2007 ISUZU KB P190 cooling

6A-36 ENGINE MECHANICAL (C24SE)



















Clean
All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface
according to the corresponding operations.

Installation
1. Install cylinder head sealing with marking "OBEN/TOP"
facing upwards and to right side of engine.
2. Install cylinder head on cylinder block.
3. Install hydraulic valve lash adjuster, pressure parts and rocker arm - molybdenum disulphate paste.
4. Install camshaft housing-Sealing Compound TB-1207C or equivalent.

Important!
Use new cylinder head bolts.
Screw in bolts until they rest on cover.




Torque - Angle Method
Cylinder head to cylinder block - 25 N ⋅m (2.5 kgf ⋅m)
Further turn angle 90 °+90 °+ 90 °.
Tighten cylinder head bolts from inside outwards. In four
stages in a spiral pattern.








5. Install rear toothed belt cover onto camshaft housing.
6. Install toothed belt and apply tension according to the corresponding operation.

Tighten (Torque)
Camshaft timing gear to camshaft - 45 N ⋅m (4.6 kgf ⋅m)




7. Install camshaft housing cover and front toothed belt
cover.
8. Install cable connections, all hoses and lines onto cylinder head.
9. Adjust accelerator cable for free of play.
10. Install V-belt according to the corresponding operation.
11. Install air intake hose.
12. Install front exhaust pipe.
13. Install ground cable onto battery.
14. Fill up cooling system and bleed according to the corresponding operation.

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-63
OPERATIONS ON COOLING SYSTEM
Caution!
Before working with the cooling system, be sure to confirm that
the temperature of the engine is cooled down.
Failure to observe this may cause burn.








Cooling System, Check for Leaks
Installation
1. Install commercially available coolant checking instrument onto compensation tank (Refer to section 6B;
Engine cooling).
2. Check coolant level.

Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.



Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium.
To avoid corrosion, use only anti-freeze with corrosion
protection.


Replace Coolant
1. Confirm the engine is cold enough.
2. Open the radiator cap, pour coolant to the filler neck level and close the cap.
3. Pour coolant into the reservoir until MAX line is reached.
4. Start the engine, run 2 ∼ 3 minutes at idling speed and
switch off the engine.
5. Refill coolant if the coolant level is lowered.


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ISUZU KB P190 2007

6A-64 ENGINE MECHANICAL (C24SE)
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. W hen opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7. Confirm that the temperature gauge reads half or more of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8. After the engine cools down, check the coolant level and refill it if necessary. W hen the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9. Pour coolant into the reservoir to MAX level.






Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92 °C/197.6F)

Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.

Check that cooling system self-bleeds during engine warming-
up phase.


Ignition Timing, Check
No Adjustment


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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-78 ENGINE MECHANICAL (C24SE)
Cooling System
Radiator

Type: Cross-flow

Radiator core surface in cm
2: 2000

Cooling system capacity (in litres): 8


Anti-freeze Mixture
Anti-freeze Mixture

Required
Quantity Up to-10
°
°°
°
C
Quantity in litres Up to-20
°
°°
°
C
Quantity in litres Up to-30
°
°°
°
C
Quantity in litres Up to-40
°
°°
°
C
Quantity of litres
(in litres) Water (80%) An ti -
Freeze (20%) Water
(66%) An ti -
Freeze (34%) Water
(56%) An ti -
Freeze (44%) Water
(48%) An ti -
Freeze (52%)
7.2 5.7 1.5 4.7 2.5 4.0 3.2 3.4 3.8


Cooling System (continued)
Fan

Type Visco Clutch Fan
Number of blades 5
Distribution of blades asymmetric
Diameter mm


Radiator cap

Boiling point 123°C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)


Thermostat

Start of opening 92°C
Fully opened 107°C
Type Bypassed


Idle Speeds, CO Content, Ignition
Adjustment

Applicable System Idle speed in min-1 (rpm)
Manual CO content
in vol. % Ignition timing in CA BTDC (adjustment
ensues at able speed,
ignition marks must align) with TDC sensor measuring instrument:
Closed Loop System 825 *<0.4 *** 8 to 12
Open Loop System 825
**1.0+0.2
-0.5 *** 8 to 12
Note) * CO content adjustment not applicable.
** CO content adjustment refer to Section 6E1 (W /O catalytic converter system)
*** Ignition timing adjustment not possible.

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ISUZU KB P190 2007

ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
General Description ....................................................................................................... 6B- 2
Service Precaution ......................................................................................................... 6B- 3
Diagnosis ...................................................................................................................... .. 6B- 5
Draining and Refilling Cooling System ........................................................................ 6B- 6
Water Pump .................................................................................................................... 6B- 7
Water Pump and Associated Parts .......................................................................... 6B- 7
Removal ...................................................................................................................... 6 B- 7
Inspection ................................................................................................................... 6 B- 7
Installation .................................................................................................................. 6B- 8
Thermostat ..................................................................................................................... . 6B- 9
Removal ...................................................................................................................... 6 B- 9
Inspection ................................................................................................................... 6 B- 9
Installation .................................................................................................................. 6B- 9
Fan clutch with Cooling Fan.......................................................................................... 6B- 9 Inspection and Repair ............................................................................................... 6B- 9
Radiator ....................................................................................................................... .... 6B-11
Radiator and Associated Parts ................................................................................. 6B-11
Removal ...................................................................................................................... 6 B-11
Inspection ................................................................................................................... 6 B-12
Installation .................................................................................................................. 6B-13
Main Data and Specifications ........................................................................................ 6B-13
Special Service Tool....................................................................................................... 6B- 14


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ISUZU KB P190 2007

6B-2 ENGINE COOLING
General Description
Legend
1 W ater Pump
2 Thermostat
3 Radiator
4 Reserve Tank 5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater




The Cooling System is a pressurized type, where the water
pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.


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ISUZU KB P190 2007