start 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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

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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ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–64

5 Specifications
General
Coolant Filler Cap Pressure Rating .............................................................................120 kPa
Cooling System Capacity
Automatic Transmission ........................................................................................ 9.9 litres
Manual Transmission .......................................................................................... 10.3 litres
Coolant Corrosion Inhibitor Quantity W hen Refilling System Automatic Transmission Models......................................................................... 5 litres
Manual Transmission Models .......................................................................... 5.2 litres
NOTE
DEX-COOL® long life coolant or equivalent such
as Extended Life Anti-freeze Coolant, conforming
to GM Specification 6277M, must be used when
changing coolant.
Thermostat Type...............................................................................................Power element (wax pellet)
Start to Open at ......................................................................................................... 82 ± 2 ° C
Fully Open at .......................................................................................................... 95° C ma x.
Coolant Pump
Type........................................................................................................................ Cen trifugal
Drive ................................................................................................ Multi-Vee Serpentine Belt
Bearing Type .................................................................................... Double Row Ball Bearing
Radiator
Core type ......................................................................................... Aluminium crossflow core
Overall width ................................................................................................................ 66 4 mm
Core width.................................................................................................................... 5 10 mm
Overall height............................................................................................................... 60 2 mm
Core height .................................................................................................................. 51 2 mm
Core thickness ............................................................................................................... 27 mm
Plastic Tanks .............................................................................. Nylon 6.6 (30% Glass Filled)
Radiator Hoses Lower Upper
Number ............................................................................... One............................. One
Type................................................................................ Moulded ...................... Moulded
Inside diameter ................................................................. 34 mm ........................ 34 mm

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 9


A small amount of fuel may be released when
connecting the fuel pressure gauge to the fuel
pressure test point. Cover the fittings with a
shop towel to absorb any fuel spillage before
connecting the fuel pressure gauge. After the
fuel pressure test procedure, place the soiled
towel in an approved container for disposal.
3 At the fuel pressure test point, remove the Schrader valve sealing cap.
4 Connect the fuel pressure gauge (1) (tool No. J 34730–1A) to the fuel gauge Schrader fitting
adapter (2) (tool No. AU453), then install to the fuel
pressure test port (3). W rap a shop towel around the
fitting while connecting the fuel pressure gauge to
avoid and/or capture any fuel spillage.
5 Route the bleed hose of the fuel gauge into an approved fuel container.


Figure 6C – 5

After connecting the fuel pressure gauge and
pressurising the fuel system, inspect for fuel
leaks at the fuel pressure gauge and the fuel
pressure test point.
6 Either: Using Tech 2, enable the fuel pump to pressurise the fuel system, refer to 0C Tech 2. Inspect for fuel leaks at the
fuel pressure gauge and fuel pressure test point, then bleed the air from the fuel pressure gauge.
or: Reinstall the fuel pump relay and fuel pump fuse, then open the fuel gauge bleed valve (4) to bleed the air from the
fuel pressure gauge, refer to Figure 6C – 5.
7 Remove and place the soiled shop towel in an approved container.
Test
1 Start the engine and record the fuel pressure.
2 Turn the ignition switch off.
3 If required, perform any tests and/or diagnostic procedures:
• For the fuel system leak test, refer to 3.3 Fuel Leak Test.
• For the fuel injector leak-down test (for vehicles fitted with a V6 engine, refer to 6C1-3 Engine Management –
V6 – Service Operations.
4 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
Removal
1 Turn the ignition switch off.
2 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.

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Fuel System – V6 Page 6C – 10


After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing the fuel lines or connections. Cover
the fittings with a shop towel before
disconnecting. This catches any leaking fuel.
Place the soiled towel in an approved
container when disconnection is completed.
3 W rap a shop towel around the fuel pressure test point to absorb any fuel spillage.
4 Remove the fuel pressure gauge and drain any fuel remaining in the fuel pressure gauge into an approved fuel container.
5 Remove the soiled shop towel and place in an approved container.
6 Repressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
7 Road-test the vehicle and check for correct operation.
3.3 Fuel Leak Test

After installing any fuel system component
and before starting the engine, check the fuel
system for leaks.
NOTE
For the fuel injector leak-down test (for vehicles
fitted with a V6 engine), refer to 6C1-3 Engine
Management – V6 – Service Operations.
1 Turn the ignition switch on for two seconds.
2 Turn the ignition switch off for 10 seconds.
3 Turn the ignition switch on.
4 Check for fuel leaks, particularly at points marked z (that is, quick-connect fittings, fuel rails, fuel injectors,
Schrader valve and evaporative emission control canister purge solenoid, refer to Figure 6C – 6.

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ISUZU KB P190 2007

Fuel System – V6 Page 6C – 11


Figure 6C – 6
5 Replace any faulty components and repeat step 2 to step 5 inclusive.
6 Replace all engine components removed to perform the fuel leak test, refer to 6C1-3 Engine Management – V6 – Service Operations.
3.4 Fuel System Depressurisation

To reduce the risk of fire or personal injury,
depressurise the fuel system before servicing
any fuel system components.
1 Turn the ignition switch off.
2 Remove the fuel pump fuse and fuel pump relay, refer to 8A Electrical Body and Chassis.
3 Loosen the fuel filler cap to relieve the fuel tank vapour pressure.
4 W ith the throttle closed, crank the engine.
NOTE
The engine may start and operate until the fuel
remaining in the fuel delivery system depletes.
5 W hen the engine stops, crank the engine for another 10 seconds to ensure the fuel feed line pressure has been fully relieved.
6 Clean the area around the fuel pressure test point.

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Fuel System – V6 Page 6C – 12


A small amount of fuel may be released when
pressing on the Schrader valve. Cover the
fitting with a shop towel to absorb any fuel
spillage before removing the Schrader valve
sealing cap. Place the soiled towel in an
approved container for disposal.
7 At the fuel pressure test point (2), remove the Schrader valve sealing cap (1), refer to Figure 6C – 7.

Figure 6C – 7
Legend
1 Schrader Valve Sealing Cap
2 Pressure Test Point 3 Schrader Valve

Wear safety glasses when performing the fuel
pressure relief procedure.
8 Place a shop towel around the Schrader valve to soak up the expelled petrol.
9 Use a small screwdriver to press the Schrader valve down (3).
10 Remove the soiled shop towel and place in an approved container.
Repressurise
1 Reinstall the fuel pump relay and fuel pump fuse.
2 Perform the following procedure to inspect for leaks at the fuel pressure test point: a Turn the ignition switch on for two seconds.
b Turn the ignition switch off for 10 seconds.
c Turn the ignition switch on.
d Check for leaks at the fuel pressure test point.
3 Tighten the fuel filler cap.
4 Start the engine and recheck for leaks.
5 Reinstall the Schrader valve sealing cap.

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