2007 ISUZU KB P190 check engine

ENGINE MECHANICAL (4JK1/4JJ1) 6A-141
Functional Check
Oil pressure check
1. Check whether the engine oil is contaminated with
dirt, light oil, or water. If contaminated with dirt,
light oil, or water (after examining the cause and
taking the appropriate measures for light oil o
r
water contamination), replace the oil.
2. Check the engine oil level. The oil level should be between the two holes of the level gauge. If the oil
level is insufficient, replenish it.
3. Remove the oil pressure switch on the nipple.
4. Install the oil pressure gauge on the nipple.






RTW 56ASH015501
Legend
1. Oil Pressure Switch

5. W arm the engine.
6. Measure the oil pressure, to check whether it is more than 400 kPa (4 kg/cm
2 / 58 psi) at 3600
rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure switch.
10. Start the engine and check for oil leakage.
Engine oil
•
Ensure the car is on level ground. Before starting
the engine or when 30 minutes or more have
elapsed after stopping the engine, check the
engine oil volume using the level gauge. The
volume is appropriate if the engine oil is between
the upper and lower limits of the level gauge.
Replenish the engine oil, if level is below the lowe
r
limit. Also, check for contamination of the engine
oil.




RTW 56ASH015601







RTW 56ASH015701
Legend
1. Lower Limit
2. Upper Limit



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ISUZU KB P190 2007

6A-160 ENGINE MECHANICAL (4JK1/4JJ1)
• Install the gasket in the slot of the gear case
cover.
• Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)





RTW 56ASH012101
3. Install the crank pulley.
• Tighten the bolts to the specified torque.
Tightening torque: 294 N ⋅
⋅⋅
⋅
m (30.0 kg ⋅
⋅⋅
⋅
m / 217 lb ft)
4. Install the noise cover to the timing chain cove
r
lower.
• Tighten the bolts to the specified torque.
Tightening torque: 10 N ⋅
⋅⋅
⋅
m (1.0 kg ⋅
⋅⋅
⋅
m / 87 lb in)
5. Install the vacuum pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the oil pipe (feed side and return side) o
f
vacuum pump.
• Install the vacuum pipe bracket and vacuum
pipe.
6. Install the power steering pump. • Tighten the nuts to the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)
• Install the bracket of power steering oil hose
clip (1).






LTW 56ASH000101
7. Install the lower fan shroud.
8. Install the fan drive belt and pulley. • Install the fan drive belt with the fan pulley.
9. Install the fan and fan clutch. • Tighten the bolts to the specified torque.
Tightening torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kg ⋅
⋅⋅
⋅
m / 69 lb in)
10.
Adjust the drive belt of generator and A/C
compressor.
• Apply tension to the fan drive belt by moving
the generator.
•
Apply a force of 98 N (10 kg / 22 lb) to the drive
belt mid portion to check the drive belt
deflection.
Generator drive belt deflection mm (in)
New belt 5 - 6 (0.20 – 0.24)
Reuse belt 7 - 8 (0.28 – 0.31)

A/C compressor drive belt deflection mm (in)
New belt 6 - 7 (0.24 – 0.28)
Reuse belt 8 - 9 (0.31 – 0.35)
11. Install the upper fan shroud.
12. Install the radiator upper hose.
13. Replenish the engine coolant.

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ISUZU KB P190 2007

6A-162 ENGINE MECHANICAL (4JK1/4JJ1)
Removal
1. Remove the oil pressure SW .
2. Remove the nipple; oil gallery.
3. Remove the nipple; oil pressure warning SW and gasket.
Inspection
Check the continuity between the switch terminal and
the body grounding in a no-load condition.
If there is no connectivity, replace with normal parts.





LNW 21HSH003301

Circuit check
1. Turn the starter switch to ON.
2. Disconnect the oil pressure switch connector, and confirm that the oil pressure-warning lamp lights
when the connector on the harness side is
grounded.
If the warning lamp does not light up, check the circuit between the meter and the oil pressure
switch, and repair the disconnected locations.






