ECU ISUZU KB P190 2007 Workshop Repair Manual

UNIT REPAIR (JR405E) 7A4-81
244L300001


21.Oil pan
• Install a new gasket and the oil pan.
• Tighten the bolts to the specified torque.
Torque: 8 N ⋅
⋅⋅
⋅
m (0.8 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
in)

47INH-SW 01

22.Inhibitor switch
• Secure the inhibitor switch (1) by hand-tightening the 2
bolts.
• Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inhibitor switch set plate: 5-8840-2763-0
NOTE:
Inhibitor switch adjustment is very important.
If the inhibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
• Tighten the 2 inhibitor switch bolts to the specified
torque.

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7B1-12 Manual Transmission (MUX)
22. Remove the transmission retaining nuts and bolts.Remove the transmission assembly (4x2 model) or
the transmission & transfer assembly (4x4 model)
from the vehicle.
23. Remove the transmission-transfer fixing bolts and nut, and disassemble the transfer from the
transmission. (4x4 model)
Installation
1. Apply grease (BESCO L-2 or equivalent) on the splined portion of the output shaft.
2. Connect the transfer to the transmission. (4x4 model)
3. Install the transmission-transfer fixing bolts and nut, and tighten them to the specified torque. (4x4
model)
Torque: 41 N ⋅m (4.2 kgf ⋅m/30 lb ⋅ft)
4. Apply a thin coat of molybdenum disulfide grease on the splined portion of the input shaft spline.
5. Slowly operate the transmission jack until the front of transmission is aligned with the rear of the
engine.
6. Align the input shaft spline with the clutch driven plate spline.
7. Install the transmission assembly (4x2 model) or the transmission & transfer assembly (4x4 model)
to the engine.
• Tighten the transmission bolts to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
8. Apply a force 69 N ⋅m (7 kgf ⋅m/51 lb ⋅ft) to the tip of
the shift fork in the direction of the transmission to
engine the clutch pressure plate and release
bearing.
Notice:
A click sound is heard when the release bearing and
the tip of the diaphragm spring engage each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine side while
applying a force of about 25 N ⋅m (2.6 kgf ⋅m/19 lb ⋅ft). If
the shift fork will not move, then they are securely
engaged. 9. Connect harness clips on the transmission left
side.
10. Install the starter assembly.
• Tighten the starter bolts to the specified torque.
Torque: 94 N ⋅m (9.6 kgf ⋅m/69 lb ⋅ft)
11. Install the transmission rear mount to the transmission.
• Tighten the transmission rear mount bolts to the specified torque.
Torque: 50 N ⋅m (5.1 kgf ⋅m/37 lb ⋅ft)
12. Install the transmission crossmember by removing four bolts and nuts.
• Tighten the transmission crossmember bolts to the specified torque.
Torque: 67 N ⋅m (6.8 kgf ⋅m/49 lb ⋅ft)
13. Install the transmission rear mount nuts fixing on crossmember from transmission crossmember.
• Tighten the transmission rear mount nuts to the specified torque.
Torque: 52 N ⋅m (5.3 kgf ⋅m/38 lb ⋅ft)
Remove the transmission jack from transmission
side.
14. Install the fuel pipe bracket bolt and connect fuel pipe clip.
• Tighten the fuel pipe bracket bolt to the specified torque.
Torque: 76 N ⋅m (7.7 kgf ⋅m/56 lb ⋅ft)
15. Install the slave cylinder fixing bolts. • Tighten the slave cylinder bolts to the specifiedtorque.
Torque: 43 N ⋅m (4.4 kgf ⋅m/32 lb ⋅ft)
RTW77BSH007201

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ISUZU KB P190 2007

TRANSFER CASE 7D-7
Installation
1. Thoroughly clean around the oil seal bore in the case
and ensure there are no burrs.
2.
Apply the engine oil to the new oil seal outer surfaces
and apply the recommended grease (BESCO L2) o
r
equivalent to the oil seal lip.
3. Tap the oil seal in to place, use an oil seal installe
r
(5-8840-2785-0) and a soft hammer.



