2007 ISUZU KB P190 engine

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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ISUZU KB P190 2007

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.







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

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-17
Fan Clutch with Cooling Fan
Inspection and Repair
Make necessary correction or parts replacement if
wear, damage or any other abnormal conditions are
found through inspection.

Visually inspect for damage, leak (silicon grease) o
r
other abnormal conditions.
1. Inspection (on-vehicle) a) Turn the fan clutch by hand when in a lo
w
temperature condition before starting the
engine, and confirm that it can be turned
readily.
b) Start the engine to warm it up until the temperature at the fan clutch portion gets to
around 85°C (185°F). 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.






RTW 56ASH025401

2. Inspection (in unit)
W arm up the bimetal of the fan clutch by using the heat gun until the temperature gets to about 85°C
when measured with the thermistor. Then confirm
that the fan clutch can be turned with considerable
effort (clutch torque).
If the fan clutch rotates more readily at this time, this indicates that the silicone grease is leaking
internally.
Replace the fan clutch with a new one.







033RY00011



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ISUZU KB P190 2007

6B-18 ENGINE COOLING (4JK1/4JJ1)
Special Tools
ILLUSTRATION PART NO.
PART NAME


5-8840-0277-0
Cap tester


5-8840-2603-0
Adapter



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ISUZU KB P190 2007