engine ISUZU KB P190 2007 Workshop Repair Manual

Engine Cooling – V6 Engine Page 6B1–50


When removing, transporting or installing the
fan and shroud assembly, do not grasp the
assembly by the fan rings (1) as this may
bend the fan motor shaft and cause fan
vibrations

Figure 6B3 – 56
When handling the fan assembly, always hold
the assembly at the fan shroud (1).

Figure 6B3 – 57
Install
Installation of the cooling fan and shroud assembly is the reverse of removal procedures, noting the following points:
1 Ensure that fan and shroud assembly to radiator attaching clips are fully engaged.
2 Ensure that the top automatic transmission cooling pipe (if fitted) is installed to the integral shroud clip.
3 Check cooling fan operation. Refer to 6C1-2 Engine Management Diagnostics. Also check for correct rotational direction of the cooling fan.

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Engine Cooling – V6 Engine Page 6B1–51

Disassemble
1 Remove cooling fan and shroud assembly as previously described.
NOTE
Neither fan is to be separated from its fan motor.
The assembly is carefully balanced during
manufacture and duplicating this balance on
reassembly, is not possible.
2 Remove the motor assembly wiring harness (1) from the integral clips that form a part of the shroud (2).
3 Remove screws (3) attaching the motor assembly (to the shroud, then remove each motor, fan and wiring
assembly (4) from the shroud.


Figure 6B1 –
––
–
58
Reassemble
Reassembly is the reverse of disassembly procedures, noting the following points:
1 Tighten motor to shroud attaching screws to the correct torque specification. Do not over-tighten.
Fan motor to shroud screw
torque specification ................................................5 N.m
2 Ensure that all wiring is routed correctly and secured by the shroud clips.
3 Install cooling fan and shroud assembly to the radiator, as previously described.
3.14 Flexible Transmission Cooler Hose
Replace
NOTE
The flexible hoses are not serviced separately.
Therefore, should a hose require replacement,
then the hose and radiator to hose cooler pipe
assembly must be fitted.
1 Place a drip tray beneath the engine and radiator section.

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Engine Cooling – V6 Engine Page 6B1–52

2 Disconnect the transmission cooler pipes from the
transmission.
• Release the verifier disk (2) by pulling back with
the fingers, then slide back down the cooler line
(1).
• Open the cooler line release tool J-41623-B and
slip over cooler line to be disconnected from the
transmission, above the verifier disk (2), as
shown.
• Slide the release tool along the line to engage
with the quick-connect fitting.
• W hile pushing inwards, rotate the tool about one
sixth of a turn to release the spring clip holding
the line.
• W ith the release tool held in this position, pull
back on the cooler line to release.
• Repeat this process with the remaining line and
quick-connect fitting.
3 Plug both pipe openings and hoses to minimise fluid loss and prevent foreign matter entry.
Figure 6B1 –
––
–
59
4 Disconnect the transmission cooler hose/line assemblies from the radiator quick connect fittings as
follows:
• Pull back the verifier disc (1) from the quick
connect fitting (2) and slide it back along the line.
• Open the release tool, Tool No J-41623-B (3),
slip it over the cooler line to be disconnected
from the radiator, ahead of the verifier disc.
• Slide the release tool along the cooler line and
engage it with the quick-connect fitting (2).
• W hile pushing inwards, rotate the release tool
clockwise, about one sixth of a turn to release
the spring clip holding the cooler line.
• W ith the release tool held in this position, pull
back on the cooler line to release it.
• Plug the openings to prevent fluid loss and/or
contamination.
• Repeat the procedure to remove the remaining
cooler line.
NOTE
If the spring clip and/or O-ring seal in the quick-
connect fitting is damaged during the removal
process, the complete fitting must be replaced.
5 Unclip the outlet cooler line (4) from the radiator fan shroud (5).
Figure 6B1 –
––
–
60

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Engine Cooling – V6 Engine Page 6B1–53

NOTE
Should the spring clip or the O-ring seal in the
quick connect fitting be damaged during the line
removal process, then the complete fitting must
be replaced.
Reinstall
1 Remove the plugs installed in the transmission cooler line and hose openings and wipe all exposed parts
with a clean shop rag.
• Smear clean automatic transmission fluid on
each cooler line end, then push into the radiator
quick connect fittings. As a security check gently
pull on the connector to ensure correct
engagement.
• As a security check, push and clip each
verification disc into place over the quick-
connect fittings. If difficulty is experienced,
repeat the installation process until the
verification disc can be clipped into place over
the radiator quick-connect fitting.

