2007 ISUZU KB P190 lock

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

ENGINE MECHANICAL (C24SE) 6A-65
ENGINE EXTERNAL PARTS
Radiator


Removal
1. Disconnect battery ground cable.
2. Loosen a drain plug to drain EC.
3. Disconnect radiator inlet hose and outlet hose from the engine.






RTW 46BSH000101
4. Remove fan guide(1), clips(2) on both sides and the
bottom lock, then remove lower fan guide(3) with fan
shroud(4).
5. Disconnect the reserve tank hose(6) from radiator.




RTW 36BMH000101
6. Remove bracket(5).

7. Lift up and remove the radiator assembly with hose,
taking care not to damage the radiator core with a fan
blade.


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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

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-82 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block
Cylinder Grinding and Piston Dimensions
Size Cylinder bore dia. in mm Cylinder to Related piston dia. in mm Piston head
Crankshaft co- efficient
housing
co-efficient
over to over to
Production
(2.4L) 1 87.48
87.49 87.49
87.50 99
00 87.46
87.47 87.47
87.48 99
00
Customer service (2.4L) - 87.99 88.00 0+0.5 87.97 87.98 7+0.5
Piston diameter must be measured at the position "D".
*inclusive


Cylinder Bore
Rebore cylinder Permissible oversize to 0.5mm (see parts
microfiche)

After reboring, invalidate original crankcase
housing coefficient and drive in new oversize
coefficient

Permissible out-of-round: 0.013mm
Permissible taper: 0.013mm
Measure out-of-round in bore at 4 different
heights
Piston projection above upper edge of cylinder block 0.40mm

Piston
Type Recessed pistons

Clearance For short-blocks and cylinder blocks with complete pistons, the clearance is 0.02 to
0.04mm

For replacement (oversize), depending on
available pistons, a clearance of 0.02 to
0.04mm is permissible

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ENGINE MECHANICAL (C24SE) 6A-83
Crankshaft, Cylinder Block (continued)
Piston Rings
2.4L
Square ring Height mm 1.2

Tapered ring Height mm 1.5

Oil scraper Height mm 2.5

Ring gap offset 180 °

Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.

Piston Pin

Length mm 61.5
Diameter mm 21
Type Shrunk into con-rod
Play mm 2.4L
in piston 0.010-0.015
in con-rod none
Installation W hen installing piston pins,
heat con-rods to approx.
280 °C in oil bath. This
temperature should under no
circumstances be exceeded.


Crankshaft, Cylinder Block (continued)
The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.


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ISUZU KB P190 2007

6A-84 ENGINE MECHANICAL (C24SE)
Crankshaft, Cylinder Block (continued)

Crankshaft jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
Normal size
Bearing journal and colour code from 57.9820 green
to 57.9885
> 57.9885 brown
to 57.9950
25.900
25.850
48.988
48.970
26.580
26.460
26.390
26.338

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown-662N
green-663N brown-655N
green-658N

Crankshaft
jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.25mm Undersize for Production and Customer Service
Bearing journal and colour code from 57.7320 green/
to 57.7385 blue
> 57.7385 brown/
to 57.7450 blue
26.100
26.050
48.738
48.720
26.580
26.460

Bearing shell identification mark Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown/blue-664 A
green/blue-655 A brown/blue-657 A
green/blue-658 A

Crankshaft jounal
I, II, IV, V Guide
bearing III Con-rod journal
1 to 4 Con-rod width
Diameter
mm Widtht
mm Diameter
mm Width
mm
mm
0.50mm Undersize Customer Service
Bearing journal and colour code from 57.4820 green/
to 57.4885 blue
> 57.4885 brown/
to 57.4950 blue
26.300
26.250
48.488
48.470
26.580
26.460

Bearing shell identification mark
Colour code and embossed Crankshaft bearing
I, II, IV, V Guide bearing
III Con-rod bearing
1 to 4
Identification mark
brown/white-666 B
green/white-667 B brown/blue-659 B
green/blue-660 B








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ISUZU KB P190 2007