ISUZU KB P190 2007 Workshop Repair Manual

ENGINE MECHANICAL (C24SE) 6A-87






Crankshaft, Cylinder Block (continued)
Flywheel
Starter ring gear Before fitting, heat ring gear to 180 °C -
230 °C

Lateral run-out Permissible lateral run-out of installed
starter ring gear to flywheel: 0.5mm

Precision turning Permissible removal of material in clutch disc lining surface area: 0.3mm

In order to achieve the functional
relationship again after removal of material,
the same removal of material must take
place on the fore part of the flywheel
(contact for clutch assembly)

Dimension A: 2.1 to 2.2mm

Cylinder block
Top deck flatness mm 0.05
Cylinder block height mm 280 ±0.075


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6A-88 ENGINE MECHANICAL (C24SE)
Recommended Torque Values
N⋅m (kgf ⋅m)

Bearing cover to cylinder block ........................................................................................ 60
1) 6.1 +40 ° to 50 °
Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission .......................................................... 60
2) 6.1
Bracket for engine damping block to engine block .......................................................... 60 6.1
Bracket for pump/compressor to engine block ................................................................ 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft ................................................................................... 50 5.1
Clamping bracket for alternator to intake manifold .......................................................... 25 2.5
Clamping bracket to alternator ......................................................................................... 25 2.5
Con-rod bearing cap to con-rod ....................................................................................... 35
1) 3.5 +45 ° to 60 °
Crankshaft pulley bolts ..................................................................................................... 2 0 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90 ° +90 °
+90 °
Engine damping block to engine bracket ......................................................................... 85 8.7
Engine damping block to side member ............................................................................ 52
1) 5.3
Exhaust manifold to cylinder head ................................................................................... 22 2.2

1) Use new bolts
2) Use new locking plates


Recommended Torque Values
N⋅m (kgf ⋅m)

Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30° to 45 °
Front exhaust pipe to exhaust manifold ........................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket .................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block ........................................................................... 6
2) 0.6
Oil intake pipe to oil pump ................................................................................................ 8 0.8
Oil pan to cylinder block ................................................................................................... 8
2)3) 0.8
Bearing bridge to cylinder block ....................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ........................................................................................ 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................. 30 3.2
Spark plugs in cylinder head ............................................................................................ 20 2. 3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side .............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head ............................................................................... 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover ................................................................................................... 4 0.4
Toothed belt rear cover .................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................. 20 2.3 (M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7 (M12) ............................................................................ 60 6.1
W ater pump to cylinder block .......................................................................................... 17 1.7

1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-89
SPECIAL SERVICE TOOLS
ITEM NO. ILLUSTRATION PART NO. PART NAME
4


5-8840-2634-0



Aligner
2


5-8840-2593-0


Cutter set
3


5-8840-2594-0


Spring Compressor
4


5-8840-0451-0


Installer
5


5-8840-2596-0


Distance Gauge
6


5-8840-0455-0


Assembly Sleeves
7

5-8840-2597-0

Installer
8


5-8840-0457-0


Remover / Installer
10


5-8840-0468-0


Remover / Installer
11


5-8840-0459-0


Installer

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6A-90 ENGINE MECHANICAL (C24SE)
ITEM NO. ILLUSTRATION PART NO. PART NAME
13


5-8840-0446-0


Flywheel Holder
4

5-8840-2598-0

Holding W rench
4

5-8840-2599-0

Reamer Set
17

5-8840-2601-0

Installer


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ISUZU KB P190 2007

ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
General Description ....................................................................................................... 6B- 2
Service Precaution ......................................................................................................... 6B- 3
Diagnosis ...................................................................................................................... .. 6B- 5
Draining and Refilling Cooling System ........................................................................ 6B- 6
Water Pump .................................................................................................................... 6B- 7
Water Pump and Associated Parts .......................................................................... 6B- 7
Removal ...................................................................................................................... 6 B- 7
Inspection ................................................................................................................... 6 B- 7
Installation .................................................................................................................. 6B- 8
Thermostat ..................................................................................................................... . 6B- 9
Removal ...................................................................................................................... 6 B- 9
Inspection ................................................................................................................... 6 B- 9
Installation .................................................................................................................. 6B- 9
Fan clutch with Cooling Fan.......................................................................................... 6B- 9 Inspection and Repair ............................................................................................... 6B- 9
Radiator ....................................................................................................................... .... 6B-11
Radiator and Associated Parts ................................................................................. 6B-11
Removal ...................................................................................................................... 6 B-11
Inspection ................................................................................................................... 6 B-12
Installation .................................................................................................................. 6B-13
Main Data and Specifications ........................................................................................ 6B-13
Special Service Tool....................................................................................................... 6B- 14


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6B-2 ENGINE COOLING
General Description
Legend
1 W ater Pump
2 Thermostat
3 Radiator
4 Reserve Tank 5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater




The Cooling System is a pressurized type, where the water
pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.


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ENGINE COOLING 6B-3


Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.



Water pump
The water pump is centrifugal type and is driven by timing belt.


Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.





110RS001
Radiator
The radiator is a flow type with corrugated fins.


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6B-4 ENGINE COOLING

Antifreeze Solution
• Calculating mixing ratio
Mixing ratio

= Antifreeze solution (Lit/gal.)
Antifreeze solution (Lit/gal.) + W ater (Lit/gal.)

NOTE: Antifreeze solution + W ater = Total cooling system
capacity.
• Total Cooling System Capacity
8Lit


• Mixing ratio
Check the specific gravity of engine coolant in the cooling system temperature ranges from 0 °C to 50 °C using a
suction type hydrometer, then determine the density of the
engine coolant by referring to the table.

NOTE: The LLC is 50% at all environment in order to prevent
the corrosion of cooling system parts.


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ENGINE COOLING 6B-5
Diagnosis
Engine Cooling Trouble
Condition Possible cause Correction
Engine overheating Low Engine Coolant level Replenish
Thermo mater 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

Damaged cylinder head gasket Replace
Loosen V-belt tension Adjust belt tension or replace.
Collapsed hoses Replace
Faulty Fan clutch Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm-up Faulty thermostat Replace
Thermo unit faulty Replace


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6B-6 ENGINE COOLING

















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
level should be between the "MIN" and "MAX" lines of reserve
tank when the engine is cold. If low, check for leakage and add
engine coolant up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator cap or
radiator filler hole, and the engine coolant should also be free
from oil.
Replace the engine coolant if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
2. 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.
3. Disconnect all hoses from the engine coolant 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.
4. Refill the cooling system with the engine coolant using a solution that is at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the engine coolant reserve tank to "MAX" line when the engine is cold.
6. Block the drive wheels and firmly apply the parking brake and place the shift lever in the "NEUTRAL" position.
7. Remove the radiator cap. Start the engine and warm it up at 2,500 - 3,000 rpm for about 30 minutes.
8. W hen the air comes out from the radiator filler neck and the engine coolant level has gone down, replenish with the
engine coolant. Repeat this procedure until the engine
coolant level does not go down. Then stop the engine and
install the radiator cap. Let the engine cool down.
9. After the engine has cooled, replenish with engine coolant up to the "MAX" line of the reserve tank.
10. Start the engine. W ith the engine running at 3,000 rpm, make sure there is no running water sound from the heate
r
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.


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