2007 ISUZU KB P190 check engine

6A-2 ENGINE MECHANICAL (C24SE)
PAGE
Camshaft Housing, Check for Plance Surface ......................................................... 6A-39
Cylinder Head, Removal and Installation.................................................................. 6A-39
Cylinder Head, Disassemble and Assemble............................................................. 6A-42
Valve, Grind ................................................................................................................. 6 A-44
Valve Guide, Ream .................................................................................................... 6A-44
Valve Seating, Mill ...................................................................................................... 6A-45
Cylinder Head, Overhaul ............................................................................................ 6A-45
Flywheel....................................................................................................................... 6A-46
Starter Ring Gear(Manual Transmission) ................................................................. 6A-47
Seal Ring, Crankshaft................................................................................................. 6A-48
Seal Ring, Crankshaft Rear ........................................................................................ 6A-48
Oil Pan and Bearing Bridge ....................................................................................... 6A-49
OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51 Con-Rod Bearing ........................................................................................................ 6A-51
Piston with Con-Rod................................................................................................... 6A-51
Con-Rod....................................................................................................................... 6A-52
Pistion Rings ............................................................................................................... 6A -53
OPERATIONS ON REMOVED ENGINE........................................................................... 6A-55 Crankshaft ................................................................................................................... 6 A-55
Bearing Free Play Measurement ............................................................................... 6A-57
Plastigage Method ...................................................................................................... 6A-57
Micrometer and gauge method.................................................................................. 6A-58
Bypass Valve ............................................................................................................... 6A- 59
Oil Filter ..................................................................................................................... .. 6A-59
Oil Pump ...................................................................................................................... 6A-59
Oil Pump Safety Valve ................................................................................................ 6A-60
Oil Pump(Overhaul) .................................................................................................... 6A-60
OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61 Cylinder Head Safety Valve ........................................................................................ 6A-61
OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63 Cooling System, Check for Leakes ........................................................................... 6A-63
Cooling System, Fill Up and Bleed ............................................................................ 6A-63
Refill Coolant............................................................................................................... 6 A-64
Ignition Timing, Check ............................................................................................... 6A-64

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-15
Engine Specification Matrix for destination
04 HEO FOR TF MODEL:
VEHICLE MODEL TFR/S 2.4L
Major Description
AUSTRALIA, CHILE,
GULF, NEW
ZEALAND, SAUDI ARABIA, SOUTH AFRICA COLOMBIA, COSTA
RICA, EQUADOR, GUATEMALA BOLIVIA, GENERAL
EXPORT, PERU, VENEZUELA
VEHICLE TYPE 4× 2 4x4 4 ×2 4 ×4 4 ×2
VEHICLE IDENT. CODE TX TY TX TY TX

ENGINE TYPE C24SE ← ←

FUEL CONTROL SYSYTEM CLOSE LOOP CLOSED LOOP OPEN LOOP

COMPRESSION RATIO 9.6:1 ← ←

FUEL OCTANE(ROD) 91RON 85RON 80RON

FUEL TYPE UN-LEADED UN-LEADED LEADED

HO2 YES YES YES NO

EVAP CANISTER YES YES YES YES
PURGE CONTROL
SOLENOID YES
YES YES YES
CHECK & RELIEF VALVE YES YES YES YES

ECM YES YES YES YES

EXHAUST SYSTEM
FRONT PIPE
SILENCER
TW C YES YES YES NO

CO ADJUSTMENT NO NO NO YES
Refer to 6A-77 Refer to 6A-77 Refer to 6A-77


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ISUZU KB P190 2007

6A-20 ENGINE MECHANICAL (C24SE)






6. Install power steering pump and V-belt.

Adjust
Adjust power steering pump V-belt tension according to the
corresponding operation.


Installation
7. Install radiator according to the corresponding operation.
8. Install air inlet hose.
9. Install all electrical cable connections, hoses and lines to engine.
10. Install accelerator cable from inlet pipe.
11. Install bonnet.


Inspection
1. Check engine oil level.
2. Fill up cooling system and bleed according to the corresponding operation.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-21
Toothed Belt and Timing Check



Removal
1. Remove the belts on the bracket for alternator.
2. Remove the fan.
3. Remove the V-belt for power steering.
4. Remove the V-belt for A/C.
5. Remove the fan belt.
6. Remove the fan shroud.


