2007 ISUZU KB P190 belt

ENGINE MECHANICAL (C24SE) 6A-1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
General Description ........................................................................................................ 6A- 4
ENGINE PICTORIAL .................................................................................................... 6A- 6
Main Data and Specification ........................................................................................... 6A-11 CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16
ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17
OPERATIONS ON ENGINE AGGREGATES.................................................................... 6A-18 Engine Damping Blocks(Engine without Transmission) ........................................ 6A-18
Toothed Belt and Timing Check ............................................................................... 6A-21
Toothed Belt Tension, Adjust .................................................................................... 6A-23
Toothed Belt, Replace ................................................................................................ 6A-24
OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26 Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26
Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26
Seal Ring, Camshaft Housing, Timing Side.............................................................. 6A-27
Seal Ring, Thermostat Housing, Cylinder Head....................................................... 6A-27
Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28
Toother Belt Rear Cover............................................................................................. 6A-30
Toother Belt Tension Roller ....................................................................................... 6A-31
COMPONENT PARTS ...................................................................................................... 6A-32 Cylinder Head .............................................................................................................. 6A- 32
Hydraulic Valve Lifter ................................................................................................. 6A-33
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34 Camshaft ..................................................................................................................... 6 A-34
Camshaft Housing Removal and Installation ........................................................... 6A-35
Cylinder Head .............................................................................................................. 6A- 35
Hydraulic Valve Lifers, Replace................................................................................. 6A-37
Camshaft Housing, Replace ...................................................................................... 6A-37

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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-3
PAGE
ENGINE EXTERNAL PARTS ........................................................................................... 6A-65 Radiator ....................................................................................................................... 6A-65
Thermostat .................................................................................................................. 6A -66
Water Pump ................................................................................................................. 6A- 66
Coating sealing surfaces with Silicone Grease ....................................................... 6A-67
Alternator ..................................................................................................................... 6A-67
Starter ........................................................................................................................ .. 6A-67
V-belt Tension of Alternator ....................................................................................... 6A-68
FUEL INJECTION SYSTEM ............................................................................................. 6A-70 Map Sensor ................................................................................................................. 6A- 70
Pressure Regulator..................................................................................................... 6A-70
ECM (Engine Control Module) ................................................................................... 6A-70
ECT............................................................................................................................ ... 6A-71
Idle Air Control(IAC) Valve ......................................................................................... 6A-71
Ignition Coil ................................................................................................................. 6A-71
Crank Position Sensor ............................................................................................... 6A-72
FUEL INJECTOR .............................................................................................................. 6A- 73
Knock Sensor.............................................................................................................. 6A-7 3
Oxygen Sensor............................................................................................................ 6A-74
Throttle Valve Position Sensor .................................................................................. 6A-74
Acclelerator Pedal and Cable .................................................................................... 6A-74
Air Cleaner Filter ......................................................................................................... 6A- 75
Spark Plug Thread ...................................................................................................... 6A-76
TECHNICAL DATA ........................................................................................................... 6A-77
Recommended Troque Values .................................................................................. 6A-88
SPECIAL SERVICE TOOL ............................................................................................... 6A-89


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ISUZU KB P190 2007

ENGINE MECHANICAL (C24SE) 6A-11
Main Data and Specifications
Engine - General C24SE
Engine type Four-cycle, water cooled cross-flow with single over head
camshaft
Micro-computer control, fuel injection
Combustion chamber type (Volume) Hemispherical (43.3cm3)
Timing train system Belt drive
No. of cylinders-bore × stroke mm (in) 4-87.5 ×100.0 (3.44 ×3.93)
Bore Spacing(C/L to C/L) 93.0 mm (3.66 in)
Firing Order 1-3-4-2
Bore×Stroke mm (in) 87.5 ×100.0 (3.44 ×3.93)
Total piston displacement cm3 (in3) 2,405(146.80)
Combustion Chamber Volume 43.3cm3
No. of piston ring Compression ring: 2, Oil ring: 1
Compression pressure kg/cm2 (psi/pa) 12.2-16.3 (174-232/1200-1600)
Ignition timing (BTDC) No adjustment
Idling speed: rpm(W O/AC,W /AC) A/C off 825
Valve clearances (At cold)
Intake mm (in) 0 (0) (Hydraulic valve lash adjustment)
Exhaust mm (in) 0 (0) ( " )
Open at (BTDC) deg 17°30’
Close at (ABDC) deg 76°30’
Exhaust valves
Open at (BBDC) deg 58°30’
Close at (ATDC) deg 35°30’
Ignition system Fully transistorized battery ignition
Distributor type Not applicable, Electronic Spark Timing control
Distributor advance type Not applicable, Electronic Spark Timing control
Spark plug type RN9YC4
Spark plug gap mm (in) 1.0--1.1 (0.039--0.043)
Lubrication system
Lubricating method Fully flow pressure circulation
Special engine oil (API grade) SE, SF, SG or SH grade
Oil pressure kg/cm2 (psi/Pa) rpm 4-4.6 (56.9-65.4/400-450)
Oil pump type Gear
Oil filter type Cartridge full flow
Oil capacity lit. (US/UK gal.) 4.25
Cooling system
Radiator type Corrugated fin with reserve tank
Coolant capacity lit.
(US/UK gal.) 2.3 (0.66/0.55)
W ater pump type
Centrifugal
Thermostat W ax pellet with jiggle hole

