brake ISUZU KB P190 2007 Workshop Repair Manual

1

WORKSHOP
REPAIR MANUAL
GE NERAL INFORMATION 0
HEATING AND VENTILATION
BRAKESMAIN INDEX ISUZU

CONTENTS
WHEELS AND TYRES
4
5
BODY 8
SECURITY 11 SUSPENSION

3
STEERING
2
AXLE
FRAME AND CAB
ENGINE
6
TRANSMISSION 7
MY 2007
RESTRAINTS 9
CAB 10
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KB P190

ISUZU KB P190 2007

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.
This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.
Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups. This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate. Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. W hen removing or replacing parts that require refrigerant to the discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the aim of the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.


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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-3


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate

SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
CLUTCH
Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Automatic transmission fluid (HFV6)
- - I - - I - - I - - I - - I - - I - R (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - - - I - - - I - - - I - - - I - - - I
* Transfer case oil
- - - I - - - I - - - I - - - I - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I

PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve
(4W D) - L - L - L - L - L - L - L - L - L - L

FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I


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ISUZU KB P190 2007

0B-4 MAINTENANCE AND LUBRICATION


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
PARKING BRAKE
Parking brake function I I I I I I I I I I I I I I I I I I I I Parking brake lever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage
and guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage - I - I - I - I - I - I - I - I - I - I
SUSPENSION Leaf / Coil / Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for looseness or damage I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorber mount for looseness - I - I - I - I - I - I - I - I - I - I Rubber bushes of suspension for
wear or damage - I - I - I - I - I - I - I - I - I - I
Spring action for loss of balance
due to weakening - - - I - - - I - - - I - - - I - - - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I
WHEELS W heel nuts T T - T - T - T - T - T - T - T - T - T W heel disc for damage I I - I - I - I - I - I - I - I - I - I Front hub bearing grease - - - - - R - - - - - R - - - - - R - - Front and rear hub bearing for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation
(Rotate as required) OTHERS Bolts and nuts on chassis and body I I - I - I - I - I - I - I - I - I - I Lube front free – wheeling hubs - - - - - L - - - - - L - - - - - L - -


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ISUZU KB P190 2007

0B-6 MAINTENANCE AND LUBRICATION


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage
- I - I - I - I - I - I - I - I - I - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I

SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and play I I I I I I I I I I I I I I I I I I I I Pipes and hoses for loose
connections or damage I I - I - I - I - I - I - I - I - I - I

PARKING BRAKE Parking brake function I I I I I I I I I I I I I I I I I I I I Parking brake lever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage
- I - I - I - I - I - I - I - I - I - I SUSPENSION Leaf/Coil/Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for looseness or damage
I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - I - I
Spring action for loss of balance due
to weakening - - - I - - - I - - - I - - - I - - - I
Joint ball rubber boot for damage
- I - I - I - I - I - I - I - I - I - I WHEELS W heel nuts T T - T - T - T - T - T - T - T - T - T W heel disc for damage I I - I - I - I - I - I - I - I - I - I Front hub bearing grease
- - - - - R - - - - - R - - - - - R - - Front and rear hub bearings for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation
Rotate as required OTHERS Bolts and nuts on chassis and body I I - I - I - I - I - I - I - I - I - I Lube front free - wheeling hubs - - - - - L - - - - - L - - - - - L - -


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ISUZU KB P190 2007

0B-8 MAINTENANCE AND LUBRICATION


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and play I I I I I I I I I I I I I I I I I I I I Pipes and hoses for loose
connections or damage I I - I - I - I - I - I - I - I - I - I

PARKING BRAKE Parking brake function I I I I I I I I I I I I I I I I I I I I Parking brake lever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage - I - I - I - I - I - I - I - I - I - I
SUSPENSION Leaf/Coil/Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for looseness or damage I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - - - I
Spring action for loss of balance due
to weakening - - - I - - - I - - - I - - - I - I - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I
WHEELS W heel nuts T T - T - T - T - T - T - T - T - T - T W heel disc for damage I I - I - I - I - I - I - I - I - I - I Front hub bearing grease - - - - - R - - - - - R - - - - - R - - Front and rear hub bearings for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation
(Rotate as required) OTHERS Bolts and nuts on chassis and body - - - I - - - I - - - I - - - I - - - I Lube front free - wheeling hubs - - - - - - - L - - - - - - - L - - - -


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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-9
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
C24SE : C24SE Gasoline engine
B : Driving on rough roads
HFV6 : HFV6 Gasoline engine
C : Driving on dusty roads
G : Gasoline engine
D : Driving in extremely cold weather and/or on salted roads
4JA1-T : 4JA1-T Diesel engine
E : Towing trailer or climbing mountain frequently
4JH1-TC : 4JH1-TC Diesel engine
F : Operation in high ambient temperature conditions
4JJ1 (Standard Output):
4JJ1 Standard Output Diesel engine

4JJ1 (High Output): 4JJ1 High Output Diesel engine

D : Diesel engine

MT : Manual transmission

AT : Automatic transmission

4W D : Four wheel drive


Condition
A B C D E F A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month
4JA1-T : Change every 2,500 km (1,500 miles) 4JH1-TC 4JJ1 (Standard Output) 4JJ1 (High Output):