7. Remove the crankshaft pulley while counterholding on
the fastening bolt of toothed belt drive gear.
8. Remove the toothed belt from cover.

Inspection
1. Turn the crankshaft in the engine rotational direction mark(2) so that the notch (1) on the camshaft gear aligns
with the mark on toothed belt rear cover.
2. Check the timing belt for worn, cracks or oil adhesion.

3. Check that the cast on the water pump aligns with the counterpart on cylinder block (arrowed).
4. The tension of a toothed belt is correctly adjusted when the pointer and the center of the notch are aligned(I).
The tension of a run-in toothed belt (regardless of
mileage covered) is correctly adjusted when the pointer
is positioned approx. 4mm (0.16 in.) to the left of the
center of the notch(II).
Check the condition of the run-in toothed belt for
suitability for reuse. Only toothed belts of the toothed
belt tension rollers must be replaced and the source of oil
contamination must be eliminated.

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-23
Toothed Belt Tension, Adjust
(Engines with toothed belt tension
roller)
Removal
Refer to 6A-21. Toothed Belt and Timing check and removal
steps.


Adjust
1. Loosen the fastening bolt of the toothed belt tension roller.
2. Turn the toothed belt tension roller at adjustment eccentric (1) in the direction of arrow (counterclockwise),
until pointer (2) comes to the right stop.
3. If necessary tighten the fastening bolt of toothed belt tension roller.


4. Rotate the crankshaft twice (720
°) in the engine
rotational direction until marks (2) and (1) align again.


5. Turn the eccentric in the direction of arrow (clockwise)
until pointer (1) and notch (2) are positioned to suit age of
toothed belt.
6. Rotate the crankshaft twice (720 °) in the engine
rotational direction again and correct adjustment if
necessary.

Installation
Refer to 6A-21. Toothed Belt and Timing check and installation
steps.


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ISUZU KB P190 2007

6A-28 ENGINE MECHANICAL (C24SE)


2. Install cable to temperature sensor.
3. Install upper bolts of rear toothed belt rear cover.
4. Install camshaft timing gear then check timing according to the corresponding operation.
5. Install camshaft housing cover.
6. Install toothed belt and front cover.
7. Fill up and bleed cooling system according to the corresponding operation.


Tighten (Torque)
Thermostat housing to cylinder head - 15 N ⋅m/1.5 kgf ⋅m.




Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation “Toothed Belt, Replace”.

Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.


Removal
Screw self-tapping screw into seal ring.

Edge out seal ring.

Installation
Lightly coat sealing lip of seal ring with protective grease.

Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-33
HYDRAULIC VALVE LIFTER

1. Hydraulic Valve Lifter

1. Oil reservoir
2. Piston with ball head (moving)
3. Pressure cylinder (fixed)
4. Check ball
5. Pressure chamber
6. Oil feed



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ISUZU KB P190 2007

6A-36 ENGINE MECHANICAL (C24SE)



















Clean
All sealing surfaces, drill holes in cylinder head bolts.

Check cylinder block and cylinder head for plane surface
according to the corresponding operations.

Installation
1. Install cylinder head sealing with marking "OBEN/TOP"
facing upwards and to right side of engine.
2. Install cylinder head on cylinder block.
3. Install hydraulic valve lash adjuster, pressure parts and rocker arm - molybdenum disulphate paste.
4. Install camshaft housing-Sealing Compound TB-1207C or equivalent.

Important!
Use new cylinder head bolts.
Screw in bolts until they rest on cover.




Torque - Angle Method
Cylinder head to cylinder block - 25 N ⋅m (2.5 kgf ⋅m)
Further turn angle 90 °+90 °+ 90 °.
Tighten cylinder head bolts from inside outwards. In four
stages in a spiral pattern.








5. Install rear toothed belt cover onto camshaft housing.
6. Install toothed belt and apply tension according to the corresponding operation.

Tighten (Torque)
Camshaft timing gear to camshaft - 45 N ⋅m (4.6 kgf ⋅m)




7. Install camshaft housing cover and front toothed belt
cover.
8. Install cable connections, all hoses and lines onto cylinder head.
9. Adjust accelerator cable for free of play.
10. Install V-belt according to the corresponding operation.
11. Install air intake hose.
12. Install front exhaust pipe.
13. Install ground cable onto battery.
14. Fill up cooling system and bleed according to the corresponding operation.

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ISUZU KB P190 2007