warning ISUZU KB P190 2007 Workshop Manual Online

Engine Cooling – V6 Engine Page 6B1–4

1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
1.2 Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.

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Engine Cooling – V6 Engine Page 6B1–16

3 Service Operations
3.1 Service Notes
Safety

• To avoid serious personal injury, never
remove the coolant filler pressure cap on
the coolant outlet housing when the
engine is hot, even if the cooling system
should require filling. Sudden release of
cooling system pressure is very
dangerous.
• The vehicle is fitted with an electric
radiator cooling fan. When working around
the engine compartment, keep clear of the
fan as it may start without warning.
Before removing the coolant filler cap, allow the engine to cool, then place a shop rag over the coolant filler cap and then
slowly turn the cap anticlockwise, approximately 1½ turns, until the pressure relief position is reached. The pressure
relief position will allow any remaining pressure within the system to escape into the coolant recovery reservoir. Continue
to rotate the cap anticlockwise until the cap can be safely removed.
Periodic Servicing
The cooling system requires little attention except for maintaining the coolant to the correct level in the recovery reservoir
and periodic servicing at the time or distance intervals as outlined in 0B Lubrication and Service.
Periodic servicing includes:
1 Checking coolant level. Refer to 3.3 Draining and Filling Cooling System in this Section.
2 Checking coolant concentration. Refer to 3.2 Coolant Maintenance – Testing Coolant Concentration in this Section.
3 Pressure test cooling system and coolant filler cap. Refer to 3.7 Pressure Testing in this Section.
4 Tighten hose clamps and inspect all hoses. Refer to 3.6 Coolant Hoses in this Section. Replace hoses if swollen or deteriorated.

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
5 Clean out cooling system, refer to 3.4 Cleaning Cooling System – Cooling System Flush, in this Section and refill. Refer to 3.3 Draining and Filling Cooling System in this Section.
Environmental Issues
To reduce environmental impact and maintenance cost, whenever the coolant is drained from any engine, the service
records are to be checked to determine when the coolant was last changed. If more than six months life is left before the
next coolant change, then the following procedure is to be followed:
1 W hen draining the coolant from the engine, use a clean container to hold at least 12 litres of coolant and ensure that the coolant is not contaminated in the draining process.
2 After repairs have been completed, refill the engine cooling system with the drained coolant.

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Engine Cooling – V6 Engine Page 6B1–22

3.3 Draining and Filling Cooling System
Draining

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), and then remove the coolant filler cap (located near
the brake booster assembly).

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 6D1– 3 Battery – V6.
3 Drain the coolant from the system via the radiator drain tap on the lower RHS of the radiator below the lower hose outlet. Attach a suitable piece of rubber tubing to the tap outlet to help direct the flow of the coolant into a suitable
container (capacity at least 12 litres).
Filling
During any service operation that requires the cooling system to be partly or completely drained, the following
instructions must be followed when refilling the cooling system, to ensure that all air is bleed from system.

• Refer to 3.1 Service Notes in this Section,
for important safety items.
• Before opening the radiator bleed screw,
the cooling system must first be
completely depressurised with the engine
coolant filler cap removed.

Do not mix different types of anti-freeze or
corrosion inhibitors, as they may be
incompatible. Always check which coolant is
to be added to the particular vehicle being
serviced. If a different type has been used in
the cooling system (or is added accidentally),
flush the system with clean water. Refer to 3.4
Cleaning Cooling System in this Section.
NOTE
Ensure that the radiator drain tap located at the
bottom of right-hand side radiator tank is closed
before proceeding.

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Engine Cooling – V6 Engine Page 6B1–34

3.8 Thermostat
Remove

Do not remove coolant filler cap while the
engine coolant temperature is above 50 °
°°
°
C, as
personal injury may result.
1 Allow engine to cool to ambient temperature (less than 50 ° C), then remove the coolant filler cap (located at the
front left-hand side of the engine).

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 6D1-3 Battery – V6.


Refer to ‘
‘‘
‘
Environmental Issues ’
’’
’
in 3.1
Service Notes, before draining the coolant.
3 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System in this Section.
4 Remove the complete intake manifold assembly. Refer to 6A1 Engine Mechanical – V6.
5 Plug each of the exposed intake ports with lint free cloth to prevent the entry of foreign matter.
6 Remove the coolant inlet pipe. Refer to 3.12 Coolant Inlet Pipe in this Section.


