engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Cooling – V6 Engine Page 6B1–20

COOLANT CONCENTRATION
Litres Of Coolant To Be Added
Concentration Reading % Automatic Transmission Manual Transmission
0 4.95 5.15
5 4.46 4.62
10 3.96 4.12
15 3.47 3.61
20 2.97 3.08
25 2.48 2.57
30 1.98 2.01
35 1.48 1.54
40 0.99 1.05
45 0.50 0.52
50 0 0

NOTE
If the reading is not clear, then properly clean
and dry the measuring surface, then conduct
another test. Also ensure that there is
sufficient fluid on the measuring prism.
9 If the reading shows that the concentration level of the coolant is inadequate, refer to the Coolant
Concentration table to determine the amount of
coolant that needs to be added to the coolant
recovery reservoir.
10 Start and run the engine until normal operating temperature is reached, to allow the added coolant
to be distributed throughout the engine cooling
system.
Figure 6B1 – 17

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Engine Cooling – V6 Engine Page 6B1–21

Calibrating the Tester
The coolant tester calibration is checked at manufacture. If however, the calibration check detailed in Step 1 of this
method shows that the instrument is not reading correctly, then conduct the following recalibration procedure:
1 Remove the sealant covering the adjustment screw on the underneath of the tester.
2 W ith a distilled water sample on the measuring surface, carefully adjust the screw until a zero reading is obtained.
NOTE
DO NOT completely remove the screw.
3 After recalibration, reseal the screw with a small amount of silicone sealant.
Method 2 – Hydrometer
1 The cooling system should be at or close to ambient temperature.
2 Carefully remove the coolant filler cap from the coolant outlet housing and, while holding the rubber
bulb squeezed, insert nozzle of coolant tester
hydrometer, Tool No. AU505 into coolant. Releasing
the rubber bulb will then draw sufficient coolant into
the tester to float hydrometer bulb freely.
3 Hold tester at eye level and read scale on hydrometer bulb at coolant level.
The reading shows the percentage of ethylene glycol antifreeze contained in the engine coolant.
4 The hydrometer reading should show 50% if the coolant concentration is correct.
• If a reading of less than 50% is achieved, the
cooling system requires topping up with either
DEX-COOL® long-life coolant or its equivalent,
known as Extended Life Anti-freeze Coolant
conforming to GM specification 6277M.
• Refer to the Coolant Concentration table
shown for the previous method to determine
how much coolant additive of either type is
required to be added to the cooling system to
bring the coolant to the specified
concentration.

Figure 6B1 – 18
5 Drain sufficient quantity of coolant from cooling system to allow top-up with coolant additive, then add the required amount of the correct additive. Install coolant filler cap to the coolant outlet housing.
6 Start and run the engine until normal operating temperature is reached. This will allow the added coolant to be distributed throughout the engine cooling system.

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Engine Cooling – V6 Engine Page 6B1–22

3.3 Draining and Filling Cooling System
Draining

Refer to 3.1 Service Notes in this Section, for
important safety items.
1 Allow engine to cool to ambient temperature (less than 50 ° C), and then remove the coolant filler cap (located near
the brake booster assembly).

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 6D1– 3 Battery – V6.
3 Drain the coolant from the system via the radiator drain tap on the lower RHS of the radiator below the lower hose outlet. Attach a suitable piece of rubber tubing to the tap outlet to help direct the flow of the coolant into a suitable
container (capacity at least 12 litres).
Filling
During any service operation that requires the cooling system to be partly or completely drained, the following
instructions must be followed when refilling the cooling system, to ensure that all air is bleed from system.

• Refer to 3.1 Service Notes in this Section,
for important safety items.
• Before opening the radiator bleed screw,
the cooling system must first be
completely depressurised with the engine
coolant filler cap removed.