If the verifier disc does not clip into place,
the quick-connect fitting is not engaged,
rectify this before proceeding.
• Snap the outlet cooler line (4) in the clip (5) of
the radiator fan shroud
• At the transmission end, again clean the line
ends and proceed as detailed in step 2. As a
further security check ensure that each
verification disc can be pushed into place over
the quick connect fitting. If difficulty is
experienced, then the line has not been
completely installed. Remove and repeat the
installation process again until the verification
disc can be clipped into place over the
transmission quick connect fitting
• Ensure that all line clamps are fitted correctly
and that the lines and hoses are correctly routed
and free of obstructions
• Tighten the screw attaching the cooler lines
bracket to the correct torque specifications
• If required, top up the transmission fluid level
(cold)
• Start the engine and check for any fluid leak at
the fittings. If a leak is found, stop the engine
and rectify the leak
Figure 6B1 – 61

Transmission cooler lines bracket
attaching screw torque specification ..................23.0 Nm


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Engine Cooling – V6 Engine Page 6B1–54

3.15 Radiator
Remove

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), then remove coolant filler cap.

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 00
Warnings, Cautions and Notes, before
removing the ground lead.
2 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis.
3 Depress the tang on the main wiring harness to the cooling fan motor wiring harness connector (1) and
separate the connector.
4 Remove the radiator cooling fan and shroud assembly. Refer to 3.13 Cooling Fan and Shroud
Assembly in this Section.
5 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this
Section.



Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the
coolant.

Figure 6B1 – 62








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Engine Cooling – V6 Engine Page 6B1–55


Figure 6B1 – 63
Legend
1 Radiator Hose – Upper
2 Radiator Hose – Lower
3 Hose Clamp – Upper Hose to Engine Outlet Housing 4 Hose Clamp – Upper Hose to Radiator Inlet
5 Hose Clamp – Lower Hose to Radiator Outlet
6 Hose Clamp – Lower Hose to Engine Coolant Inlet Pipe

6 Remove radiator upper hose (1) from radiator connection.
7 Remove radiator lower hose (2) from radiator connection.
8 Remove the two rubber insert mounting brackets supporting the top of the radiator.
9 Remove the two lower attaching bolts (either side) and the rubber mounts.
10 Remove the radiator from the vehicle.

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.




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Engine Cooling – V6 Engine Page 6B1–56

Reinstall
Installation of the radiator is the reverse of removal procedures, noting the following points:
1 Before installing radiator, inspect core to ensure that there is no foreign matter in core fins. Clean out between core fins with compressed air, blowing from rear to front.
2 If the vehicle is fitted with an automatic transmission, remove plugs from the removed cooling pipe ends and the two quick connect fittings.
3 After wiping cooler line ends and smearing clean automatic transmission fluid over each flared line end, push into the quick connect fitting to engage. As a security check, tug on each line to ensure correct engagement.
4 Check the transmission fluid level. Refer to the following references as required:
• 7C4 Automatic Transmission
• 4L60E On-vehicle Servicing
5 Install the following hoses:
a. Lower radiator hose, securing with the hose clamp.
b. Upper radiator hose, securing with the hose clamp.
6 Install the radiator cooling fan and shroud assembly. Refer to 3.13Cooling Fan and Shroud Assembly in this Section. Ensure that electrical connectors and the transmission cooler lines are seated correctly in the integral
retainer clips before install upper radiator shroud.
7 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
8 Check for coolant leaks. Refer to 3.7 Pressure Testing in this Section.
9 Reconnect battery ground lead. Refer to 8A Electrical Body & Chassis.
10 Check cooling fan operation. Refer to 6C1-2 Engine Management Diagnostics. Also check for correct rotational direction of cooling fan.

