2007 ISUZU KB P190 power steering

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

ENGINE MECHANICAL (C24SE) 6A-49







Reassembly
Reassemble clutch assembly.

Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0

Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgf xm.




RTW 46ASH002801
Oil Pan and Bearing Bridge
Removal
1. Remove the crossmember.
2. Shift downward the power steering unit (and front axle [4 ×4 model only]).
3. Loosen fixing bolts.
4. Remove oil pan from oil pump and cylinder block.
5. Remove oil intake pipe, oil intake pipe bracket, and oil baffle plate.
6. Remove the bearing bridge.















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ISUZU KB P190 2007

6A-50 ENGINE MECHANICAL (C24SE)

Clean
Sealing surfaces.





013RW 004










Installation
1. Apply a bead of Sealing Compound, TB120TC or eguivalent to joint of oil pump.
2. Apply the recommended light gasket to the oil pan fitting surface as shown in the illustration.
3. Install the bearing bridge.
4. Install baffle plate, or reuse baffle plate.

Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.

5. Install oil intake pipe to oil pump and oil intake pipe bracket to cylinder block.
6. Install oil pan and new gasket to cylinder block and insert bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7. Return the power steering unit (and front axle [4 ×4 model
only]).
8. Install the crossmember.

Tighten (Torque)
Oil intake pipe to oil pump -8N ⋅m (0.8 kgf ⋅m)
Oil intake pipe bracket to cylinder block - 6 N ⋅m (0.6 kgf ⋅m)
Oil pan to cylinder block - 8 N ⋅m (0.8 kgf ⋅m)
Bearing bridge to cylinder block – 8 N ⋅m (0.8 kgf ⋅m)



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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

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

ENGINE DRIVEABILITY AND EMISSIONS 6E–5
ENGINE CRANKS BUT WILL NOT RUN ..... 6E-233
HARD START SYMPTOM ............................ 6E-236
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM ............................... 6E-239
SURGES AND/OR CHUGS SYMPTOM ...... 6E-242
HESITATION, SAG, STUMBLE SYMPTOM 6E-245
CUTS OUT, MISSES SYMPTOM ................. 6E-248
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM ................................................. 6E-251
DETONATION/SPARK KNOCK SYMPTOM 6E-254
POOR FUEL ECONOMY SYMPTOM .......... 6E-256
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM ................................... 6E-258
DIESELING, RUN-ON SYMPTOM ............... 6E-261
BACKFIRE SYMPTOM ................................. 6E-262
ON-VEHICLE SERVICE PROCEDURE ....... 6E-264
ENGINE CONTROL MODULE (ECM) .......... 6E-264
CRANKSHAFT POSITION (CKP) SENSOR 6E-264
ENGINE COOLANT TEMPERATURE (ECT) SENSOR .................................................... 6E-265
INTAKE AIR TEMPERATURE (IAT) SENSOR 6E-265
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR .................................................... 6E-266
THROTTLE POSITION SENSOR (TPS) ...... 6E-266
IDLE AIR CONTROL (IAC) VALVE .............. 6E-267
KNOCK SENSOR ......................................... 6E-268
POWER STEERING PRESSURE (PSP) SWITCH ..................................................... 6E-268
HEATED OXYGEN SENSOR (HO2S) ......... 6E-269
EVAP CANISTER PURGE VALVE SOLENOID 6E-269
FUEL PRESSURE RELIEF .......................... 6E-270
FUEL RAIL ASSEMBLY ............................... 6E-270
FUEL INJECTOR .......................................... 6E-271
FUEL PRESSURE REGULATOR ................ 6E-273
IGNITION COIL ............................................ 6E-275
SPARK PLUGS ............................................ 6E-275
SPARK PLUG CABLES ................................ 6E-277
EMISSION CONTROL ; *CO ADJUSTER (W/O
CATALYSTIC CONVERTER) .................. 6E-277
SPECIAL SERVICE TOOLS ......................... 6E-279

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6E–10 ENGINE DRIVEABILITY AND EMISSIONS
(1) Canister(1)
(2) Fuel Tank
Fuel Pump
2
1
(1)
(2) Vehicle Speed Sensor (VSS)
Transmission Assembly
12
(1)
(2) Power Steering Pressure Switch
Power Steering Oil Pump Assembly
12

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6E–44 ENGINE DRIVEABILITY AND EMISSIONS
Connector J2 Port: View Looking Into ECM Case
1
17 16
32
PIN32
PIN1
PIN17
PIN16
Pin
No. B/
Box No. Pin Function
Wire
Color Signal or Continuity
ECM
Connection Tester Position
Key SW Off Key SW
On Engine
Idle Engine
2000rpm Range (+) (-)
J2-1 J2-1 Intake Air Temp. (IAT) Sensor Ground GRN Continuity
with
ground -
- - Disconnect ΩJ2-1 GND
J2-2 J2-2 Battery Power Supply RED/ WHT10-14V
Connect DC V J2-2 GND
J2-3 J2-3 Ignition Power Supply BLU/ YELLess than
1V 10-14V
Connect DC V J2-3 GND
J2-4 J2-4 To Data Link Connector No. 6 BLU -
-- - -- - -
J2-5 J2-5 No Connection -- - - - -- - -
J2-6 J2-6 Oxygen Sensor (Ground) PNK Continuity
with
ground -
- - Connect ΩJ2-6 GND
J2-7 J2-7 No Connection -- - - - -- - -
J2-8 J2-8 No Connection -- - - - -- - -
J2-9 J2-9 No Connection -- - - - -- - -
J2-10 J2-10 CO Adjust Signal (W/O Catalystic
Converter) YEL -
-- - -- - -
J2-11 J2-11 Fuel Pump Relay GRN/ WHT10-14V
While relay
is activated; 10-14V
Relay is not
activated;
Less than 1V10-14V Connect DC V J2-11 GND
J2-12 J2-12 No Connection -- - - - -- - -
J2-13 J2-13 A/C Compressor Relay GRY/
RED Less than
1V A/C comp. is operated: Less than 1V
A/C comp. is not operated: 10-14V Connect DC V J2-13 GND
J2-14 J2-14 No Connection -- - - - -- - -
J2-15 J2-15 No Connection -- - - - -- - -
J2-16 J2-16 No Connection -- - - - -- - -
J2-17 J2-17 CO Adjust (W/O Catalystic Converter) RED -
-- - -- - -
J2-18 J2-18 Battery Power Supply RED/ WHT10-14V
Connect DC V J2-18 GND
J2-19 J2-19 No Connection -- - - - -- - -
J2-20 J2-20 Power Steering Pressure Switch GRN/
YEL Less than
1V
Pressure switch is turned on: Less than 1VPressure switch is turned off: 10-14VConnect DC V J2-20 GND
J2-21 J2-21 Oxygen Sensor BLU Less than 1VApprox.
0.4V Wave form D or 0.1 -
0.9V Connect DC V J2-21 J2-6
J2-22 J2-22 Intake Air Temp. (IAT) Sensor (Signal) YEL/
GRN Less than
1V
20℃: Approx. 2.9V / 40 ℃: Approx. 1.8V V
/ 60 ℃: Approx. 1.1V / 80 ℃: Approx. 0.6VConnect DC V J2-22 33

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