2007 ISUZU KB P190 service

Engine Cooling – V6 Engine Page 6B1–62


Refer to 3.1 Service Notes in this Section, for
important safety items before removing the
coolant filler pressure cap or servicing the
system.

The cooling system is designed to operate at
120 –
––
–
130 kPa and a maximum temperature
not above 130 °
°°
°
C.
Cooling System Diagnosis
Step Action Result Yes No
1
Check Temperature gauge reading High Temp.
Low Temp. Go to Step 2
Go to Step 6 –
2
Check drive belt condition and tension. Refer to 6A1
Engine Mechanical. To Specification Go to Step 3 Replace drive
belt or
tensioner.
3 Check coolant Boiling Go to Step 4 Go to Step 5
4 Check coolant level. Refer to 3.2 Coolant
Maintenance in this Section. Low Go to Step 10 Go to Step 6
5
Check coolant filler cap. Refer to 3.7 Pressure
Testing – Coolant Filler Cap Pressure Testing in this
Section OK? Go to Step 8
Replace
Coolant filler
cap
6 Check thermostat. Refer to 3.8 Thermostat in this
Section. OK? Go to Step 9 Go to Step 13
7
Check Engine Coolant Temperature (ECT) sensor.
Refer to 6C1 Engine Management General Information. Faulty Replace Go to Step 12
8
Check cooling fan operation. Refer to 6C1 Engine
Management General Information. Operational Go to Step 10 Repair
9
Check for collapsed upper or lower radiator hose. Collapsed Replace Go to Step 13
10 Visual system check Leaks Go to Step 13 Go to Step 11
11 Check coolant concentration. Refer to 3.2 Coolant
Maintenance. To Specification Go to Step 12 Correct
Concentration Level
12 Check radiator core for bent fins, dirt, bugs or other
obstructions. Obstructed Clean or
straighten Go to Step 14
13
Pressure Test cooling system. Refer to 3.7 Pressure
Testing in this Section. Leaks Repair System OK
14
If none of the above require repair, the problem is
complex or of a major nature.
Refer to 4.5 Problems Not Requiring Disassembly of
Cooling System or 4.6 Problems Requiring Disassembly
of Cooling System. – – –

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Engine Cooling – V6 Engine Page 6B1–63

4.5 Problems Not Requiring Disassembly of
Cooling System
1 Large obstructions blocking radiator or condenser airflow.
• Auxiliary oil coolers
• License plate
• Obstruction of radiator grille, for example, driving lights or mud
2 Loose, damaged or missing air chute side panels.
3 Missing or damaged air baffle.
4 Cracked or loose coolant recovery system hose.
5 Leaking heater component such as the heater core or water valve.
4.6 Problems Requiring Disassembly of Cooling System
1 Damaged cooling fan or faulty motor operation.
2 Pressure test cooling system.
3 Defective coolant pump.
• Eroded or broken impeller vanes
• Failed bearing or seal – check for shaft or bearing end play
4 Internally blocked radiator core.
5 Obstruction of coolant recovery system.
6 Internal system leaks.
• Head gaskets
• Cracked cylinder block
• Engine front cover
• Intake manifold gaskets
7 Blocked coolant passages in cylinder heads or block – remove cylinder heads and check.
4.7 Black Light and Dye Leak Diagnosis Method
It is strongly recommended that this diagnostic method be used to diagnose fluid leaks. This method is a proven and
reliable method that identifies the specific leak source.
The black light kit can be used for the leak detection of a number of fluids, when used with the appropriate tracer dye.
Examples are: Coolant, Engine Oil, Automatic Transmission Fluid and Air Conditioning Refrigerant (R134A).
The following is a summary of the steps involved in detecting a cooling system fluid leak using black light and dye:
1 Pour specified amount of dye into the cooling system via the coolant filler cap on the outlet housing. Refer 3.1 Service Notes in this Section.
2 Road test the vehicle under normal operating conditions.
3 Direct the light towards the suspect area. The fluid leak will appear as a brightly coloured path leading from the source.
4 Repair fluid leak and recheck to ensure that leak has been rectified.
5 Refer to the manufacturer’s directions when using this method.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 1