RTW 77DSH000301
4. Install the output flange to the front output shaft.
5. Apply the engine oil to the new O-ring and install it to the front output shaft.
6. Secure the output flange with a flange holde
r
(5-8840-0133-0).
7. Install the new end nut and tighten them to specified torque.
Front coupling driver fixing nut torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅
⋅⋅
⋅
ft)

8. Use a punch (5-8840-2293-0) to caulk the end nut.




226R300012




RUW 34DSH000301
Legend
(1) MAX 26mm (1.02in)
(2) MIN 4mm (0.16in)


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ISUZU KB P190 2007

7D-26 TRANSFER CASE
2-4 shift reassembly
1. Install the shift block assembly to the shift rod.
2. Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.

226R300015
3. Install the spring.
4. Install the shift arm.
5. Compress the spring and install the snap ring.
6. Install the guide roller.

Oil pump disassembly
1. Remove the clamps securing the screen.
2. Remove the screen.
3. Remove the clamps securing the hose.
4. Remove the hose.
NOTE: To maintain and protect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Oil pump reassembly

1. Tighten the clamps to secure the hose.
2. Tighten the clamps to secure the screen.
NOTE: Be careful in the direction of clamps.

RTW 37DSH000101
Legend
(1) Oil Pump Assembly
(2) Clamp
(3) Hose
(4) Screen Assembly



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ISUZU KB P190 2007

TRANSFER CASE 7D-37
226R300005



30. Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31. Use a press and an installer (9-8522-1268-0) to install
the rear output shaft ball bearings. Do not drive the
ball bearings into place with a hammer.





32. Install the rear output shaft retaining ring.
33. Place the oil pump in its specified position.
34. Secure the oil pump strainer to the rear cover and
tighten the bolts to the specified torque.
Oil pump and rear cover bolt torque:
15 N ·m (1.5 kgf ·m/11 lb ·ft)


226R300010










35.
Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
Legend

(1) Oil Pump Assembly
(2) W ire Snap Ring
(3) Retaining Ring
(4) Ball Bearing
(5) Speedometer Gear Drive Gear
(6) Rear Cover
Legend
(1) W ire Snap Ring

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ISUZU KB P190 2007

7D-38 TRANSFER CASE
226R300011
36. Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 N ·m (2.2 kgf ·m/16 lb ·ft)
37. Apply engine oil to the companion flange O-ring.
38. Install the O-ring to the front output shaft.
39. Secure the front companion flange with a flange
holder (5-8840-0133-0).
40. Install the end nuts and tighten them to the specified
torque.
Front companion flange end nut torque:
137 N ·m (14.0 kgf ·m/101 lb ·ft)


RTW 77DSH000201

41. Use a punch (5-8840-2293-0) to caulk the front
companion flange end nut.
226R300012
RUW 34DSH000301

Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)

42.
Apply Loctite 575 to the threaded portion of the
detente plugs.


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TRANSFER CONTROL SYSTEM 7D1-49
Step 4-3: (Same procedure as the step 3-3)
Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or below).
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position (stepping on the clutch lever is recommended).
Push the 4H button.
If shifting is not complete (indicator flashes at 2Hz), go to step 4-1.

5. When shifting from 4H or 4L to neutral
(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If torsional
torque has accumulated between the transmission and road surface, separation may be difficult.
Step 5-1:
If the operation is not complete, execute step 7 for confirmation.
(In case of AT): Set the transmission select lever to the D position. After confirming that the gears are at the neutral position, return the lever to the N
position.
(In case of MT): Set the transmission lever to a vehicle running position and engage the clutch gently. After confirming that the gears are at the neutral position, return the lever to the
neutral position
5-2 When the neutral indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is
impossible (restriction on operation).
Step 5-2:
Stop the vehicle.
(In case of AT): Set the transmission select lever to the N (or P) position.
(In case of MT): Set the transmission lever to the neutral position (at this time, stepping on the clutch is recommended).
Keep pushing the 2H and 4L button for 10 seconds.
Follow the start procedure for confirmation. (Confirmation of drive force is not transferred; same as in
step 5-1)
After the confirmation, set the transmission to the neutral position in the case of MT or to the neutral
position in the case of AT.

