lock ISUZU KB P190 2007 Workshop Repair Manual

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 6B1–35

9 To gain easier access to the heater pipe flange and
thermostat housing bolts, disconnect the engine
harness and lay back on the right side of the engine
bay. Apart from those harness connectors removed
during the intake manifold removal, this involves the
removal of wiring harness connectors and fasteners,
as detailed:
a Pull out the release bar (arrows) on each of the ignition coil packs (1) on cylinders 2, 4 and 6,
before disconnecting each connector.
b The coolant temperature sensor.
c The left side Pre-O2 sensor connector, 2, 4 & 6.
NOTE
Refer to 8A – Electrical Body & Chassis for the
location of harness connectors, not shown.

Figure 6B1 –
––
–
34
10 Remove the bolt (1) securing the engine harness ground terminal (2), to the cylinder block.
11 Prise both locking legs of the left side engine harness former (4), free, then lift up on the harness former to
release.

Figure 6B1 –
––
–
35
12 W orking at the rear of the engine, disconnect the engine harness to transmission harness connector (1),
as required.
13 Remove the two bolts (2) securing the engine harness former (3) to the rear of the engine.
14 Carefully lift the engine harness free and drape on the right side of the engine.


NOTE
For further information on removing the
thermostat housing and associated components,
refer to 6A1 Engine Mechanical – V6.
Figure 6B1 –
––
–
36

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Engine Cooling – V6 Engine Page 6B1–36

15 Remove the heater pipe assembly (1) to right-hand
side cylinder head (2) attaching bolt (3).
16 Remove the heater pipe assembly to thermostat housing (4) attaching bolts (5), then remove the heater
pipe assembly.
17 Remove and discard the heater pipe assembly to thermostat housing O-ring seals (6).

Figure 6B1 –
––
–
37
18 Remove the three thermostat housing attaching bolts (1), rubber grommets (2), then remove the thermostat
housing (3).
NOTE
The upper thermostat housing attaching bolt is
longer than the two lower bolts.
19 Remove and discard the thermostat housing to engine block gasket (4).

Figure 6B1 –
––
–
38

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Engine Cooling – V6 Engine Page 6B1–37

Test
1 W ith the thermostat (1) installed in the housing,
suspend it and a suitable thermometer (2) in a
container of 50% clean fresh water and 50% Dexron ®
long life coolant, (conforming to GM 6277M).
NOTE
Neither the thermostat assembly (1) nor the
thermometer (2) should rest on the bottom of the
container because of uneven concentration of
heat at this point when the container is heated.
2 Heat container until thermostat begins to open. Agitate solution to ensure uniform temperature. Note
temperature and ensure thermostat opens within
specified temperature range.
Thermostat Opening Specifications
Opening Temperature ........................................ 82 ° C
Fully Open Temperature .................................... 95 ° C
3 Replace thermostat if it does not meet these operating
conditions.
Figure 6B1 –
––
–
39
Dismantle

Only dismantle the thermostat if a reverse
flushing operation of the cylinder block is to
be carried out. If the testing operation
indicates that the thermostat is faulty, then
the housing and thermostat are only serviced
as an assembly.
Remove thermostat (1) from thermostat housing (2) as
follows:
a Secure the thermostat housing by gripping in a vice fitted with soft jaws.

Always wear protective safety glasses when
working with spring-loaded devices. Failure
to do so could result in eye injury.
b Depress the retaining bar (3) on both sides of the thermostat and rotate the thermostat until it
clears the retaining lugs (4) on the thermostat
housing (2).
c Release the thermostat spring force.
d Remove the thermostat assembly from the thermostat housing.
Figure 6B1 – 40
Reassembly
The reassembly process is the reverse to that used for disassembly, with the following exceptions:
1 Check that the valve sealing surface is undamaged.
2 W ipe the valve sealing surface to ensure a clean surface.

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Engine Cooling – V6 Engine Page 6B1–38

Install

Always wear protective safety glasses when
working with spring-loaded devices. Failure to
do so could result in eye injury.
1 Install the thermostat into the housing (reverse to removal procedure).
2 Ensure that the engine block and thermostat housing mating surfaces are clean and dry.
3 Install a new gasket to the thermostat housing.
4 Install the thermostat housing to the engine block and secure with the attaching bolts (with rubber grommets installed). Tighten all bolts to the correct torque specification.
Thermostat housing to engine
block bolt torque specification ..............................10 N.m
5 Ensure that the heater pipe assembly and thermostat housing mating surfaces are clean and dry.
6 Install new O-rings to the heater pipe assembly.
7 Install heater pipe assembly to thermostat housing and secure with the attaching bolts. Tighten all bolts to the correct torque specification.
Heater pipe assembly to thermostat
housing bolt torque specification ..........................10 N.m
8 Install heater pipe assembly to right-hand cylinder head bolt. Tighten bolt to the correct torque specification. Heater pipe assembly to cylinder
head bolt torque specification ..............................35 N.m

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
9 Reinstall the engine wiring harness, securing the rear harness former to the rear of the engine with the two retaining bolts, tightened to the correct torque specification.
Rear engine harness former
retaining bolts torque specification .......................15 N.m
10 Reinstall the left side engine harness former to the two locating pegs, then push inward to secure.
11 Reinstall the bolt securing the engine harness ground terminal, to the left side of the cylinder block and tighten to the correct torque specification.
Engine harness ground terminal
attaching bolt torque specification ........................12 N.m
12 Reinstall each wiring harness connector to its correct location, ensuring that all security clips are installed correctly.
13 Connect the heater hoses to the heater pipe assembly.
14 Install the coolant inlet pipe. Refer to 3.12 Coolant Inlet Pipe in this Section.
15 Close the radiator drain tap on the lower LHS of the radiator and remove the piece of rubber tubing to the tap outlet.
16 Reinstall the complete intake manifold assembly. Refer to 6A1 Engine Mechanical.
17 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.

