2007 ISUZU KB P190 coolant reservoir

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

ENGINE COOLING 6B-13

Installation
1. Install radiator assembly, taking care not to damage theradiator core.
2. Install the radiator assembly.
3. Connect reserve tank hose.
4. Connect radiator inlet hose and outlet hose.
5. 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.
• Remove radiator cap.
• Fill with engine coolant to the radiator filler neck.
• Fill with EC to the "MAX" line on the reservoir tank.
• Start the engine with the radiator cap removed and bring to
operating temperature by running engine at 2,500 - 3,000
rpm for 30 minutes.
• By engine coolant temperature gauge reading make sure
that the thermostat is open.
• If air bubbles come up to the radiator filler neck, replenish
with engine coolant. Repeat until the EC level does not drop
any further. Install the radiator cap and stop the engine.
• Replenish engine coolant to the "MAX" line on the reservoi
r
tank and leave as it is until the engine gets cool.
•
After the engine gets cool, start the engine and make sure
there is no water running noise heard from the heater core
while the engine runs at 3000 rpm.
• Should water running noise be heard, repeat the same
procedure from the beginning.


Main Data and Specifications
General Specifications
Cooling system Engine Coolant forced circulation
Radiator Tube type corrugated (2 tube in row)
Heat radiation capacity 66.3 kcal/h
Heat radiation area 7.08 m2
Radiator front area 028 m2
Radiator dry (weight) 3.1 kg
Radiator cap valve opening pressure 93.3 – 122.7 kpa
Engine coolant capacity 3.4L
Engine coolant pump Centrifugal type
Thermostat Bypass type
Engine coolant total capacity 8lit


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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–87

3.14 Crankshaft Front Seal
Replace
1 Remove the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
2 Using a flat bladed tool (2) or seal remover, Tool No. E-308, carefully remove the crankshaft front seal (1)
from the front cover.
Figure 6A1 – 81
3 Using crankshaft front seal installer, Tool No. J-29184 (2) and a suitable hammer, install a new crankshaft
front seal (1) until fully seated against the front cover
housing.
4 Install the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
CAUTION
Do not lubricate the crankshaft front oil seal
or crankshaft balancer sealing surfaces. The
crankshaft balancer is installed into a dry
seal.
Figure 6A1 – 82
3.15 Front Cover Assembly
Remove
1 Drain the engine coolant, refer to 6B1_Engine Cooling.
2 Remove the water outlet pipe and coolant pump assembly, refer to 6B1_ Engine Cooling:
3 Remove the camshaft covers, refer to 3.12 Camshaft Cover.
4 Remove the crankshaft balancer assembly, refer to 3.13 Crankshaft Balancer Assembly.
5 Disconnect the purge vent hose from the water outlet pipe.
NOTE
Do not disconnect the power steering pipes or
drain the power steering fluid.
6 Remove the power steering pump reservoir mounting bracket, refer to 3.8 Power Steering Pump Bracket.
7 Remove the camshaft position sensor, refer to 6C1-3 Engine Management – V6 – Service Operations.

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–162

9 Remove and discard the cylinder head gasket (1).

Figure 6A1 – 276
Left-hand Side (Bank 2) Cylinder Head
1 Remove the intake manifold assembly, refer to 3.10 Intake Manifold Assembly – Complete.
2 Remove the exhaust manifold, refer to 3.11 Exhaust Manifold Assembly.
3 Remove the power steering reservoir and pump mounting brackets, refer to 3.8 Power Steering Pump Bracket.
NOTE
Do not disconnect the power steering pipes
and/or hoses.
4 Remove the oil filter adapter upper bolt. NOTE
Do not remove the oil filter adapter.
5 Remove the engine coolant temperature (ECT) sensor, refer to 6C1-3 Engine Management – V6 – Service Operations.
6 Remove engine harness ground terminal attaching bolt from cylinder head, refer to 8A Electrical Body & Chassis.
7 Remove the left-hand bank secondary timing chain, refer to 3.16 Timing Chains, Tensioners, Shoes and Guides.
8 Remove the camshaft position actuators, refer to 3.18 Camshaft Sprocket.
9 Remove the front M8 (1) cylinder head attaching bolt, two places.
10 Remove the cylinder head attaching bolt (2), eight places.
11 Remove the cylinder head (3).

Figure 6A1 – 277

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–104
Page 6A1–104
3.15 Front Cover Assembly
Remove
1 Drain the engine coolant, refer to Section 6B1 Engine Cooling.
2 Remove the water outlet pipe and coolant pump assembly, refer to Section 6B1 Engine Cooling:
3 Remove the camsha ft covers, refer to 3.12 Camshaft Cover .
4 Remove the crankshaft bal ancer assembly, refer to 3.13 Crankshaft Balancer Assembly .
5 Disconnect the purge vent hose from the water outlet pipe.
NOTE
Do not disconnect the power steering pipes or
drain the power steering fluid.
6 Remove the power steering pump reservoir mounting bracket, refer to 3.8 Power Steering Pump Bracket.
7 Remove the camshaft position sensor, refer to Section 6C1-3 Engine Management – V6 – Service Operations.
NOTE
Do not disconnect the A/C compressor pipes.

8 Remove the bolt (2), 22 places, attaching the front cover assembly (1).

CAUTION
Only use the prise points and a bolt in the
jackscrew hole to remove the engine front
cover.

