Isuzu C 190 Work Shop Repair Manual

21.1 MB·English

by  isuzu ltd

WORKSHOP MANUAL

#

&

ISUZU MOTORS LIMITED
The following manuals in English language version are available for use in inspection, adjustments
and repaire of Isuzu light-duty truck and bus series.

MaNuaLs:
7 AVAILABLE
a WORKSHOP MANUALS.
UNIT oR EQUIPMENT
APPLICABLE

ENGINE 161 G161-we-7a1

c1s0,c240 1924.We-101

481, 48C1 -48AC-WE-001

4901 ‘acen-we-011

wren LeLuwe-o0r

PROPELLER SHAFT LPRC-WE.001

‘TRANSMISSION UTRMWE.001

REAR AXLE LRAX-WE-061

FRONT AXLE LFAX-WE-001

BRAKE LpaK-WE-001

‘STEERING LSTALWE-001

‘SUSPENSION Lsus-we.oct

CHASSIS ELECTAICA.S LceL-we-001

t ENGINE ELECTRICALS, HUEE-We-001
| INJECTION PUMP. - Ins se-011

When design change is effected on some equipment for 1981 year model. the details of changes are
outlined in the workshop manusls and those manuels are issued with the new publication number

(0G00-WE-OT?,

a
SECTION INDEX

| section NAME
ISUZU 1. | cenenes mronarion
RKSHOP MANUAL 2 | encine assemety
DIESEL ENGINE ——

| wanicarine system
C190GB,C190KE,C190,C240
MODELS

4 | coouns system

FOREWORD 5 rurteveren

“This manval includes special nctes, important points e"=
vice dt precautions, ete that are razded for tre ma nte-
‘ance, adjustments sere, removal and mstlston a the 6 INTAKE AND.
components of the model ied EXHAUST SYSTEM
AN infor tons and specications contained 0
this manual are Eased on the atest produ informatin
avalabe at he time of publication

7

| “The right is reserved fo make changes a any tire without AUXILIARIES

is shown b hal ot on
Stns page ok speea
Btvt pape tes otion ov teste ont Coe 8
tho took tow secon me. Ame at a

Eons recedes enh eet,

SPECIAL TOOL LIST

Tix manual pps tothe 1981 ger and or male
Q | convension taste
GENERAL INFORMATION 1—

SECTION 1
GENERAL INFORMATION

INDEX
CONTENTS PAGE
Goneral repair instructions 4
How to use this manual 2
‘Application chart 1-5
Main data and specification . 6
Tarque specifications 1-7
Engine repair Kit ....2..e cscs ccscseesseesensesssrcseseveeneenens 114
Servicing 113,
Engine oll viscasity chart oo... esos cessseeeesssseeseseesseseseneansreeanere se 1230
Recommended lubricants .... 1-31

GENERAL REPAIR INSTRUCTIONS

1 Forassurance ut safery, park te vehicle on
te

| ground and brace the front or ear whoets when iftig the vei=
2. Reine the vehicle with x jack set against he axe or frame and pertorin service cperatior aller supporting he veh
cle on chassis stands

3. Bolore performing service operation, disconnect grounding cable trom the battery to reduce the chance of eable
damage ard burring due to shurc-uheutrg,

4. Use 2 cover on bo, seats and "our to protec: them agains damage and contamination

5. Brac fu ond entstreeze solution mst be hanelog with reasonable care as they can cause paint damage

18. The use of proper tools and special os where spc feds Important to eifiiert and relate service operation
7. Use genuine evry ports

8. Used cotter pins. gaskets O-rings, oil seals Jocs washers asf lek nuts shu be dscarded and new ones
shoul be prepared for intatstion st normal funstion ofthe part een not Be maiaed i hese parte ar ruse

‘8 To lactate proper snd smooth resseemby operation, kedp diacssembled parts neath in gious.
Keeping fixing bolts anc nuts saarate ie very emporiant ae thoy very in harness and Gouin depending on postion
of instalation
Ra

2 GENERAL INFORMATION

4

‘lean the pats beote inspection oreossemby. Also clan ol prt, te. sing compres io make certain
they ae fee from restrictor

before instalation

Lubricate roating and siding faces cf the parts with ul or arm

whan necessary use seat on gaskets 1 Prevent lsh,

Ccerafuly observe all specifications for bol ne nut trues
|Whan sevice operation ix completed. make a tna check tobe sure sewvies has been dane propery

or assurance of safety, shvaysreleos ar oessure suey from the ar tanks etorecisconnecting oes hoses oF
thor part fm ang Unit under a pressure.

