2007 ISUZU KB P190 Workshop Repair Manual

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Page 3137 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–2

Cooling System Pressure Testing ................................................................................................ ...................... 32

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

Page 3138 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–3

1 General Information
The cooling system for the HFV6 engine has been re-designed to accommodate this engine’s unique configuration and
engine coolin

Page 3139 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–4

1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the ris

Engine Cooling – V6 Engine Page 6B1–4

1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
1.2 Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:
• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.

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Page 3140 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–5

2 General Description
2.1 Radiator Assembly
The radiator has an aluminium core and is of the cross-flow design. Plastic side tanks are attached to the c

Engine Cooling – V6 Engine Page 6B1–5

2 General Description
2.1 Radiator Assembly
The radiator has an aluminium core and is of the cross-flow design. Plastic side tanks are attached to the core by clinch
tabs. The clinch tabs are formed as part of the core assembly.
The lower frame of the radiator assembly is attached to the vehicle frame by two bolts supported in rubber mounts, pegs
are attached to the upper area of each side tank. These pegs are used to support the radiator with two rubber insert
mounting brackets.
A high temperature rubber seal is used to seal the mating surface between the core and each side tank. The seal(s)
must be replaced any time the side tank is removed from the core.
NOTE
The radiator core side tanks or transmission oil
cooler cannot be replaced separately. If there is a
fault with any of these components, the radiator
assembly must be replaced. Small core repairs
may be made using an aluminised silicon based
liquid repair agent. Refer to 3.15 Radiator in
this Section.
For vehicles with automatic transmission, a transmission oil cooler is located in the right-hand side radiator tank. The
cooler pipes from and to the transmission are connected to the oil cooler flexible hoses by means of quick connect
fittings.
The cooling fan motor is attached by three screws to the one-piece plastic fan shroud. In turn, the fan shroud is mounted
to the rear of the radiator and is located and supported by two bolts and two locating tabs. The upper clips lock the fan
shroud in place and can be released by hand to facilitate fan shroud removal. The shroud must be removed to allow fan
motor and blade assembly removal.
One harness connector is mounted to the upper section of the fan shroud allowing the fan motor and blade assemblies
to be removed individually from the shroud. The fan motor and blade is balanced as an assembly. These two
components are serviced only as a unit and are not to be separated.
The shroud, fan assembly and transmission cooler hoses can be removed and installed individually from the vehicle. For
removal and installation procedures, refer to 3.13Cooling Fan and Shroud Assembly, 3.14 Flexible Transmission
Cooler Hose and 3.15 Radiator in this Section.

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Page 3141 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–6

Figure 6B1 – 1
Legend
1 Fan and Motor Assembly
2 Fan Shroud
3 Radiator 4 Lower Transmission Cooling Line and Seal
5 Upper Transmission Cooli

Page 3142 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–7

2.2 Cooling Fan – Standard Specification
Overview
The fan is a standard cooling system rated at 400 W atts with a blade diameter of 500 mm, which con

Page 3143 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–8

Cooling Fan and Shroud Assembly

Figure 6B1 – 3
Legend
1 Fan Harness Connector
2 Fan Shroud
3 Radiator
4 Fan Shroud Upper Support 5 Oil Cool

Engine Cooling – V6 Engine Page 6B1–8

Cooling Fan and Shroud Assembly

Figure 6B1 – 3
Legend
1 Fan Harness Connector
2 Fan Shroud
3 Radiator
4 Fan Shroud Upper Support 5 Oil Cooler, Upper Line Connection (Auto Trans Only)
6 Fan Shroud Lower Support
7 Oil Cooler, Lower Line Connection (Auto Trans Only)
8 Radiator Drain Tap
9 Fan Motor
Fan Motor
W hen the Standard Cooling Fan System is fitted to the HFV6 engine, the fan motor is 12 Volt and variable-speed. The
internal construction of the fan motor consists of two brushes and two permanent magnets. A three-wire pigtail harness is
permanently connected to the motor and is attached to the polypropylene fan shroud by integral clips moulded as part of
the fan shroud.
The enclosed fan motor housing is constructed of yellow zinc coated steel. A drain hole is located in the bottom of the
housing to allow for breathing and draining of any moisture ingress.
The fan motor rotates in an anticlockwise direction when viewed from the fan motor side.
The motor is rated at 400 W atts and drives a (500 mm) diameter fan blade at approximately 2,400 ± 240 rpm at high
speed (stage 4).
The fan and motor is balanced as a unit and the fan blade must not be separated from the motor. The fan motor and
blade are serviced only as an assembled unit. However, it should be noted that the central nut attaching the fan blade to
the motor shaft has a left-hand thread.
Fan Operation
On vehicles with HFV6 engines, the engine cooling fan motor has three terminals; one positive and one negative and
one the drive signal from the ECM. The positive terminal is permanently connected to battery voltage, via fuse SBF –3.
The cooling fan operation is enabled when the ECM via connector C – 56, pin 20 supplies a duty signal which varies
dependant on the engine temperature, vehicle speed, A/C request (where fitted) and A/C system pressure, the speed
varies from low speed (Stage 1) up to high speed (Stage 4). Refer to 6C1 – 1 Engine management general information.

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Page 3144 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Engine Cooling – V6 Engine Page 6B1–9

V6 Cooling Fan Wiring Diagram

Figure 6B1 – 4

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