9 Loosely install a 10 x 1.5 mm bolt in the jackscrew hole (1).

10 Using the prise points (2) located at the edge of the
front cover and the jackscrew, shear the RTV sealant.
Figure 6A1 – 83






Figure 6A1 – 84

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ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–1

Section 6B1
Engine Cooling – 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
1.1 WARNING, CAUTION and NOTES ..................................................................................................... ................... 4
1.2 Definition of WARNING, CAUTION and NOTE Statements ......................................................................... .. 4
WARNING defined ............................................................................................................................................. 4
CAUTION defined .............................................................................................................................................. 4
NOTE defined..................................................................................................................................................... 4
2 General Description ............................................................................................................ ...................5
2.1 Radiator Assembly .............................................................................................................. .................................. 5
2.2 Cooling Fan – Standard Specification.................................................................................................................. 7
Overview ................................................................................................................................................................. 7
Cooling Fan and Shroud Assembly ................................................................................................ .................... 8
Fan Motor ........................................................................................................................................................... 8
Fan Operation .................................................................................................................. .................................. 8
V6 Cooling Fan Wiring Diagram .................................................................................................. ....................... 9
Fan Assembly connector .................................................................................................................................. 10
2.3 Coolant Pump....................................................................................................................................................... 10
2.4 Coolant Outlet Housing ......................................................................................................... .............................. 11
2.5 Thermostat ........................................................................................................................................................... 11
2.6 Coolant Filler Cap ............................................................................................................. ................................... 13
2.7 Coolant Recovery Reservoir ..................................................................................................... .......................... 14
2.8 Engine Coolant Temperature Sensor .............................................................................................. ................... 15
3 Service Operations ...............................................................................................................................16
3.1 Service Notes ....................................................................................................................................................... 16
Safety .................................................................................................................................................................... 16
Periodic Servicing............................................................................................................. ................................... 16
Environmental Issues ........................................................................................................... ............................... 16
3.2 Coolant Maintenance ........................................................................................................................................... 17
Topping Up the Cooling System.................................................................................................. ....................... 18
Testing Coolant Concentration........................................................................................................................... 18
Method 1 – Refractometer................................................................................................................................ 18
Method 2 – Hydrometer.................................................................................................................................... 21
3.3 Draining and Filling Cooling System ............................................................................................ ..................... 22
Draining ................................................................................................................................................................ 22
Filling .................................................................................................................................................................... 22
3.4 Cleaning Cooling System ........................................................................................................ ............................ 25
Cooling System Reverse Flush ................................................................................................... ....................... 25
Radiator............................................................................................................................................................ 25
Engine .............................................................................................................................................................. 26
Heater Hoses and Core.......................................................................................................... .......................... 27
3.5 Drive Belt Tension ............................................................................................................................................... 28
Inspect .................................................................................................................................................................. 29
3.6 Coolant Hoses ...................................................................................................................................................... 30
3.7 Pressure Testing ............................................................................................................... ................................... 31
Coolant Filler Cap Pressure Testing ............................................................................................ ...................... 31

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Engine Cooling – V6 Engine Page 6B1–2

Cooling System Pressure Testing ................................................................................................ ...................... 32
3.8 Thermostat ........................................................................................................................................................... 34
Remove ................................................................................................................................................................. 34
Test ....................................................................................................................................................................... 37
Dismantle ...................................................................................................................... ........................................ 37
Reassembly .......................................................................................................................................................... 37
Install .................................................................................................................................................................... 38
3.9 Coolant Recovery Reservoir ..................................................................................................... .......................... 39
Remove ................................................................................................................................................................. 39
Inspect .................................................................................................................................................................. 39
Install .................................................................................................................................................................... 39
3.10 Coolant Pump................................................................................................................... .................................... 40
Remove ................................................................................................................................................................. 40
Inspect .................................................................................................................................................................. 43
Reinstall ................................................................................................................................................................ 43
3.11 Coolant Outlet Housing ......................................................................................................... .............................. 45
Remove ................................................................................................................................................................. 45
Reinstall ................................................................................................................................................................ 46
3.12 Coolant Inlet Pipe............................................................................................................. .................................... 46
Remove ................................................................................................................................................................. 46
Install .................................................................................................................................................................... 48
3.13 Cooling Fan and Shroud Assembly ................................................................................................ ................... 48
Remove ................................................................................................................................................................. 48
Install .................................................................................................................................................................... 50
Disassemble ......................................................................................................................................................... 51
Reassemble .......................................................................................................................................................... 51
3.14 Flexible Transmission Cooler Hose .............................................................................................. ..................... 51
Replace ................................................................................................................................................................. 51
Reinstall ................................................................................................................................................................ 53
3.15 Radiator ....................................................................................................................... ......................................... 54
Remove ......................................................................................................................... ........................................ 54
Reinstall ................................................................................................................................................................ 56
Radiator Repair Procedure...................................................................................................... ............................ 57
Repairable Leaks ............................................................................................................................................. 57
Repair Method.................................................................................................................................................. 58
Tube Blocking................................................................................................................................................... 58
Header Repair .................................................................................................................. ................................ 58
General Core Repair ............................................................................................................ ............................ 59
Transmission Oil Cooler Leak Test .............................................................................................. .................... 60
Transmission Oil Cooler Seal Replacement. ...................................................................................... .............. 60
4 Engine Cooling System Diagnosis .....................................................................................................61
4.1 Poor Heater Operation......................................................................................................................................... 61
4.2 Leaking Cylinder Head Gasket ................................................................................................... ........................ 61
4.3 Question the Customer ....................................................................................................................................... 61
4.4 Diagnostic Chart .................................................................................................................................................. 61
4.5 Problems Not Requiring Disassembly of Cooling System ........................................................................... .... 63
4.6 Problems Requiring Disassembly of Cooling System ...................................................................................... 63
4.7 Black Light and Dye Leak Diagnosis Method .................................................................................................... 63
5 Specifications .......................................................................................................................................64
6 Torque Wrench Specifications................................................................................................... .........66
7 Special Tools ........................................................................................................................................67

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ISUZU KB P190 2007