HOW TO USE THIS MANUAL

Find the splcabie section by refers 1 the index
“This manual inc udes “Genera iformation” section in which service ds, maintenance tars snd specifications
With torques are cluded

ach ection inches renova and installation disaecombN, inspection and repair andreassembly | When the
ea ee ration apples to more tan one units or equipments notin nsoted stating, “Refer to manus
for other units 9raquipments”

Intemova and nstalloton section, desription of ait exparatory items sich as remeval of indivi parts from
ee arcyved is omited a unoortont operation such as adjustments, torque specieatons etc. are dealt
wth rainy.

GENERAL INFORMATION 1-3

ach sevice opaaton ston bagi with caseebled ve of nt oo
iow of un or equoment wns ut toa ompo-
nents, sarvice procedure, availablity and content of repair kits, etc. ‘compe

‘MALON COMPONENT Fete” incieating models applica

| 4 pars contained in pai kit

arts 10 be removed oF installed 35 3

Allunis ot pats witin frome ae to be
Comidarad 38 “oajr component”
Each itor port within froma is 10 bo
‘ondored 26 "minor component”

‘The number roprosents sequence of
service operation

Removal of the parts without numer
lexcloding bolts, ruts, washes,
gaskets, comer ps, etc) is unnecess-
Sy unless wren replacement is
noeaea

‘Where parts replacement requires
pecite not, instructions 2@ gwen in
“inspecton ard tepa’

+ indicates reps ft ovaibity

Name of parte listed in sequence of

4. inccates important operation

Detail of sevice operation sre

‘sched in the paragraph "Important
+4 sperations”
=

1-4 GENERAL INFORMATION GENERAL INFORMATION 1-5

APPLICATION CHART

6. The section ‘ollowing iusiatonlal desls with important sevice steps marked with“
‘Tvs section also includes “nates”. "ven of special tools”. “sorvice dots", etc

©19088.c189KE “gine with VE type injsctior pump and bot spe

ing ve ein

130, c240 F nine with in-ine type jection pump and gear ype umng ave ain
-
Yee ltemn shown ie the istration and
~ a, TF emares wih a
} a © Applicable model
Special toole are anti’ ith Sook 7 Fagine model
name andor part number. crs06s | crvoce | coo | czeo
‘The drawing ilustratas how the tool is | etic inate
aed Passenger car PAD
‘ighe-duy racks *Ke0 2:
Important note Keo e
KAD 9
wo °

“The symbol indicates the step ot ser-
vice tabs fotowed

Refer ta the fallowing paragraph for
meaning ef eoch symbol.

Modelwith* mick Fer spacial teritares

_{ Sewice cata and specitcations are
ted in abi

7. tn this manual. the folowing symbols are used to indicate the type o service operations tc be performed,

[oa]. remove Acivsiment
| lost Clean
| [ape] Dissent Pay close attention — important
i EA Resssemble ‘Tighten to speciiad torqa
y
[x] ‘Align the marks Use specie! tools! lsuzu’s toclts)
[een] const drecton Les spacial oll (puts manatee tol
Te] sree Lubreste with of
i lal ‘Texe measurement Lubricate with grease

\ 18 The service standard is incicated in terms of "Standard and “Limit
‘The “standard” means the assembly standard and standordrange within which the oats sre ccnsidered servcea-
be
Limit ingicates the limit value (Correction or replacement is necessary when measurements beyond this bit}