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ENGINE MECHANICAL (C24SE) 6A-13
Valve System C24SE
Actuation Type Direct-acting Inverted Bucked Tappet
Valve Clearance Adjustment Hydraulic
Valve Rotor Type None
Inlet-Valve Material Chromium Alloyed Steel
-Seat Insert MaterialSintered Iron
Exhaust-Valve Material Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated
-Seat Insert MaterialSintered Iron
Valve Spring Material GME 06 100-C1
Valve Guide Material QS 13 MR 00
Valve Seal Type Lip

Water Pump C24SE
Type Centrifugal
Drive-Material &Type HNBR Toothed-belt
Bearing Type Double Row Ball
Shaft Seal Type Mechanical Ceramic

Thermostat-Coolant C24SE
Type Bypass

Oil Pump & Filter C24SE
Type Gear Pump
Location Front of Engine
Drive Direct Crankshaft Driven
Filter Type Full Flow with Bypass for blocked filter

Oil & Oil Reservoir C24SE
Reservoir-Description & Location 1-piece below Engine
Reservoir Material Aluminum Alloy (pressure cast)
Replacement Oil Fill Volume
-W ith Filter change4.25liters
-W ithout Filter change 4.00liters
Recommended Oil-Run-in 10W /30SG
-Service (above-18°C) 10W /40SG
-Service (below-18°C) 5W /30SG
Oil Classification API&CCMC

Ignition Components C24SE
Spark Plugs Conventional
Type Electronic Spark Control
No. of Coils &Type 2 Solid State
Coil Location Engine-mounted
Ignition Lead Type Inductive (hi-resistance)



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6A-14 ENGINE MECHANICAL (C24SE)
Crankshaft C24SE
Material Nodular Cast Iron
Bearing subjected to End Thrust Guide Bearing NO.3
Main Bearing-Material &Type Steel Backed Tri-metal Babbitt
Front Seal-Diameter &Type 35.0mm Lip Seal
Rear seal-Diameter &Type 90.0mm Micro-lip Seal
Crankshaft Balancing Individually Balanced
No. of Counterweights 8

Camshaft C24SE
Location Overhead (Cylinder Head)
Material Grey Cast Iron
Bearing Material Aluminum
No. of Bearings Camshaft Drive-Material
&Type 200-250 HB5/750
(Camshaft drive type: toothed belt
Camshaft drive material: rubber composite GD380)

Pistons C24SE
Material Aluminum Alloy
Finish & Type Tin-coated Strutless
Piston Rings
Function (top to bottom)
-Ring 1 Compression Ring

-Ring 2 Compression Ring
-Ring 3 Oil Ring
Description -Ring 1 Rectangular
-Ring 2 Taper Face
-Ring 3 3-piece (2 Scrapers&1 Expander)
Material -Ring 1 Molybdenum Inlay Nodular Cast Iron
-Ring 2 Cast Iron (individually cast)
-Ring 3 Steel
Material Case Hardened Steel
Retention Locked in Rod
Bearing Machined in Piston Pin Boss

Connecting Rod C24SE
Material Nodular Cast Iron
Bearing-Material &Type Steel Backed Tri-metal Babbitt

Inlet Manifold C24SE
Material Aluminum Alloy

Exhaust Manifold C24SE
Description Dual Take-down
Material High Si-Mo Nodular Iron

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ENGINE MECHANICAL (C24SE) 6A-17
ENGINE ASSEMBLY & LOOSE PARTS


Loose Parts
1 Alternator
2 P/S Pivot Spacer
3 P/S Adjusting Screw
4 P/S Adjusting Plate
5 P/S Adjusting Nut
6 Alternator & Fan Drive Belt
7 A/C Compressor Drive Belt
8 P/S Pump Drive Belt
9 Tensioner Bolt
10 Tensioner Pulley
11 Pulley Dust Shield Cover
12 Pulley Spacer
13 A/C Compressor Bracket
14 Pulley Bolt
15 Fan Pulley
16 Cooling Fan
Engine Assembly
20 C24SE


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6A-18 ENGINE MECHANICAL (C24SE)
OPERATIONS ON ENGINE AGGREGATES
Engine Damping Blocks (Engine Without
Transmission)
Removal
1. Remove bonnet.
2. Remove radiator.
3. Remove air inlet hose.
4. Remove power steering pump drive belt and power steering pump from engine.




5. Remove all cable connections, hoses and lines from
engine.
6. Remove accelerator cable from inlet pipe.


7. Remove exhaust pipe from manifold.




8. Remove lower nine bolts and transmission from engine
block.
9. Remove clutch slave cylinder and allow to hang free.
10. Remove starter from engine block.

11. Remove upper bolts of left and right engine mounting
from damping blocks.
12. Raise engine slightly.
13. Remove lower bolts of left and right damping blocks.
14. Remove damping blocks.

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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