Isuzu KB P190. Manual — part 784

Engine Cooling – V6 Engine

Page 6B1–1

Section 6B1

Engine Cooling – V6

A T T E N T I O N

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

1.1

WARNING, CAUTION and NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Definition of WARNING, CAUTION and NOTE Statements. . . . . . . . . . . . . . . . . . ... 4

WARNING defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CAUTION defined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4

NOTE defined. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...5

2.1

Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2

Cooling Fan – Standard Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cooling Fan and Shroud Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 8

Fan Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V6 Cooling Fan Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fan Assembly connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10

2.3

Coolant Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 10

2.4

Coolant Outlet Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 11

2.5

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 11

2.6

Coolant Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.7

Coolant Recovery Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 14

2.8

Engine Coolant Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3

Service Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

3.1

Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 16

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Periodic Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Environmental Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16

3.2

Coolant Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 17

Topping Up the Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Testing Coolant Concentration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 18

Method 1 – Refractometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Method 2 – Hydrometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3

Draining and Filling Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4

Cleaning Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Cooling System Reverse Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25

Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26

Heater Hoses and Core. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.5

Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 28

Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29

3.6

Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30

3.7

Pressure Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

Coolant Filler Cap Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31

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

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 cooling performance requirements. The following list is a summary of new and modified components:

•

Revised radiator assembly.

•

New plumbing including radiator hoses, inlet pipe, heater pipes, heater hoses and heater water valve.

•

New rear mount thermostat assembly and thermostat housing.

•

New coolant outlet with pressure cap.

•

New coolant specification.

•

New side chutes and radiator shroud.

•

Modified cooling fan operating strategy.

•

A four stage cooling fan operating system is used.

The cooling fan motor is controlled by duty signal from the ECM which results in the fan operating from low speed Stage
1), up to high speed (Stage 4).

Operation of the cooling fan is dependant on the engine temperature, vehicle speed, A/C request (where fitted) and A/C
system pressure. Refer to 6C1 – 1 Engine management general information.

Engine Cooling – V6 Engine

Page 6B1–4

1.1

WARNING, CAUTION and NOTES

This Section contains various WARNINGS, 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. WARNINGS, 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 WARNING, 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. WARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.

WARNING defined

A WARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A WARNING statement alerts you to take necessary action or not to take a
prohibited action. If a WARNING 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.