LNW 21HSH003401
Installation
1. Install the nipple; oil gallery, oil pressure warning
SW and gasket.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m/18 lb ft)
2. Install the Nipple. Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)
3. Install the oil pressure SW . Tightening torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kg ⋅
⋅⋅
⋅
m/11 lb ft)


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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS

Main Data and Specifications ............................. 6B-2
General Description............................................ 6B-3 Coolant Flow ................................................... 6B-3
W ater Pump .................................................... 6B-4
Thermostat ...................................................... 6B-4
Radiator ........................................................... 6B-5
Antifreeze Solution .......................................... 6B-5
Diagnosis............................................................ 6B-6
Draining and Refilling Cooling System ............... 6B-7
W ater Pump ....................................................... 6B-8 Removal .......................................................... 6B-8
Inspection and Repair ..................................... 6B-9
Installation ....................................................... 6B-9
Thermostat ......................................................... 6B-11 Removal .......................................................... 6B-11
Inspection and Repair ..................................... 6B-11
Operating Test of Thermostat ......................... 6B-11
Installation ....................................................... 6B-12

Radiator .............................................................. 6B-13 Radiator and Associated Parts........................ 6B-13
Removal .......................................................... 6B-14
Inspection and Repair ..................................... 6B-15
Radiator Cap ................................................... 6B-15
Radiator Core .................................................. 6B-15
Flushing the Radiator ...................................... 6B-15
Cooling System Leakage Check ..................... 6B-15
Installation ....................................................... 6B-16
Engine Coolant Change .................................. 6B-16
Fan Clutch with Cooling Fan .............................. 6B-17 Inspection and Repair ..................................... 6B-17
Special Tools................................................... 6B-18

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-7
Draining and Refilling Cooling System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
“MIN" and “MAX" lines of the reserve tank when the
engine is cold. If low, check for leakage and add EC up
to the “MAX" line.
There should not be any excessive deposit of rust o
r
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.

1. Remove the radiator skid plate.
2. Completely drain the cooling system by opening the drain plug at the bottom of the radiator.




RTW 56BSH000301
3. Remove the radiator cap.
WARNING:
To avoid the danger of being burned, do not
remove the cap while the engine and radiator are
still hot. Scalding fluid and steam can be blown out
under pressure.
4. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water,
then drain it. Install the reserve tank and hoses.

5. Refill the cooling system with the EC using a
solution that is at least 50 percent antifreeze.

Procedure for filling with coolant (in case of full change).
• Make sure that the engine is cool.
• Open radiator cap and pour coolant up to fille
r
neck.
• Pour coolant into reservoir tank up to “MAX" line.
• Tighten radiator cap and start the engine. Afte
r
idling for 2 to 3 minutes, stop the engine and
reopen the radiator cap. If the water level is lower,
replenish.
WARNING:
When the coolant is heated to a high temperature,
be sure not to loosen or remove the radiator cap.
Otherwise you might get scalded by hot vapor o
r
boiling water. To open the radiator cap, put a piece
of thick cloth on the cap and loosen the cap slowly
to reduce the pressure when the coolant has
become cooler.
• After tightening the radiator cap, warm up the
engine at about 2000 rpm. Set heater adjustment
to the highest temperature position, and let the
coolant circulate also into heater water system.
• Check to see the thermostat has opened through
the needle position of the water thermometer,
conduct a 5–minute idling again and stop the
engine.
• W hen the engine has been cooled, check fille
r
neck for water level and replenish if required.
Should extreme shortage of coolant be found,
check the cooling system and reservoir tank hose
for leakage.
• Pour coolant into the reservoir tank up to “MAX"
line.

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ISUZU KB P190 2007

ENGINE COOLING (4JK1/4JJ1) 6B-9
Inspection and Repair
The water pump is not disassembled type.
Make necessary parts replacement if extreme wear o
r
damage is found during inspection. Should any of the
following problems occur, the entire water pump
assembly must be replaced.
• Cracks in the water pump body.
• Coolant leakage from the sealed unit.
• Excessive radial play or abnormal noise in the fan
center when rotated by hand.
• Excessive thrust play in the fan center (Standard
play: less than 0.2 mm (0.0078 in)).
• Cracks or corrosion in the impeller.
Installation
1. W ater Pump





RTW 56BSH000201
a. Install the water pump with a new gasket.
b. Tighten bolts and nuts to specified torque.
Water Pump Nut/Bolt Torque: 25 N·m (2.5 kg·m /18 lb ft)

2. Fan Drive Belt and Pulley and Fan and Fan Clutch.






RTW 56ASH025401
a. Install the fan drive belt and fan pulley and fan
and fan clutch.
b. Tighten the nuts to specified torque.
Fan Clutch Nut Torque: 8 N·m (0.8 kg·m /69 lb in) c. Apply tension to the fan drive belt by moving the generator.
d. Apply a force of 98 N (10 kg/22 lb) to the drive belt mid-portion to check the drive belt
deflection.
Fan Drive Belt Deflection mm (in)
New belt 5 - 6 (0.20 – 0.24)
Reuse belt 7 - 8 (0.28 – 0.32)
3. Upper Fan Shroud
4. W ater Outlet Pipe.
a. Install the water outlet pipe 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.

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ISUZU KB P190 2007

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

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