radiator ISUZU KB P190 2007 Workshop Manual PDF

ENGINE COOLING (4JK1/4JJ1) 6B-11
Thermostat
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. Remove the engine cover.
2. Radiator Upper Hose a. Partially drain the engine coolant.
b. Remove the radiator upper hose.
c. Remove the engine harness clip.






RTW 56FSH000101
3. W ater Outlet Pipe
a. Disconnect the turbocharger-cooling pipe from outlet pipe.
b. Loosen the fixing bolt and remove the wate
r
outlet bolt.
4. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.




RTW 56BSH000101
Legend
1. Front
2. Thermostat
3. Jiggle Valve

Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Operating Test of Thermostat
1. Completely submerge the thermostat in water.
2. Heat the water.Stir the water constantly to avoid direct heat being applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature °C (°F)
85 (185)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature °C (°F)
100 (212)
Valve Lift At Fully Open Position mm (in)
10 (0.39)


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ISUZU KB P190 2007

6B-12 ENGINE COOLING (4JK1/4JJ1)







MFW 41CSH001401
Legend
1. W ooden Piece
2. Agitating Rod

Installation
1. Thermostat
Install the thermostat.
Mount the jiggle valve with the valve facing engine front.




RTW 56BSH000101
Legend
1. Front
2. Thermostat
3. Jiggle Valve


2. W ater Outlet Pipe.
a. Install the water outlet pipe with new gasket to the thermostat housing.
b. Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque: 25 N·m (2.5 kg·m /18 lb ft)
c. Connect the turbocharger-cooling pipe to outlet pipe.
d. Install the engine harness clip.
3. Radiator Upper Hose.






RTW 56FSH000101
a. Connect the radiator upper hose to the water
outlet pipe.
b. The knob of the clamp should be directed to the horizontal side.
c. Replenish the engine coolant.
4. Install the engine cover.

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ENGINE COOLING (4JK1/4JJ1) 6B-13
Radiator
Radiator and Associated Parts


RTW 76BLF000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket



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ISUZU KB P190 2007

6B-14 ENGINE COOLING (4JK1/4JJ1)
Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic transmission (A/T).
4. Remove the engine cover.
5. Disconnect radiator inlet hose and outlet hose from the engine.




RTW 56BSH000301
6. Remove fan guide (1), clips (2) on both sides and
the bottom lock, then remove lower fan guide (3)
with fan shroud (4).



PTW 46BSH000101

Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud

7. Disconnect the reserve tank hose (1) from
radiator.
8. Remove bracket (9).




RTW 76BMH000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket

9. Lift up and remove the radiator assembly with
hose, taking care not to damage the radiator core
with a fan blade.

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-15
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is
discovered during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure: 93.3 - 122.7 kPa (0.95 - 1.25 kg / cm
2 / 13.5 -
17.8 psi)
Cap tester: 5–8840–0277–0
Adapter: 5–8840–2603–0
Check the condition of the vacuum valve in the cente
r
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
Valve opening vacuum: 1.96 - 4.91 kPa (0.02 - 0.05 kg / cm
2 / 0.28 - 0.71
psi)



110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator
Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.
Cooling System Leakage Check
Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (2.0 kg / cm2 / 28.5 psi) with a cap tester:
• Leakage from the radiator.
• Leakage from the coolant pump.
• Leakage from the water hoses.
• Check the rubber hoses for swelling.



110RS005


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ISUZU KB P190 2007

6B-16 ENGINE COOLING (4JK1/4JJ1)
Installation
1. Install radiator assembly (6) with hose, taking care
not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (9) and secure the radiator.
3. Connect reserve tank hose (1).
4. Install lower fan guide (4).
5. Connect radiator inlet hose and outlet hose (3) to the engine.
6. Install the engine cover.
7. Connect oil cooler hose to automatic transmission.
8. Connect battery ground cable.



RTW 76BMH000101
Legend
1. Reserve Tank Hose
2. Reserve Tank
3. Radiator Hose
4. Fan Guide; Lower
5. Fan Guide
6. Radiator Assembly
7. Drain Plug
8. Radiator Cap
9. Bracket


9. Pour engine coolant up to filler neck of radiator,
and up to MAX mark of reserve tank.
Important operation (in case of 100% engine coolant change) procedure for filling with engine
coolant.







RTW 76BSH000101
Engine coolant change
Refer to change procedure for Draining and Refilling
Cooling System in this section.

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ISUZU KB P190 2007

6C-28 FUEL SYSTEM (4JK1/4JJ1)
Removal
1. Partially drain the engine coolant.
Refer to drain procedure for engine cooling in this manual.
2. Remove the radiator upper hose.





RTW 56FSH000101
3. Remove the fan guide.




RTW 46BSH000101
Legend
1. Fan Guide
2. Clips
3. Lower Fan Guide
4. Fan Shroud


4. Remove the cooling Fan.




RTW 56ASH025401
5. Remove the A/C compressor drive belt.
6. Remove the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut

7. Remove the battery.


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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-37
24. Install the A/C compressor.




RTW 56ASH004201
Legend
1. A/C Compressor Bracket
2. Intake Duct
3. A/C Compressor

Tighten the bolts to the specified torque.
Tightening torque: 44 N ⋅
⋅⋅
⋅
m (4.5 kg ⋅
⋅⋅
⋅
m / 33 lb ft)
25. Install the battery.
26. Install the A/C compressor adjust pulley.






RTW 56ASH010601
Legend
1. Bolt
2. Nut


Tighten the nut and bolt to the specified torque.
Bolt Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
Nut Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
27. Install the A/C compressor drive belt.
Refer to the drive belt tension check procedure fo
r
Heating and air conditioning in this manual.
28. Install the cooling fan.
29. Install the fan guide.
30. Install the radiator upper hose.
31. Replenish the engine coolant.