6C
Fuel System – 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
Description ............................................................................................................................................................. 3
Service Precautions............................................................................................................................................... 3
1.1 WARNING, CAUTION and NOTES ..................................................................................................... ................... 4
Definition of WARNING, CAUTION and NOTE Statements ............................................................................. .... 4
WARNING defined ............................................................................................................................................. 4
CAUTION defined .............................................................................................................................................. 4
NOTE defined..................................................................................................................................................... 4
2 System Components .............................................................................................................. ................5
Fuel System ............................................................................................................................................................ 5
Description ......................................................................................................................................................... 5
Fuel Pump............................................................................................................................................................... 6
Single Turbine Fuel Pump ....................................................................................................... ........................... 6
Fuel Flow ................................................................................................................................................................ 7
3 System Checks .......................................................................................................................................8
3.1 Fuel Pump Flow Test ............................................................................................................................................. 8
3.2 Fuel Pressure Test ................................................................................................................................................. 8
Gauge Installation .................................................................................................................................................. 8
Test ......................................................................................................................................................................... 9
Removal .................................................................................................................................................................. 9
3.3 Fuel Leak Test ...................................................................................................................................................... 10
3.4 Fuel System Depressurisation................................................................................................... ......................... 11
Repressurise ........................................................................................................................................................ 12
4 Service Operations ...............................................................................................................................13
4.1 Fuel Lines And Quick Connect Fittings .......................................................................................... ................... 13
Description ........................................................................................................................................................... 13
Leak Test and Inspection .................................................................................................................................... 13
Removal ................................................................................................................................................................ 14
Reinstall ................................................................................................................................................................ 15
4.2 Fuel Filter.............................................................................................................................................................. 15
Removal ........................................................................................................................ ........................................ 15
Inspection ............................................................................................................................................................. 16
Reinstallation ................................................................................................................. ...................................... 16
4.3 Fuel Tank and Pump Assembly .................................................................................................... ...................... 17
4.4 Fuel Tank Assembly ............................................................................................................................................ 18
Remove ................................................................................................................................................................. 19
Reinstall ................................................................................................................................................................ 22
4.5 Modular Fuel Pump and Sender Assembly .......................................................................................... ............. 23
Remove ................................................................................................................................................................. 23
Fuel Level Sender Assembly ..................................................................................................... ......................... 26
Test .................................................................................................................................................................. 26
Reinstall ................................................................................................................................................................ 26

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 2

4.6 Evaporative Emission Control Canister............................................................................................................. 27
Remove ................................................................................................................................................................. 27
Service Check .................................................................................................................. .................................... 28
Reinstall ................................................................................................................................................................ 29
4.7 Fuel Tank Siphon Procedure ..................................................................................................... ......................... 30
4.8 Fuel Filler Cap ...................................................................................................................................................... 32
Remove ................................................................................................................................................................. 32
Inspection ......................................................................................................................................................... 32
Reinstall ................................................................................................................................................................ 32
4.9 Fuel Lines ..................................................................................................................... ........................................ 33
Remove ................................................................................................................................................................. 33
Fuel Tank Lines ................................................................................................................ .................................... 34
Reinstall ................................................................................................................................................................ 34
Fuel Line Routing.............................................................................................................. ................................... 35
Bell Housing Fuel Lines ........................................................................................................ .............................. 36
Engine Bay Fuel Lines......................................................................................................................................... 36
4.10 Rollover Valve ...................................................................................................................................................... 37
5 Specifications .......................................................................................................................................38
6 Torque Wrench Specifications................................................................................................... .........39
7 Special Tools ........................................................................................................................................40



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 3

1 General Information
Description
Fuel is injected into the engine by separate fuel injectors that are mounted in the intake manifold (common chamber).
Fuel is supplied to the injectors under pressure from the fuel tank through the fuel lines and the fuel rail, which is
attached to the top of the common chamber.

A fuel pressure control valve is installed on the fuel rail to maintain fuel line pressure across the injectors under all
operating conditions. Fuel pressure is maintained by controlling the amount of fuel that is supplied from the fuel tank,
based on the demand of the engine via the engine control module (ECM).

Two interchangeable “O” rings are used on the fuel injector and must be replaced when the injectors are removed.
The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution.
The ECM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions.
The V6 engine is designed to use only unleaded petrol.

Unleaded petrol must be used for correct emission control system operation and its use will also minimize spark plug
fouling and extend engine oil life.