8. In this manual the components anc parts ae printed in single frm.
| 1-6 GENERAL INFORMATION
GENERAL INFORMATION 1-7

MAIN DATA AND SPECIFICATIONS

TORQUE SPECIFICATIONS

— Engine mod Tivos | cr T
|_ tems —Evanemoatt cramer |e, STANDARD BOLTS
Engine pe Water-coke, yc on, ovr 8 908 oe
Ene WF ater se Aap icion on torque valine gan tha folowing table ehoud bo appl vere parle torque inet specie
Cinder rar ve vy ype: Cromardtint
Simo oar syste sor ana | Gear ene
Ne of ston ng Compression ag 2, of 1 tend
No.of evinger bore xstoke mi) a axe J 's-28 102 eat
‘tt ition dpiscorent ‘ce 198 2.959 irceaton
Compression ratio. 20:1 7
Engine simersicns Aporax, | Apores. | Aperos
enn wish 2 Pit mm | BPCtsresea5 | Gs S00 oss | 688008 « 698
Cecsereonxrns fort \ es
Ensine weight Gd 1a eeese | approx 221 | Anerox 223 diameter xtc. ar nH
Feel njction order 134-2 mm) (Low carbon steel (thon carbon stesh (atoy sed
Fuel ingetor tning BX-D.C. state) 1 18 1 mon seed se
Tope ot ol ed igh sped dese! us (SAE No.2 frery casos | oss a0 |
| ee ter type Cortige te 80125 03-18
Ijecton pom = foxch cuter Bosch ne A ype with 12-23 vie an
Vee Suton mer 104125 2 38 2a 47 3B 64
| overor te Mactanea! | Paoumete and meshanca s0418 20 34 —
vara sed Tova soeee | 37 61
Thatta speed) | teeta so- 75 e2- te
iseten nore to ‘vote ve 2195 as 78 7
| CCanspression pressure luge! 23 (at 200 ror 14x20 73-10: - elie |
\ Wie speed lupm | G3.600~ 650 | (675 — 725 tae a ao- jos-163 |
Ke e75 — 725 son 108-160 138 163 — 245
Intake ond exhaust vale clarance eo x20 107 — 152 pon id
| om 04s tests ane ee to 258
i wea vabe opt yemroe 20018 pees Be wean see
} Exhaust ve open a sr @aoc) wis 258-422 mo 433649
| pe cred 24x20 365 ~ 950 429-728 565 _ 847
] Labricoton mato Pressuized exciton {
Gear type 4) ‘esses indcates hatte bt
pump type coe 8) oor wee any cicoes het te bots reused for ema-tveaced para tha re mode of so motel such cacti
| i iter pe Pape kent bw type
Corkiage 9 oF
artigo type | Raita
Paton cooing ‘With oa its
Lubrestng of coscity teri | S800, KE65 | os
Ot coom 160 Wote-eocie
| Coating meres ressurand exoulstion
Cooling water cacy thers 30
int pure oe Ino We
emestat oe ‘Wes pate 5p ith ale ae)
Arlene ne cyto ape comin! wi pape element YP0
avery tye — Vote V) x No.of unit NOPONRIDOT T2et | NTO = 12H4
See onage capacity WA) | 12 — S0rG6r00 ns a
Sete Gage Souper KW) 1aae | tet 2-22
=

= r

Sot GENEnAL INPoEMATION GENERAL INFORMATION 1-9
MAJOR PARTS FIXING BOLTS (Crankshaft and camshaft

Cylinder head and eylinder body (gem _ (kg.

{ cross, creoxe

ew bok 8)

30
[Reed to 90\(Labrzas with engine of

[BEB] wen oving
[Fea] with Copper washer
(0. GENERAL INFORMATION

GENERAL INFORMATION 1-11

Injection pump and others

ENGINE REPAIR KIT

619068, C190KE models

{ craoce
1g0KE

toate

‘lpan to beeing 3p

tappet cover

ater pur to ovine blocs
outlet pipe

{eylincer head to housing

rina
‘fit black
throttle valve
Gasket noe holier
Washer :corugeted, holder
Gasket vacuum pipe

Oil sat crankshaft, front
Gasket body to housing
Gasket pulley te pump
Gasket headcover

Repair kit: top over hau
1-12 GENERAL INFORMATION

GENERAL INFORMATION 113

ENGINE REPAIR KIT

€190; 6240 model

1. Gasket: cylinder head
2. Gasket: evinder head cover

42. Gasket intake and oxhaust manifold
4. Gaseet:ointbott

5. Sea‘ evank shaft-oar

6. Gaske: front late

7. Gasket :dran plan

8. Gasket: olpar tocase

8. Gasket: ol pan to bearing cap

10. Gasket: tappet cover

12. Gasket: goer case

13, Seal-ol

14, Gasket: goar case

estat: water ump to cylinder block
asker: cutet pipe

Gasket cylinder head to housing
Fing seating

Gasket iter to cock
Gosket: fuel pum
GGasko:- vacuum pipe
Gasket tote valve
‘washer: nozze holder
‘Washer corrugated ho
Gockel: bracket Font plate
Gasket vacuum ine
Gasket: headcover bot
epi kt: opoverhau kt

CYLINDER HEAD

SERVICING

R

+ =e
Ty cise di

C190 KE

Tighten the cylinder head bolts iv sequence a8 shown in ti
fi

Torque tka

i

fooler gauge “

Turn the erankshatt un

ste 706 notes ine on canst
peter bres ith he pone to bg on tr No.
Tor Ro. cyinr ito top ded ane on compesion
Soke Hansel wovees of ako ai evs va ah
Ten on tte No yinder hen tathne push ode ae 8
Diy inst tt te Wo. pon a pea eer oy
Comorssinseohe Wen the ver oF ein
Pate op cat he Wo pao 3 op ad