ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (C24SE) 6A-57



Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"


Bearing Free Play Measurement
Two methods for measuring bearing free play are described -
1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.











1.Plastigage Method
Removal
1. Remove bearing cap and shell.
2. Lightly coat journals and bearings with engine oil to prevent Plastigage from tearing when cap is removed.

Installation
1. Lay a length of Plastigage across width of crank pin and fit bearing cap and shell using old bolts at this stage.

Important!
Do not allow crankshaft to rotate.

Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° + to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.6 kgf ⋅m) +45 °.



Removal
1. Remove bearing cap and shell.

Measure
W idth of Plastigage -use scale supplied with Plastigage.

If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. -
check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"

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ISUZU KB P190 2007

6A-58 ENGINE MECHANICAL (C24SE)








Clean
Plastigage from journals.

Lightly coat journals and bearings with engine oil.

Installation
Install bearing cap and shell using new bolts.

Torque - Angle Method
Main bearing cap bolt - 60 N ⋅m (6.1 kgf ⋅m) +40 ° to 50 °.
Con-rod bearing cap bolts - 35 N ⋅m (3.9 kgf ⋅m) +45 °.








2.Micrometer and gauge method.
Crankshaft removed.

Installation
1. Install caps and bearing shells to con-rods and cylinder block.


Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.

The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.



Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.

Crankshaft must be replaced if mean diameter of main or con-
rod journals is below specified limit - see "Technical Data".

If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.

Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.

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ENGINE MECHANICAL (C24SE) 6A-59






Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx. 15mm/0.6in.).







Oil Filter
Removal
1. Remove oil filter using commercially available tool.

Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.



Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil pump from cylinder block, and oil pressure switch from
oil pump.










Clean
Sealing surfaces

Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.

Tighten (Torque)
Oil pressure switch to oil pump - 30 N ⋅m (3.2 kgf ⋅m)
Oil pump to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil intake pipe to oil pump - 8 N ⋅m (0.8 kgf ⋅m)
Intake pipe bracket to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)


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ISUZU KB P190 2007

6A-60 ENGINE MECHANICAL (C24SE)

Oil Pump Safety Valve
Removal
1. Remove closure plug.
2. Remove seal ring.
3. Remove spring.
4. Remove piston.








Installation
1. Install piston (observe installation position).
2. Install spring.
3. Install seal ring.
4. Install closure plug.

Tighten (Torque)
Closure plug - 30 N ⋅m (3.0 kgf ⋅m)













Oil Pump (Overhaul)
Removal
1. Remove oil pump according to the corresponding operation.
2. Remove oil cover and pressure control valve.

Inspect
Clearance between gear pair and housing upper edge - see
“Technical Data”.
Check housing, cover and pressure control valve.

Installation
1. Install pump cover with Sealing Compound 15 03 166 (90 094 714).
2. Install oil pump safety valve according to the corresponding operation.
3. Install oil pump according to the corresponding operation.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-61
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1. Remove cylinder head according to the corresponding operation.
2. Make hole in core plugs with pointed drift, turn in self tapping screw and edge out.

Important!
Cover oil duct in cylinder head with piece of cloth.

3. Pull out valve retainer, using commercially available tool.
4. Remove ball and spring.


5. Cut three threads in the ball seating with M 10 tap (3rd
stage).
6. Coat tap with grease.




7. Remove ball seating from cylinder head with
commercially available tool.
Do not damage cylinder head.


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ISUZU KB P190 2007

6A-62 ENGINE MECHANICAL (C24SE)
Installation
1. Install new pressure valve into cylinder head - with suitable pipe until stop.

2. Install core hole plugs into cylinder head - with suitable
pipe to end of chamfer.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-63
OPERATIONS ON COOLING SYSTEM
Caution!
Before working with the cooling system, be sure to confirm that
the temperature of the engine is cooled down.
Failure to observe this may cause burn.








Cooling System, Check for Leaks
Installation
1. Install commercially available coolant checking instrument onto compensation tank (Refer to section 6B;
Engine cooling).
2. Check coolant level.

Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.



Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium.
To avoid corrosion, use only anti-freeze with corrosion
protection.


Replace Coolant
1. Confirm the engine is cold enough.
2. Open the radiator cap, pour coolant to the filler neck level and close the cap.
3. Pour coolant into the reservoir until MAX line is reached.
4. Start the engine, run 2 ∼ 3 minutes at idling speed and
switch off the engine.
5. Refill coolant if the coolant level is lowered.


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ISUZU KB P190 2007

6A-64 ENGINE MECHANICAL (C24SE)
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. W hen opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7. Confirm that the temperature gauge reads half or more of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8. After the engine cools down, check the coolant level and refill it if necessary. W hen the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9. Pour coolant into the reservoir to MAX level.






Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92 °C/197.6F)

Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-
up phase.


Ignition Timing, Check
No Adjustment


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-65
ENGINE EXTERNAL PARTS
Radiator


Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect radiator inlet hose and outlet hose from the engine.






RTW 46BSH000101
4. Remove fan guide(1), clips(2) on both sides and the
bottom lock, then remove lower fan guide(3) with fan
shroud(4).
5. Disconnect the reserve tank hose(6) from radiator.




RTW 36BMH000101
6. Remove bracket(5).

7. 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

6A-66 ENGINE MECHANICAL (C24SE)

Installation
Follow the removal procedure in the reverse order to install the
radiator.



Thermostat
Removal
1. Remove water outlet nozzles with thermostat from thermostat housing.
2. Remove coolant hose and collect coolant.







Important!
Remove and Install thermostat only together with water outlet
nozzles.

Tighten (Torque)
W ater outlet nozzles to thermostat housing - 8 N ⋅m (0.8 kgf ⋅m)

Installation
1. Install coolant hose.
2. Fill cooling system and bleed according to the corresponding operation.











Water Pump
Removal
1. Remove lower hose band from pipe band and collect coolant.
2. Remove front toothed belt cover according to the corresponding operation.
3. Remove water pump from cylinder block after releasing tension on toothed belt.

Clean
Sealing surfaces


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ISUZU KB P190 2007