Using leaded petrol can damage the emission control system and could void the vehicle warranty. All vehicles are
equipped with an Evaporative Emission Control System. The purpose of the system is to minimize the escape of fuel
vapours into the atmosphere.
Service Precautions
• Use extreme care when working on the fuel system and follow all safety precautions.
• W hen working on the fuel system, disconnect the battery ground cable except for tests where battery voltage is
required.
• Always keep a dry chemical (class B) fire extinguisher near the work area.
• Relace all fuel lines and fittings with the same type of line and fitting as those removed.
• Clean and inspect “O” rings carefully and replace if required.
• Always depressurize the fuel lines before servicing any fuel system components.
• Do not attempt any repairs on the fuel system until, all warnings and instructions, relating to that repair have been
read and ensure all notices and cautions are adhered to.
• Do not allow any naked frames or sparks near the work area when working on the fuel system.
• If draining of the fuel system is required, this should be done in a well ventilated area.
• Protect the fuel lines and associated parts from thermal damage, spattering when welding.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 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.
GM HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these
instructions.
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. GM 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.



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 9


A small amount of fuel may be released when
connecting the fuel pressure gauge to the fuel
pressure test point. Cover the fittings with a
shop towel to absorb any fuel spillage before
connecting the fuel pressure gauge. After the
fuel pressure test procedure, place the soiled
towel in an approved container for disposal.
3 At the fuel pressure test point, remove the Schrader valve sealing cap.
4 Connect the fuel pressure gauge (1) (tool No. J 34730–1A) to the fuel gauge Schrader fitting
adapter (2) (tool No. AU453), then install to the fuel
pressure test port (3). W rap a shop towel around the
fitting while connecting the fuel pressure gauge to
avoid and/or capture any fuel spillage.
5 Route the bleed hose of the fuel gauge into an approved fuel container.


Figure 6C – 5

After connecting the fuel pressure gauge and
pressurising the fuel system, inspect for fuel
leaks at the fuel pressure gauge and the fuel
pressure test point.
6 Either: Using Tech 2, enable the fuel pump to pressurise the fuel system, refer to 0C Tech 2. Inspect for fuel leaks at the
fuel pressure gauge and fuel pressure test point, then bleed the air from the fuel pressure gauge.
or: Reinstall the fuel pump relay and fuel pump fuse, then open the fuel gauge bleed valve (4) to bleed the air from the
fuel pressure gauge, refer to Figure 6C – 5.
7 Remove and place the soiled shop towel in an approved container.
Test
1 Start the engine and record the fuel pressure.
2 Turn the ignition switch off.
3 If required, perform any tests and/or diagnostic procedures:
• For the fuel system leak test, refer to 3.3 Fuel Leak Test.
• For the fuel injector leak-down test (for vehicles fitted with a V6 engine, refer to 6C1-3 Engine Management –
V6 – Service Operations.
4 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
Removal
1 Turn the ignition switch off.
2 Depressurise the fuel system, refer to 3.4 Fuel System Depressurisation.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

Fuel System – V6 Page 6C – 10


After relieving the fuel system pressure, a
small amount of fuel may be released when
servicing the fuel lines or connections. Cover
the fittings with a shop towel before
disconnecting. This catches any leaking fuel.
Place the soiled towel in an approved
container when disconnection is completed.
3 W rap a shop towel around the fuel pressure test point to absorb any fuel spillage.
4 Remove the fuel pressure gauge and drain any fuel remaining in the fuel pressure gauge into an approved fuel container.
5 Remove the soiled shop towel and place in an approved container.
6 Repressurise the fuel system, refer to 3.4 Fuel System Depressurisation.
7 Road-test the vehicle and check for correct operation.
3.3 Fuel Leak Test

After installing any fuel system component
and before starting the engine, check the fuel
system for leaks.
NOTE
For the fuel injector leak-down test (for vehicles
fitted with a V6 engine), refer to 6C1-3 Engine
Management – V6 – Service Operations.
1 Turn the ignition switch on for two seconds.
2 Turn the ignition switch off for 10 seconds.
3 Turn the ignition switch on.
4 Check for fuel leaks, particularly at points marked z (that is, quick-connect fittings, fuel rails, fuel injectors,
Schrader valve and evaporative emission control canister purge solenoid, refer to Figure 6C – 6.

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007