Fuel Supply Pump Relearn Procedure
The ECM goes through a fuel supply pump learn
procedure to fine tune the current supplied to the fuel
rail pressure (FRP) regulator. This learning process in
only performed when the engine is idling.
1. Install the scan tool.
2. Turn ON the ignition, with the engine OFF.
3. Command the Supply Pump Learn Reset with the scan tool.
4. Observe the Supply Pump Status parameter with the scan tool. Confirm the scan tool indicates Not
Learn.
5. Start the engine and let idle until engine coolant temperature (ECT) reads 149°F (65°C) or highe
r
while observing Supply Pump Status parameter
with the scant tool. The scan tool changes status
Not Learn > Learning > Learned.
6. If the ECM has correctly learned the fuel supply pump current adjustment, the Supply Pump Status
parameter on the scan tool will repeatedly indicate
Learning and Learned.


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ISUZU KB P190 2007

ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-135
DTC P0217 (Flash Code 542)
Circuit Description
The engine coolant temperature (ECT) sensor is
installed to the thermostat housing. The ECT sensor is
a variable resistor and it measures the temperature of
the engine coolant. If the ECM detects an excessive
high coolant temperature, this DTC will set.
Condition for Running the DTC • DTCs P0116, P0117 and P0118 are not set.
• The battery voltage is more than 9 volts.
• The ignition switch is ON.
• The engine is running.
Condition for Setting the DTC • The ECM detects that the engine coolant temperature is more than 110 °C (230 °F) for 5
seconds.
Action Taken When the DTC Sets • The ECM will not illuminate the MIL or SVS lamp. Refer to DTC Type Definitions for Action Taken
When the DTC Sets - Type D. Condition for Clearing the DTC
• Refer to DTC Type Definitions for Condition for Clearing the DTC - Type D.
Diagnostic Aids • After starting the engine, the ECT should rise steadily to about 80 to 85 °C (176 to 185 °F) then
stabilize when the thermostat opens.
• Use the Temperature vs. Resistance table to test the ECT sensor at various temperature levels to
evaluate the possibility of a skewed sensor. A
skewed sensor could result in poor driveability
concerns.
• The Total Engine Coolant Overtemperature Events parameter on scan tool indicates number of
overheat events.
Notice: • This DTC is caused by an engine overheat condition (e.g. low engine coolant level). Since this
DTC does not illuminate any lamps, clear the DTC
and ensure there are no signs of engine damage.
Excessive engine overheat may damage internal
engine components.
Circuit/ System Testing DTC P0217
Step Action Value(s)Yes No
1 Did you perform the Diagnostic System Check -
Engine Controls? —
Go to Step 2 Go to Diagnostic
System Check -
Engine Controls
2 1. Install a scan tool.
2. Turn OFF the ignition for 30 seconds.
3. Start the engine.
4. Monitor the DTC Information with a scan tool.
Is DTC P0117 also set? —
Go to DTC P0117 Go to Step 3
3 1. Test the engine cooling system for the
following condition. Refer to diagnosis of the
engine cooling system section for testing.
• Engine coolant level
• Engine coolant leakage
• Cooling fan belt slippage
• Cooling fan clutch working
• Thermostat working
• Water pump working
• Radiator clogging
2. Repair or replace as necessary.
Did you find and correct the condition? —
Go to Step 7 Go to Step 4
4 Start the engine and wait until engine is fully warm
upped while observing the Coolant Temperature
parameter with a scan tool.
Does the scan tool indicate more than the specified
value? 11 0
°C (230 °F)
Go to Step 6 Go to Step 5

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-367
The amount of air pressure rise and air volume
delivered to the engine from the compressor outlet is
regulated by a waste gate valve in the exhaust housing.
The position of the waste gate valve is controlled by the
amount of pressure built up on the intake side of the
turbocharger. The diaphragm on the inside of the waste
gate is pressure sensitive, and controls the position of
the valve inside the turbocharger. The position of the
valve will increase or decrease the amount of boost to
the turbocharger. (Standard output engine)
Legend
1. Turbocharger nozzle control actuator
2. Nozzle

The amount of air pressure rise and air volume
delivered to the engine from compressor outlet is
regulated by a turbocharger nozzle control actuator
indirectly. The position of the turbocharger nozzle is
controlled by the ECM. The ECM utilizes a
turbocharger nozzle control solenoid valve and a boost
pressure sensor to control the turbocharger nozzles.
When the engine is not under load, the turbocharger
nozzles are in an open position (A), or no boost
condition (vacuum pressure supply to the actuator is
reduced). When the engine is under load, the ECM
commands the control solenoid valve to close the
turbocharger nozzles (B), thus increasing the boost
(vacuum pressure supply to the actuator is increased).
The ECM will vary the boost dependant upon the load
requirements of the engine. The ECM uses a pulse
width modulation (PWM) on the control circuit to open and control the solenoid valve. (High output engine)
The charge air cooler also helps the performance of the
diesel. Intake air is drawn through the air cleaner and
into the turbocharger compressor housing. Pressurized
air from the turbocharger then flows forward through
the charge air cooler located in the front of the radiator.
From the charge air cooler, the air flows back into the
intake manifold.
The charge air cooler is a heat exchanger that uses air
flow to dissipate hear from the intake air. As the
turbocharger increases air pressure, the air
temperature increases. Lowering the intake air
temperature increases the engine efficiency and power
by packing more air molecules into the same space.
RTW76EMH000201
A
B
1
2
1
2

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