Do not mix different types of anti-freeze or
corrosion inhibitors, as they may be
incompatible. Always check which coolant is
to be added to the particular vehicle being
serviced. If a different type has been used in
the cooling system (or is added accidentally),
flush the system with clean water. Refer to 3.4
Cleaning Cooling System in this Section.
NOTE
Ensure that the radiator drain tap located at the
bottom of right-hand side radiator tank is closed
before proceeding.

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Engine Cooling – V6 Engine Page 6B1–23

1 W ith the engine off, remove the coolant filler cap on
the coolant outlet housing, located at the front left-
hand side of the engine.

Figure 6B1 – 19
2 If filling a completely empty cooling system for automatic transmission models, mix 5 litres of clean
water with 5 litres of the recommended coolant or
5.2 litres of each for manual transmission models.
3 Add coolant via the engine coolant filler neck on the coolant outlet housing.
NOTE
Do not replace the coolant filler cap before
starting the engine (in step 6). Leaving the filler
cap off allows the engine to warm up without
pressurising.
4 Reconnect battery ground lead. Refer to 6D1 – 3 Battery – V6.
5 Start the engine and set the HVAC controls to: • Full hot
• Low fan
Figure 6B1 – 20
6 Run the engine at approximately 2,000 rpm to warm up the engine.
7 W ait until the radiator fan switches on.
8 W hen the radiator fan has switched on, let the engine rpm drop back to idle.
9 Turn the engine off when the radiator fan switches off.
10 Top up the coolant until full.
11 Replace the coolant filler cap.

Do not loosen or remove the radiator filler cap
when the coolant temperature is high. Steam
or boiling coolant will gush out and you may
be burnt. To open the radiator filler cap, cover
the filler cap with a thick cloth when the
coolant has cooled, release the pressure by
slowly turning the filler cap, and remove the
cap.


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Engine Cooling – V6 Engine Page 6B1–24


12 Open the coolant reservoir tank cap.
13 Top up the radiator coolant recovery reservoir to the MAX line.
14 Reinstall the coolant recovery reservoir cap.

NOTE
This condition only applies when the cooling
system is first being filled after a major loss of
coolant. The level of coolant in the reservoir
will then drop, once the engine is started and
normal operating temperature is reached. The
coolant level should then be maintained at the
correct level (between the MAX and MIN
Lines).

Figure 6B1 – 21

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Engine Cooling – V6 Engine Page 6B1–25

3.4 Cleaning Cooling System
NOTE
• Before carrying out reverse flushing
procedures, it is recommended that a
cleaning solution be used to loosen scale and
corrosion. Only use a Holden approved
radiator cleaner following the instructions on
the container label.
• This operation should only be carried out
when the engine and radiator are at ambient
temperature.
• When using specialised cooling system
flushing equipment, connect the equipment as
recommended by the manufacturer.
Cooling System Reverse Flush
Radiator

Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
1 Drain the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

Always wear eye protection when working
with spring-type hose clamps. Failure to do
so may result in eye injury.
2 Remove the lower radiator outlet hose (1) at the coolant inlet pipe connection (2).
3 Remove the upper radiator inlet hose (3) at the coolant outlet housing connection (4).
4 Attach a lead-away hose to the open end of the upper radiator hose.
5 Attach a suitable piece of hose or adaptor between the flushing gun and the open end of the lower
radiator hose.
6 Connect and operate the flushing equipment as recommended by the manufacturer.

