clutch ISUZU KB P190 2007 Workshop Service Manual

6B – 10 ENGINE COOLING

WATER PUMP
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.




Removal
1. Radiator Upper Hose 1) Partially drain the engine coolant.
2) Remove the radiator upper hose.





031R300003
2. Water Outlet Pipe
1) Disconnect the turbocharger-cooling pipe from outlet pipe.
2) Loosen the fixing bolt and remove the water outlet bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud

5. Fan and Fan Clutch 1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.

030R300001 7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.

030R300002

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ISUZU KB P190 2007

ENGINE COOLING 6B – 11
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.
・ Cracks in the water pump body
・ Coolant leakage from the seal unit
・ Excessive radial play or abnormal noise in the fan center
when rotate by hand
・ Excessive thrust play in the fan center (Standard play: less
than 0.2mm)
・ Cracks or corrosion in the impeller





























Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
W ater Pump Bolt/Nut Torque N·m(kg·m/lb ft)
20 (2.0/14)

2. Fan Drive Belt and Pulley
1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt mid- portion to check the drive belt deflection.
Fan Drive Belt Deflection mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
030R300002


030R300001














3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque N·m(kg·m/lb in)
8(0.8/69)

4. Upper Fan Shroud

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ISUZU KB P190 2007

6B – 20 ENGINE COOLING
FAN CLUTCH WITH COOLING FAN
INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.


033R300001
Visually inspect for damage, leak (sillicon grease) or other
abnormal conditions.
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at the fan clutch portion gets to around 80 °C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.



033RY00011
2. Inspection (in unit)
W arm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80 °C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.

SPECIAL TOOLS
Illustration Tool Number Tool Name

5-8840-0277-0 Cap tester



5-8840-2663-0 Adapter


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ENGINE ELECTRICAL 6D – 23


DISASSEMBLY



RTW460LF000201
Disassembly Step
1.
Lead wire
14. Armature
2.
Bolt 15. Bolt
3.
Magnetic switch assembly 16. Bearing retainer
4.
Torsion spring 17. Pinion assembly
5.
Plunger 18. Pinion stopper clip
6.
Dust cover 19. Pinion stopper
7.
Magnetic switch 20. Return spring
8.
Screw 21. Pinion shaft
9.
Through bolt 22. Clutch
10.
Rear cover 23. Dust cover
11.
Motor assembly 24. Shift lever
12.
Brush holder 25. Gear case
13.
Yoke


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ISUZU KB P190 2007

6D – 28 ENGINE ELECTRICAL
BRUSH AND BRUSH HOLDER
1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)


RTW46DSH004001













RTW46DSH004101
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.





3. Inspect the brushes for excessive wear. If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.

OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise. It should turn smoothly.
3. Try to rotate the pinion in the opposite direction. The pinion should lock.
065RY00035


RTW46DSH004401
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.


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ISUZU KB P190 2007

ENGINE ELECTRICAL 6D – 29
REASSEMBLY



RTW46DLF000601


Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring



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ISUZU KB P190 2007

6D – 32 ENGINE ELECTRICAL


MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the “M ”
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).





RTW46DSH004601
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.




RTW46DSH005901
2. Hold-in Maintenance Test
Disconnect the lead at the M terminal. The pinion should
continue to flutter.




RTW46DSH004701
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.




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Engine Control System (4JH1) 6E-17
EGR Solenoid Valve, Turbocharger Solenoid Valve, Clutch Switch and Stop Light Switch




RTW 76EXF003501



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6E-20 Engine Control System (4JH1)





1

Legend
1. Engine Control Module (ECM)







2 1

Legend
1. Engine Coolant Temperature (ECT) Sensor
2. Thermo Unit for W ater Temperature Gauge






2
3 14

Legend
1. EGR Solenoid Valve
2. To Vacuum Pump
3. To EGR Valve
4. To Intake Duct








2 1

Legend
1. Crankshaft Position (CKP) Sensor
2. Clutch Housing


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6E-22 Engine Control System (4JH1)

Engine Control Module (ECM) Connector End Views





RTW 66ESF000301

Connector No. C-56
Connector Color Black
Test Adapter No. J-35616-4A (Pin 1 - 5)
J-35616-64A (Pin 6 - 81)
Pin W ire Color Pin Function
1 BLK ECM Ground
2 BLK ECM Ground
3 BLU/RED ECM Battery Voltage
4  Not Used
5  Not Used
6 – 24  Not Used
25  Not Used
26  Not Used
27 BLK/RED Engine Speed Signal Output to
Tachometer and TCM (A/T Only)
28  Not Used
29 RED/W HT APP PW M Signal Output (A/T
Only)
30 RED Brake Pedal 1 Switch (Stop Lamp Pedal Switch) Signal
31 YEL Clutch Pedal Switch (M/T Only)
32  Not Used
33 GRN Thermo Relay Signal Input
34  Not Used
35 W HT Keyword 2000
36  Not Used
37  Not Used
38 W HT APP Sensor Signal
39 BLU/YEL Ignition Voltage Feed
40  Not Used
41 BRN/RED A/C Compressor Relay Control
Connector No. C-56
Connector Color Black
Test Adapter No. J-35616-4A (Pin 1 - 5)
J-35616-64A (Pin 6 - 81)
Pin W ire Color Pin Function
42 BRN/YEL MIL Control
43 ORN/BLU Glow Indicator Lamp Control
44  Not Used
45 BLU Diag Request Switch
46  Not Used
47  Not Used
48  Not Used
49 RED APP Sensor Low Reference
50  Not Used
51  Not Used
52  Not Used
53  Not Used
54  Not Used
55  Not Used
56  Not Used
57 BLK APP Sensor 5 Volts reference
58 BLU/BLK ECM Main Relay Control
59  Not Used
60  Not Used
61  Not Used
62  Not Used
63 BLU/RED ECM Voltage Feed via ECM Fuse
64  Not Used
65 W HT/BLK Brake Pedal 2 Switch Signal
66  Not Used

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ISUZU KB P190 2007