6A-42 ENGINE MECHANICAL (C24SE)
Installation
1. Install the fastening bolts.
2. Loosen the lower alternator fastening bolt.
3. Install the alternator, power steering and V-belts.
Cylinder Head, Disassemble and Assemble
Removal
1. Remove the hydraulic valve lifters.
Lay aside in installation positions.
2. Remove the spark plugs, exhaust manifold and intake manifold from cylinder head.
Removal
1. Mark valves.
2. Remove the tension valve springs with 5-8840-2594-0 (1).
3. Remove valve keepers, valve spring cap and valve spring.
Removal
1. Remove the valve and valve stem seal.
2. Remove the valve spacer ring (1-exhaust) and valve spring seat (2-intake).
3. Remove valve from cylinder head.
Clean
Sealing surfaces.
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ISUZU KB P190 2007
6A-48 ENGINE MECHANICAL (C24SE)
Seal Ring, Crankshaft
(Oil Pump Housing)
Removal
1. Remove toothed belt rear cover according to the
corresponding operation.
2. Remove sealing ring by making hole in middle of ring, turning in self-tapping screw and edging out.
Installation
1 Install the protective sleeve to the crankshaft.
2. Coat the sealing lip with protective grease.
3. Install the sealing ring.
4. Install the sealing ring using 5-8840-0455-0.
5. Install the rear toothed belt cover and toothed belt according to the corresponding operations.
6. Replace the sealing ring with a new one.
7. Tighten the belt to the crankshaft.
Seal Ring, Crankshaft Rear
Removal
1. Remove transmission and clutch.
2. Remove flywheel or flex plate according to the corresponding operations.
3. Make hole in middle of sealing ring, turn in self-tapping screw and edge out.
Installation
1. Install protective sleeve.
2. Coat sealing lip with Protective Grease.
3. Install sealing ring using 5-8840-0459-0 and 5-8840- 2597-0.
4. Install flywheel, clutch and transmission.
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ISUZU KB P190 2007
ENGINE MECHANICAL (C24SE) 6A-59
Bypass Valve
Removal
1. Remove oil filter.
2. Remove bypass valve by cutting thread in locking disc with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1. Install bypass valve using drift (diameter approx. 15mm/0.6in.).
Oil Filter
Removal
1. Remove oil filter using commercially available tool.
Installation
1. Install oil filter by hand and oil seal ring.
2. Fill up engine oil while preventing overflow.
Oil Pump
Removal
1. Remove rear toothed belt cover, and oil pan according to the corresponding operations.
2. Remove oil filter, wiring plug from oil pressure switch, oil pump from cylinder block, and oil pressure switch from
oil pump.
Clean
Sealing surfaces
Installation
1. Install oil pressure switch to oil pump, oil pump to cylinder
block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.
Tighten (Torque)
Oil pressure switch to oil pump - 30 N ⋅m (3.2 kgf ⋅m)
Oil pump to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil intake pipe to oil pump - 8 N ⋅m (0.8 kgf ⋅m)
Intake pipe bracket to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)
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ISUZU KB P190 2007
6A-66 ENGINE MECHANICAL (C24SE)
Installation
Follow the removal procedure in the reverse order to install the
radiator.
Thermostat
Removal
1. Remove water outlet nozzles with thermostat from thermostat housing.
2. Remove coolant hose and collect coolant.
Important!
Remove and Install thermostat only together with water outlet
nozzles.
Tighten (Torque)
W ater outlet nozzles to thermostat housing - 8 N ⋅m (0.8 kgf ⋅m)
Installation
1. Install coolant hose.
2. Fill cooling system and bleed according to the corresponding operation.
Water Pump
Removal
1. Remove lower hose band from pipe band and collect coolant.
2. Remove front toothed belt cover according to the corresponding operation.
3. Remove water pump from cylinder block after releasing tension on toothed belt.
Clean
Sealing surfaces
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ISUZU KB P190 2007
ENGINE MECHANICAL (C24SE) 6A-67
Coating sealing surfaces with Silicone Grease
Installation
1. Install water pump to cylinder block with new rubber O-ring.
2. Apply tension to toothed belt according to the corresponding operation.
3. Install coolant hoses.
4. Fill cooling system and bleed according to the corresponding operation.
Alternator
Removal
1. Remove ground cable from battery.
2. Remove cable connection from alternator and V-belt.
3. Remove alternator from retaining strap and lower fastening.
Installation
1. Install alternator by tightening firmly by hand.
2. Install V-belt and apply tension according to the corresponding operation.
3. Install cable connections to alternator.
4. Install ground cable to battery.
Starter
Removeal
1. Remove cable connections from starter.
2. Remove upper bolt of transmission side.
3. Remove lower bolt of engine side.
Tighten (Torque)
Starter to cylinder block:
Engine side - 51 N ⋅m (5.2 kgf ⋅m)
Transmission side - 75 N ⋅m (7.6 kgf ⋅m)
Starter support to cylinder block - 25 N ⋅m (2.5 kgf ⋅m)
Re-connect cables.
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ISUZU KB P190 2007
6A-68 ENGINE MECHANICAL (C24SE)
V-belt Tension of Alternator
RTW 66ASH000101
Measure
Measure V-belt tension of alternator.