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Engine Cooling – V6 Engine Page 6B1–41

Figure 6B1 – 42 shows the drive belt routing for the HFV6 engine without air conditioning.

Figure 6B1 – 43
Legend
1 Coolant Pump
2 Generator
3 Idler 4 Power Steering
5 Crankshaft
6 Tensioner
4 Remove the drive belt from the coolant pump pulley:
a Rotate the drive belt tensioner pulley clockwise (arrow) using a 1/2” drive
extension in order to release the drive
belt tension.
b Remove the drive belt from the coolant pump pulley.
c Slowly release the drive belt tensioner.
Figure 6B1 – 44

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Engine Cooling – V6 Engine Page 6B1–43

Inspect
1 Rotate the coolant pump hub (1). The hub and
impeller (2) should turn straight and smoothly. If the
hub wobbles, is noisy or feels rough when rotated,
replace the coolant pump.
2 Inspect the exterior of the coolant pump for the following:
• Damage to the coolant pump hub bolt threads
for the coolant pump pulley
• Damage to the coolant pump bolt holes
3 Examine the coolant pump shaft (3) and the weep hole (4) in the coolant pump housing (5) for signs of
leakage. If coolant leakage is evident, replace the
coolant pump.
4 Inspect the interior of the coolant pump for the following:

Figure 6B1 – 48
• Damage to the coolant pump gasket-sealing flange surface (6)
• Damage, corrosion or restrictions to the coolant pump impeller
• Damage, corrosion or restrictions to the coolant passages (7)
NOTE
Hub Flange to rear of Pump Housing
measurement (A) should be 44 ± 0.25 mm.
5 Replace the coolant pump as necessary.
Reinstall
1 Ensure that the coolant pump and front cover mating surfaces are clean and dry.
2 Install a new gasket to the front cover.
3 Clean threads of coolant pump to front cover and cylinder block attaching bolts.
4 Install coolant pump and attaching bolts. Tighten all bolts to the correct torque specification.
Coolant pump to front cover
bolt torque specification .......................................10 N.m

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Engine Cooling – V6 Engine Page 6B1–47


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 8A – Electrical Body & Chassis.

Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
3 Draining the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this Section.
4 Raise the front of the vehicle and support on safety stands. Refer to 0A General Information for the location of jacking and support points.

Always wear protective safety glasses when
working with spring type hose clamps.
Failure to do so could result in eye injury.
5 Remove lower radiator outlet hose clamp (1) at the coolant inlet pipe connection, then disconnect the
hose from coolant inlet pipe (2).
6 Remove the coolant inlet pipe from the engine block by removing the attaching bolt (3).

Figure 6B1 –
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–
52
7 Remove the coolant inlet pipe (1) to thermostat housing (2) attaching bolt (3).
8 Remove the coolant inlet pipe by manoeuvring the pipe to the front of the vehicle and withdrawing the
pipe from below the vehicle, between the cross
member and radiator.
9 Remove and discard coolant inlet pipe O-ring (4) from the thermostat end of the coolant inlet pipe.

Figure 6B1 –
––
–
53

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Engine Cooling – V6 Engine Page 6B1–48

Install
1 Ensure that the coolant inlet pipe and thermostat housing mating surfaces are clean and dry.
2 Install new O-ring to the coolant inlet pipe.
3 Install coolant inlet pipe at the thermostat housing and secure with the attaching bolt. Tighten all bolts to the correct torque specification.
Coolant inlet pipe to thermostat
housing bolt torque specification ..........................23 N.m
4 Raise the front of the vehicle and support on safety stands. Refer to 0A General Information for the location of jacking and support points.
5 Reinstall the coolant inlet pipe to the engine block and secure with the bolt tightened to the correct torque specification.
Coolant inlet pipe to engine block bolt
torque specification .............................................25 N.m

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
6 Connect the lower radiator outlet hose and clamp to the coolant inlet pipe connection.
7 Close the radiator drain tap on the lower RHS of the radiator and remove the piece of rubber tubing to the tap outlet.
8 Lower the front of the vehicle.
9 Refill cooling system. Refer to 3.3 Draining and Filling Cooling System in this Section.
10 Check for coolant leaks. Refer to 3.7 Pressure Testing in this Section.
11 Reconnect battery ground lead. Refer to 8A – Electrical Body & Chassis.

3.13 Cooling Fan and Shroud Assembly
Remove

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES, before
removing the ground lead.
1 Disconnect the battery ground lead. Refer to 8A – Electrical Body & Chassis.
2 Remove the intake duct and mass air flow as an assembly. Refer to 6A1 Engine Mechanical.
3 Remove the coolant recovery hose from the fan shroud retaining clip.

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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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