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Engine Cooling – V6 Engine Page 6B1–57

Radiator Repair Procedure
Repairable Leaks

Figure 6B1 – 64
Legend:
1 Left-hand Side Tank Seal
2 Core Tubes
3 Right-hand Side Tank Seal 4 Oil Cooler Pipe Fittings
5 Joint Between Tube and Header
There are two types of leaks that can be repaired on the aluminium-plastic radiator; core leaks and automatic
transmission oil cooler seal leaks. Leaks in the plastic tanks or the seals between the side tanks and the headers cannot
be repaired; therefore the radiator must be replaced.
Core leaks may occur in a tube or in the joints between the tubes and the headers. Seal leaks may occur in the joints
between the plastic tanks and the headers or in the joints between the oil cooler fittings and the tank (vehicles with
automatic transmission).
W hile some leaks can be repaired while the radiator is installed in the vehicle, it is strongly recommended that the
radiator is first removed from the vehicle.
NOTE
Minor damage to tubes, or tube to header joint
(holes up to 1 mm diameter max.) can be
repaired. Core replacement is necessary if
damage is any greater.

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Engine Cooling – V6 Engine Page 6B1–58

Repair Method
Repairs to the aluminium radiator core should only be made using the recommended 'Aluminised Silicon' based liquid
repair agent, in accordance with the recommended procedure outlined in General Core Repair in this Section. Refer to
the current Partfinder™ for Aluminised Silicon base liquid part number.
For damaged areas that are between the cooling fins, it
may be necessary to remove some of the fins. Do not
remove more fins than is necessary. Usually 6 mm
(distance ‘A’) beyond the leak or damage area, up to a
maximum of 25 mm of total fin material, is enough to
make an effective repair.


Figure 6B1 – 65
Tube Blocking
If a tube is severely damaged, it can be blocked off.
NOTE
Do not block off more than two tubes in a
radiator. Blocking off more than two tubes will
reduce the cooling capacity and efficiency of
the system and possibly result in an
overheated engine.
The tube should be cut off 6 mm from the header (1) and
pinched shut before it is cleaned and sealed. Refer to
General Core Repair in this Section.

Figure 6B1 – 66
Header Repair
If the header or a tube near the header requires a repair, the side tank does not have to be removed. If the repair
requires the removal of the header tank, then the radiator must be replaced.

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Engine Cooling – V6 Engine Page 6B1–59

General Core Repair
NOTE
The need for careful preparation of the surface in
the repair area cannot be over-emphasised. If the
leak area surface is not clean, the repair material
will not adhere to the surface.

Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
1 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this Section.
2 Remove the radiator. Refer to 3.15 Radiator in this Section.
3 If necessary, carefully cut away fins to expose the damaged area.
NOTE
Do not cut away more than 25 mm total fin
material.
4 Clean away dirt etc. with water. Dry the affected area using hot air from a hair drier.

Do not apply flame to dry damaged area.
5 Clean affected area with petrol to remove any traces of oil.
6 Thoroughly stir contents of repair agent.
NOTE
In cases of extended shelf life, the silicon in
solution may separate from the thinner base.
Should this occur, mix contents well until agent is
again homogeneous.
7 Apply repair agent sparingly to damaged area. Do not apply an excessive amount, as this will cause blockage of the radiator tube.
NOTE
Use a clean, dry wooden applicator to 'DRIP'
agent onto damaged area of radiator.
8 Allow radiator to stand in a clean, dry area for a minimum of 3 hours (at ambient temperature of 20 – 30 ° C) with
adequate ventilation.
NOTE
Do not apply heat or flame to promote drying.
9 Reinstall the radiator. Refer to 3.15 Radiator in this Section.

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