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ELECTRICAL-BODY AND CHASSIS 8A-9
SPLICING WIRE
Open the Harness
If the harness is taped, remove the tape.
To avoid wire insulation damage, use a sewing “seam ripper”
(available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the
desired wire.
Cut the wire
Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to cut
more wire off to change the location of a splice.
You may have to adjust splice locations to make certain that
each splice is at least 1-1/2” (40 mm) away from other splices,
harness branches, or connectors.
Strip the insulation
W hen replacing a wire, use a wire of the same size as the
original wire.
Check the stripped wire for nicks or cut strands.
If the wire is damaged, repeat the procedure on a new section
of wire.
The two stripped wire ends should be equal in length.



Crimp the Wires
Select the proper clip to secure the splice.
To determine the proper clip size for the wire being spliced,
follow the directions included with your clips.
Select the correct anvil on the crimper.
(On most crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them between
your thumb and forefinger.
Then, enter the splice clip under the stripped wires and hold it
in place.



•
Open the crimping tool to its full width and rest one handle
on a firm flat surface.
• Center the back of the splice clip on the proper anvil and
close the crimping tool to the point where the back of the
splice clip touches the wings of the clip.
• Make sure that the clip and wires are still in the correct
position. Then, apply pressure until the crimping tool closes.



Before crimping the ends of the clip, be sure that:
• The wires extend beyond the clip in each direction.
• No strands of wire are cut loose.
• No insulation is caught under the clip.
Crimp the splice again, once on each end.
Do not let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.


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8A-12 ELECTRICAL-BODY AND CHASSIS
ABBREVIATIONS
Abbreviation Meaning of abbreviation Abbreviation Meaning of abbreviation
A Ampere (S) kW Kilowatt
ABS Anti-lock brake system LH Left hand
ASM Assembly LW B Long wheel base
AC Alternating current MPI Multipart fuel injection
A/C Air conditioner M/T Manual transmission
ACC Accessories PA Passenger
CARB Carburetor PIM Power train interface module
C/B Circuit breaker PJT Projector
CKP Crankshaft position QOS Quick On Start system
CSD Cold start device RH Right hand
DIS Direct ignition system RR Rear
DR Driver RW AL Rear wheel anti-lock brake system
DRM Data Recording Module SCV Suction control valve
EHCU Electronic Hydraulic control Unit SRS Supplemental restraint system
ECGI Electronic control gasoline injection ST Start
ECM Engine control module STD Standard
ECU Electronic control unit SW Switch
EFE Early fuel evaporation SW B Short wheel base
EGR Exhaust gas recirculation TCM Transmission control module
2W D Two-wheel drive TCCM Transfer case control module
4W D Four-wheel drive V Volt
FL Fusible link VSV Vacuum switching valve
FRT Front W W att (S)
H/L Headlight W OT W ide open throttle
W/ With HVAC
Heater, Ventilation, and Air
Conditioning W /O W ithout
IC Integrated circuit W /S W eld Splice
IG Ignition


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ELECTRICAL-BODY AND CHASSIS 8A-33
FUSE LOCATION


RHD/LHD

FUSE
NO. Capacity Indication on label NO. Capacity Indication on label
C 1 10A STARTER C 1110A AUDIO
C2
  C
12 20A CIGAR/ACC SOCKET
10A TRAILER *3 C 13 15A AUDIO (+B)
C3 10A ELEC IG C 14 10A METER
C4 10A TURN C 15 15A STOP
C5 10A ABS/4WD C 16
 
C6 10A ENGINE C 17 10A ROOM
10A ECU *4 C19 10A METER (+B)
C7 15A TCM/IG COIL/ C2 120A DOOR LOCK
10A GLOW ENGINE *4 C22
 
C8 10A SRS 10A ANTI THEFT *5
C9 20A FRT WIPER
C10 15A BACKUP

SLOW BLOW FUSE
NO. Capacity Indication on label
C 18 20A RR DEF
C20 30A POWER WINDOW

FUSE BOX
*3 … HFV6 (AUSTRALIA)
*4 … HFV6
*5 … 4JJ 1-TC (EUROPE)



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