overheating
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Faulty thermostat Replace Engine slow to warm–up
Thermo unit faulty Replace


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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-7
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“MIN" and “MAX" lines of the reserve tank when the
engine is cold. If low, check for leakage and add EC up
to the “MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.

1. Remove the radiator skid plate.
2. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.




RTW 56BSH000301
3. Remove the radiator cap.
WARNING:
To avoid the danger of being burned, do not
remove the cap while the engine and radiator are
still hot. Scalding fluid and steam can be blown out
under pressure.
4. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.

5. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change).
• Make sure that the engine is cool.
• Open radiator cap and pour coolant up to fille
r
neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and
reopen the radiator cap. If the water level is lower,
replenish.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor o
r
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure when the coolant has
become cooler.
• After tightening the radiator cap, warm up the
engine at about 2000 rpm. Set heater adjustment
to the highest temperature position, and let the
coolant circulate also into heater water system.
• Check to see the thermostat has opened through
the needle position of the water thermometer,
conduct a 5–minute idling again and stop the
engine.
• W hen the engine has been cooled, check fille
r
neck for water level and replenish if required.
Should extreme shortage of coolant be found,
check the cooling system and reservoir tank hose
for leakage.
• Pour coolant into the reservoir tank up to “MAX"
line.

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ENGINE COOLING (4JK1/4JJ1) 6B-13
Radiator
Radiator and Associated Parts


RTW 76BLF000101
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



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6B-14 ENGINE COOLING (4JK1/4JJ1)
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Remove the engine cover.
5. Disconnect radiator inlet hose and outlet hose from the engine.




RTW 56BSH000301
6. Remove fan guide (1), clips (2) on both sides and
the bottom lock, then remove lower fan guide (3)
with fan shroud (4).



PTW 46BSH000101

Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud

7. Disconnect the reserve tank hose (1) from
radiator.
8. Remove bracket (9).




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. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.

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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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ISUZU KB P190 2007

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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ISUZU KB P190 2007