Change every 5,000 km (3,000 miles)




Engine oil filter G : Replace every 5,000 km (3,000 miles) or 3 monthD : Replace every 5,000 km (3,000 miles)



Exhaust pipes and mounting Inspect every 5,000 km (3,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)


Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000 miles)




Transmission or transmission
with transfer case oil MTC24SE D Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)
MT HFV6 Change every 40,000 km (24,000 miles)

AT Transmission:
Change every 20,000 km (12,000 miles)








4W D Transfer:
Change every 20,000 km (12,000 miles)


Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and di
scs
wear Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)





Interval
Item

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ISUZU KB P190 2007

0B-10 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)

Severe driving conditions
MT : Manual transmission
A: Repeated short trips
AT : Automatic transmission
B: Driving on rough roads
4W D : Four wheel drive
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountein frequently

Condition
Item Interval A B C D E A+D
Engine oil Change every 5,000 km (3,000 miles)





Engine oil filter Replace every 5,000 km (3,000 miles)





Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 miles)



Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)


Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)




Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)


AT
Transmission:
Inspection every 20,000 km (12,000 miles)







4W D Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)


Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and di
scs wear Inspect every 5, 000 km (3,000 miles)




Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)







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ISUZU KB P190 2007

0B-12 MAINTENANCE AND LUBRICATION

GRADE
LUBRICATION MAKE BRAND/TYPE API ACEA

Grease fitting
(Multi purpose grease) ISUZU GENUINE
CALTEX/TEXACO
SHELL
TOTAL
CASTROL
BP BESCO L-2 GREASE (No. 2), L-3 GREASE (No. 3)
STARPLEX-2 (No. 2)
RETINAX LX2 (No. 2)
MULTIS EP2, EP3 (No. 2, No. 3)
LM GREASE (No. 2, No. 3)
ENERGREASE LS (No.2, No3)


Propeller shaft sliding yoke
Universal joint
(Multi purpose grease
containing molybdenum
disulfide) ISUZU GENUINE
CALTEX
SHELL
TOTAL ONE LUBER MO GREASE
MOLYTEX GREASE EP2 (No.2)
RETINAX HDX2 (No.2)
TOTAL MULTIS MS2 (No.2, No.3)

Engine cooling system ISUZU GENUINE
CALTEX/TEXACO/
CHEVRON
BESCO LLC SUPER TYPE E
EXTENDED LIFE COOLANT
HAVOLINE XLC
DELO XLC

NOTE:
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant mixed with 1 bottle (118ml) of Limited
Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or equivalent.

FLUID TYPE
Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade

DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD) Based on K2204 GAS OIL
DIN (DEUTSCHE INDUSTRIE NORMEN) Based on EN590 : 1997
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE J-313C
BS (BRITISH STANDARD) Based on BS EN590 : 1997

NOTE:
Use the applicable standard or equivalent for diesel fuels.


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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-13
RECOMMENDED FLUIDS AND LUBRICANTS (For EUROPE)


In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly the best lubricants and diesel fuels.
W hen lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.

LUBRICATION/FLUID GRADE
API ACEA OTHER
Diesel engine crankcase B2/B3
E2/E3
Manual transmission
Transfer case B2/B3
E2/E3
Differential
Shift on the fly system
(GL-5 only)
GL-5

BESCO GEAR OIL SH (80W-90, 90, 140) (ISUZU GENUINE)
BESCO SHIFT ON THE FLY (75W-90) (ISUZU GENUINE)
THURBAN GL-5 EP (80W-90, 85W-140) (CALTEX)
SPIRAX A (140) (SHELL)
TRANSELF TYPE B (80W-90, 85W-140) (ELF)
TRANSMISSION TM (80W-90, 85W-140) (TOTAL)
EPX90 (90)(CASTROL)
DYNA DRIVE (80W-90) (CASTROL)
ENERGEAR HYPO (90) (BP)
ENERGEAR EP (80W-90) (BP)
Differential
(Limited Slip Differential)
(GL-5 only) GL-5

BESCO GEAR OIL LSD (140) (ISUZU GENUINE)
GEAR OIL LSD (90) (CALTEX)
SPIRAX A LS 90 (90) (SHELL)
TRANSELF TYPE BLS (90) (ELF)
TRANSMISSION DA (85W-90) (TOTAL)
HYPOY LSX (90) (CASTROL)
ENERGEAR LS-M (90) (BP)
Automatic transmission MOBIL ATF 3309
Power steering

DEXRON III
Propeller shaft sliding yoke
Universal joint
(General purpose grease in
Molybdenum) NLGI #2 or #3
multi purpose type grease
containing molybdenum disulfide
Engine cooling system Good quality ethylene glycol antifreeze or GM spec.
6033-M or equivalent

NOTE:
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant mixed with 1 bottle (118ml) of Limited
Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or equivalent.



FLUID TYPE

Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade


DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
BS (BRITISH STANDARD) Based on K2204 GAS OIL
Based on EN590: 1997L
Based on SAE J-313C
Based on BS EN590: 1997

NOTE:
Use the applicable standard or equivalent for diesel fuels.



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ISUZU KB P190 2007