Apply air pressure gradually and not in
excess of 120 kPa, otherwise radiator
damage will result.
Figure 6B1 – 22
7 Continue flushing until the water from the lead-away hose runs clean and clear.
8 Install all disconnected hoses, ensuring that they are correctly positioned and securely clamped.
9 Fill the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

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Engine Cooling – V6 Engine Page 6B1–26

10 Pressure test the cooling system. Refer to 3.7 Pressure Testing in this Section.
Engine

Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
1 Drain the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

Always wear eye protection when working
with spring-type hose clamps. Failure to do
so may result in eye injury.
2 Remove the upper and lower radiator hoses from the coolant outlet housing and coolant inlet pipe connections. Refer to Figure 6B1 – 22.
3 Remove the thermostat housing from the rear of the engine block. Refer to 6A1 Engine Mechanical – V6..
4 Remove the thermostat from the thermostat housing and reinstall the housing to the rear of the intake manifold. Refer to 3.8 Thermostat in this Section.
5 Remove both heater hoses (1) and (2) from their connections at the heater pipe assembly, noting
which hose was connected to which connection.
Seal the heater pipe assembly connections by
looping the heater inlet connection to the outlet
connection using a suitable piece of hose and two
hose clamps.
6 Install a lead-away hose to the coolant inlet pipe connection and a length of suitable hose between
the coolant outlet housing connection and the
flushing equipment.
7 Connect and operate the flushing equipment as recommended by the manufacturer.
Figure 6B1 – 23
8 Continue flushing until the water from the lead-away hose runs clear.
9 Remove the coolant recovery reservoir, flush it out with clean water and install. Refer to 3.9 Coolant Recovery Reservoir in this Section.
10 Install the thermostat. Refer to 3.8 Thermostat in this Section.
11 Install all disconnected hoses, ensuring that they are correctly positioned and securely clamped.
12 Fill the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
13 Pressure-test the cooling system. Refer to 3.7 Pressure Testing in this Section.

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Engine Cooling – V6 Engine Page 6B1–27

Heater Hoses and Core

Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
1 Drain the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

Always wear eye protection when working
with spring-type hose clamps. Failure to do
so may result in eye injury.
2 Remove both heater hoses (1) and (2) from their connections at the heater pipe assembly, noting
which hose was connected to which connection.
3 Direct the hose (1) that was connected to the heater pipe assembly’s front connection into a
suitable container.
4 Attach the hose (2) from the rear-most connection to the flushing gun.
5 Cycle the heater switch to ensure that the water valve is open.


Figure 6B1 – 24
6 Connect and operate the flushing equipment as recommended by the manufacturer.

Apply air pressure gradually and not in
excess of 130 kPa, otherwise heater core
damage will result.
7 Install all disconnected hoses, ensuring that they are correctly positioned and securely clamped.
8 Fill the cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
9 Pressure test the cooling system. Refer to 3.7 Pressure Testing in this Section.

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Engine Cooling – V6 Engine Page 6B1–28

3.5 Drive Belt Tension
An automatic tensioner assembly provides drive belt tension. The tensioner is an idler pulley mounted on a spring-loaded
arm that maintains the drive belt at the proper tension, without imposing undue loads on the various components.

Throughout its functional travel, the tensioner mechanism
will maintain correct belt tension, using a pulley (1) mounted
to a spring-loaded arm (2), which compensates for increases
in belt wear and stretch.
W hen the indicator pointer (3) on the tensioner has reached
minimum tension range (4), the tensioner has reached the
full extent of its travel and replacement of the belt (5) is
necessary.
The maximum tension range is shown at (6).
Drive belt tension can be checked using Tool No. BT3373-F.
Refer to 6A1 Engine Mechanical.
Figure 6B1 – 25

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Engine Cooling – V6 Engine Page 6B1–29

Inspect
The four views in Figure 6B1 – 26 show the various stages of drive belt wear, to assist in belt replacement decisions.
NOTE
Condition of the belt ribs can be better assessed
if the belt is wrapped over the coolant pump drive
pulley.

Figure 6B1 – 26
Legend
A New Belt: No cracks or c hunks.
B Moderately Used Belt: Few cra cks, with some wear on the ribs and in the grooves. Belt replacement not required.
C Severely Used Belt: Several cracks per 30 mm. S hould be replaced before chunking occurs
D Failed Belt: Separation of rib material from backing (chunking). Belt must be replaced immediately.

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