Always wear protective safety glasses when
working with spring type hose clamps.
Failure to do so could result in eye injury.
7 Use a straight-blade screwdriver (3) to release the heater hose quick connect clips (4).
8 Disconnect the heater hoses (1) from the heater pipes (2) in two places.
Figure 6B1 –
––
–
33

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Engine Cooling – V6 Engine Page 6B1–40

2 Check coolant recovery system for leaks.
3.10 Coolant Pump
Remove

Refer to 3.1 Service Notes in this Section, for
important safety items.
NOTE
The coolant pump is not to be disassembled and
is replaced only as an assembly.
1 Allow engine to cool to ambient temperature (less than 50 ° C), and then remove the coolant filler cap (located at
the front left-hand side of the engine).

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.
3 Loosen coolant pump pulley to hub bolts (1).
NOTE
While the view shows the drive belt removed,
it will be easier to loosen the four pulley bolts,
with the belt installed.

Figure 6B1 – 42

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Engine Cooling – V6 Engine Page 6B1–45

3.11 Coolant Outlet Housing
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), and then remove the coolant filler cap (located at
the front left-hand side of the engine).

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 Battery.
3 Drain the coolant from the system. Refer to 3.3 Draining and Filling Cooling System.
4 Remove the complete intake manifold assembly. Refer to 6A1 Engine Mechanical.

Always wear protective safety glasses when
working with spring type hose clamps. Failure
to do so could result in eye injury.
5 Remove upper radiator hose clamp (1) at the coolant outlet housing connection (2), disconnect
hose from coolant outlet.

Figure 6B1 – 50

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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 –
––
–
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 6B1–54

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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Fuel System – V6 Page 6C – 1

6C
Fuel System – V6
ATTENTION
Before performing any service operation or other procedure described in this Section, refer to 1.1 WARNING,
CAUTION and NOTES for correct workshop practices with regard to safety and/or property damage.
1 General Information ............................................................................................................ ...................3
Description ............................................................................................................................................................. 3
Service Precautions............................................................................................................................................... 3
1.1 WARNING, CAUTION and NOTES ..................................................................................................... ................... 4
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 4
WARNING defined ............................................................................................................................................. 4
CAUTION defined .............................................................................................................................................. 4
NOTE defined..................................................................................................................................................... 4
2 System Components .............................................................................................................. ................5
Fuel System ............................................................................................................................................................ 5
Description ......................................................................................................................................................... 5
Fuel Pump............................................................................................................................................................... 6
Single Turbine Fuel Pump ....................................................................................................... ........................... 6
Fuel Flow ................................................................................................................................................................ 7
3 System Checks .......................................................................................................................................8
3.1 Fuel Pump Flow Test ............................................................................................................................................. 8
3.2 Fuel Pressure Test ................................................................................................................................................. 8
Gauge Installation .................................................................................................................................................. 8
Test ......................................................................................................................................................................... 9
Removal .................................................................................................................................................................. 9
3.3 Fuel Leak Test ...................................................................................................................................................... 10
3.4 Fuel System Depressurisation................................................................................................... ......................... 11
Repressurise ........................................................................................................................................................ 12
4 Service Operations ...............................................................................................................................13
4.1 Fuel Lines And Quick Connect Fittings .......................................................................................... ................... 13
Description ........................................................................................................................................................... 13
Leak Test and Inspection .................................................................................................................................... 13
Removal ................................................................................................................................................................ 14
Reinstall ................................................................................................................................................................ 15
4.2 Fuel Filter.............................................................................................................................................................. 15
Removal ........................................................................................................................ ........................................ 15
Inspection ............................................................................................................................................................. 16
Reinstallation ................................................................................................................. ...................................... 16
4.3 Fuel Tank and Pump Assembly .................................................................................................... ...................... 17
4.4 Fuel Tank Assembly ............................................................................................................................................ 18
Remove ................................................................................................................................................................. 19
Reinstall ................................................................................................................................................................ 22
4.5 Modular Fuel Pump and Sender Assembly .......................................................................................... ............. 23
Remove ................................................................................................................................................................. 23
Fuel Level Sender Assembly ..................................................................................................... ......................... 26
Test .................................................................................................................................................................. 26
Reinstall ................................................................................................................................................................ 26

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