Permitted values for new V-belt are approx. 311-489N (31-50
kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bracket and lower
alternator bracket and moving alternator.
Tighten (Torque)
Clamping bracket to alternator - 35 N ⋅m (3.6 kgf ⋅m)
Lower alternator bracket - 25 N ⋅m (2.6 kgf ⋅m)
V-Belt Tension of Power Steering Pump
Measure
Measure V-belt tension of power steering pump. Permitted
values for new belt are approx. 578-712N (59-73 kgf) and 534-
667N (54-68 kgf) for used belt.
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bolt, lower pump
bracket, and adjusting nuts and moving steering pump.
Tighten (Torque)
Adjusting nuts - 18 N ⋅m (1.8 kgf ⋅m)
Clamping bolt - 25 N ⋅m (2.6 kgf ⋅m)
Lower pump bracket - 26 N ⋅m (2.6 kgf ⋅m)
V-Belt Tension of Air Conditioning Compressor
Measure
Measure V-belt tension of air conditioning compressor.
Permitted values for new V-belt are approx. 422N (43 kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.
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ISUZU KB P190 2007
ENGINE MECHANICAL (C24SE) 6A-69
RTW 66ASH000201
Adjust
Adjust the A/C compressor V-belt (1) for adjustment of belt.
1. Loosen the tension pulley lock nut (2) and tension pulley adjusting bolt (3) of the tension pulley of the A/C
compressor V-belt (1) and bring the belt to free state.
2. Rotate the adjusting bolt (3) of A/C compressor adjust the belt (remove and fit).
• W hen replacing the belt, you must always replace both the belts.
3. After adjustments, tighten the lock nut (2) using the specified torque.
Tightening torque: 40 N ⋅m (4.1 kgf ⋅m)
• Finally, adjust the tension of A/C compressor V-belt.
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ISUZU KB P190 2007
6A-88 ENGINE MECHANICAL (C24SE)
Recommended Torque Values
N⋅m (kgf ⋅m)
Bearing cover to cylinder block ........................................................................................ 60
1) 6.1 +40 ° to 50 °
Bracket for alternator to cylinder block ............................................................................ 40 4.1
Bracket for engine damping block to transmission .......................................................... 60
2) 6.1
Bracket for engine damping block to engine block .......................................................... 60 6.1
Bracket for pump/compressor to engine block ................................................................ 35 3.6
Camshaft housing cover to housing ................................................................................ 8 0.8
Camshaft timing gear to camshaft ................................................................................... 50 5.1
Clamping bracket for alternator to intake manifold .......................................................... 25 2.5
Clamping bracket to alternator ......................................................................................... 25 2.5
Con-rod bearing cap to con-rod ....................................................................................... 35
1) 3.5 +45 ° to 60 °
Crankshaft pulley bolts ..................................................................................................... 2 0 2.0
Cylinder head to cylinder block ........................................................................................ 25
1)2) 2.5 +90 ° +90 °
+90 °
Engine damping block to engine bracket ......................................................................... 85 8.7
Engine damping block to side member ............................................................................ 52
1) 5.3
Exhaust manifold to cylinder head ................................................................................... 22 2.2
1) Use new bolts
2) Use new locking plates
Recommended Torque Values
N⋅m (kgf ⋅m)
Flywheel to crankshaft ..................................................................................................... 65
1) 6.6 +30° to 45 °
Front exhaust pipe to exhaust manifold ........................................................................... 25 2.5
Guide sleeve for pressure bearing to transmission ......................................................... 22 2.2
Intake manifold to cylinder head ...................................................................................... 22 2.2
Lower alternator bracket .................................................................................................. 25 2.5
Oil drain plug to oil pan .................................................................................................... 45 4.6
Oil intake pipe bracket to cylinder block ........................................................................... 6
2) 0.6
Oil intake pipe to oil pump ................................................................................................ 8 0.8
Oil pan to cylinder block ................................................................................................... 8
2)3) 0.8
Bearing bridge to cylinder block ....................................................................................... 8 2)3) 0.8
Oil pressure switch to oil pump ........................................................................................ 30 3.2
Pump for power steering (ribbed V-belt) to engine block ................................................. 30 3.2
Spark plugs in cylinder head ............................................................................................ 20 2. 3
Starter support to cylinder block ...................................................................................... 25 2.5
Starter to cylinder block - engine side .............................................................................. 45 4.6
Starter to cylinder block - transmission side .................................................................... 75 7.6
Thermostat housing to cylinder head ............................................................................... 15 1.5
Toothed belt drive gear to crankshaft .............................................................................. 130
1) 13.3
Toothed belt front cover ................................................................................................... 4 0.4
Toothed belt rear cover .................................................................................................... 6 0.6
Toothed belt tension roller to oil pump ............................................................................. 20 2.3 (M10) ............................................................................ 45 4.6
Transmission to engine block ......................................................................................... 76 7.7 (M12) ............................................................................ 60 6.1
W ater pump to cylinder block .......................................................................................... 17 1.7
1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes
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ISUZU KB P190 2007