fuel ISUZU KB P190 2007 Workshop Repair Manual

GENERAL INFORMATION 0A-3
NOTES ON THE FORMAT OF THIS MANUAL
1. Find the applicable section by referring to the index at the front of the W orkshop Manual binder.
2. The following technical service information is included in this Section: • Identification
• Maintenance schedules
• Recommended Iubricants
• Recommended fuels
• Oil viscosity charts
3. Individual sections of this W orkshop Manual are divided into the following categories: • Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Loctite application procedure
• Servicing
• Removal and installation
• Disassembly
• Inspection and repair
• Reassembly
• Troubleshooting
4. Each "Major Components" page of this W orkshop Manual has an exploded view of the applicable area.
A brief explanation of the notation used follows:



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ISUZU KB P190 2007

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

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
ENGINE
Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I (DIESEL) I I I I I I I R I I I I I I I R I I I I * Engine oil (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - R - R - R - R - R - R - R - R - R - R

(4JA1-T) R R R R R R R R R R R R R R R R R R R R * Engine oil filter (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination (GASOLINE) - I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage
I I - I - I - I - I - I - I - I - I - I Fuel tank - - - I - - - I - - - I - - - I - - - I O2 Sensor (C24SE) Replace every 160,000km (HFV6)
MIL diagnostic Indicates O2 Sensor Valve clearances (6VE1) Check and adjust if noisy (4JH1-TC, 4JA1-T) A - - A - - - A - - - A - - - A - - - A (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - A - - - - - - - A - - - -
Spark plugs (C24SE) (for leaded fuel
use) - R - R - R - R - R - R - R - R - R - R
Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
Spark plugs
(HFV6) Replace every 120,000km Spark plug wire - - - - - - - - - - - - - - - - - - - I Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R (4JH1-TC, 4JA1-T) - - R - - R - - R - - R - - R - - R - - ** (4JJ1 (Standard Output),
4JJ1 (High Output)) Replace the fuel filter when the fuel filter indicator light is lit.
Fuel pump in fuel tank
(4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - I - - - - - - - I - - - -
Engine / Accessory drive belt
(C24SE) - - - - - - - - - I - - - - - - - - - I

(HFV6) Replace every 100,000km Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system
I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (HFV6) - I - I - I - I - I - I - I - I - I - R (C24SE) - I - I - I - I - R - I - I - I - I - R (DESEL) - I - I - I - I - I - I - I - I - I - I Engine coolant
(4JJ1 (Standard Output),
4JJ1 (High Output)) Change every 2 years
Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
Timing belt
(C24SE) - - - - - - - - - - - - - - - I - - - - Replace every 120,000km Timing belt (6VE1) Replace every 160,000km

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MAINTENANCE AND LUBRICATION 0B-5
MAINTENANCE SCHEDULE (For EUROPE)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

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
DIESEL ENGINE * Engine oil - R - R - R - R - R - R - R - R - R - R* Engine oil filter - - - R - - - R - - - R - - - R - - - ROil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - I I I I I I I I I I I I I I I I I I I
Valve clearance
- - - A - - - A - - - A - - - A - - - A * Air cleaner element I I I I I I I R I I I I I I I R I I I I ** Fuel filter Replace the fuel filter when the fuel filter indicator light is lit. Engine coolant concentration - I - I - I - I - I - I - I - I - I - I Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I CLUTCH Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Manual transmission with fluid - R - I - - - R - - - I - - - R - - - I * Transfer case oil (MT) - - - I - - - 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 Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I
* Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * Transfer case oil (AT)
- - - 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 case for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I

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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-7

Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
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
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R*
Engine oil filter
- - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - - - I - - - I - - - I - - - I - - - I
Valve clearance
- - - A - - - A - - - A - - - A - - - A * Air cleaner element I I I I I I I R I I I I I I I R I I I I ** Fuel filter Replace the fuel filter when the fuel filter indicator light is lit. Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil (MT) - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * Transfer case oil (AT)
- - - R - - - I - - - R - - - I - - - R 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 case for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle shafts 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


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MAINTENANCE AND LUBRICATION 0B-11
Recommended Fluids and Lubricants (For GENERAL EXPORT)
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.
The lubrication intervals in the maintenance schedule and coverage and period of new vehicle warranty are based
on the use of ISUZU genuine lubricants or recommended lubricants listed in the chart, which will serve as a guide
for selecting lubricants of the correct brand name.

GRADE
LUBRICATION MAKE BRAND/TYPE API ACEA JASO
Gasoline engine
crankcase C24SE
ISUZU GENUINE
ISUZU GENUINE
CALTEX
SHELL
ELF
TOTAL
CASTROL
BP BESCO RACING ACE TYPE SJ (5W-30)
BESCO MULTI ACE (7.5W-30)
HAVOLINE FORMULA (15W-40, 10W-30, 20W-50) HELIX PLUS (15W-50)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
GTX-7 (15W-40)
VISCO 3000 (15W-40) SJ
SG SL
SJ/CF SG
SJ/CF
SG/SH
SG/SH


A3/B3
A2/B2


Gasoline engine
crankcase HFV6

CALTEX 10W-30

HAVOLINE FORMULA (10W-30) SL
SL
Diesel engine crankcase
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
CALTEX/CHEVRON
CALTEX/CHEVRON
SHELL
SHELL
ELF
TOTAL
CASTROL
CASTROL
BP BESCO MULTI-Z TYPE CF-4 (10W-30)
BESCO MULTI-Z SUV (5W-30)
BESCO S-3 (10W, 20W, 30, 40)
DELO CXJ (15W-40, 20W-50, 40)
DELO 400 MULTIGRADE (15W-40)
RIMULA X (15W-40)
RIMULA D (15W-40, 30, 40)
PERFO 3F (15W-40)
RUBIA XT (15W-40)
RX SUPER PLUS (15W-40)
TECTION J PLUS (15W-40)
BP VANELLUS C6 (15W-40) CF-4
CD
CD
CD/CF
CD/CE/CF/CI-4 CH-4
CD/CF
CF-4/CE CF-4
CH-4
CH-4
CH-4



E3/E5 E3
B2/E2 E2
E3
E3/B3 E3


DH-1
DH-1
DH-1



DH-1
Manual transmission
C24SE D
Transfer case
ISUZU GENUINE
CALTEX/CHEVRON
SHELL
ELF
TOTAL
CASTROL
BP

BESCO GEAR OIL TRANSAXLE (5W-30)
DELO 400 MULTIGRADE (15W-40)
HELIX PLUS (15W-50)
SUPER SPORTI (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
RX SUPER PLUS (15W-40)
BP VANELLUS C6 (15W-40)

SG CD/CE/CF/CI-4 SJ/CF
SG/CD SJ/CF
CD/CE/CF
CD/CE/CF


E3/E5
A3/B3
A2/B2

DH-1




Manual transmission
HFV6
MOBIL 75W-90
MOBIL XHP (75W-90) GL-3



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


Differential
(Limited Slip Differential) ISUZU GENUINE
CALTEX
SELL
ELF
TOTAL
CASTROL
BP BESCO GEAR OIL LSD (140)
GEAR OIL LSD (90)
SPIRAX A LS 90 (90)
TRANSELF TYPE BLS (90)
TRANSMISSION DA (85W-90)
HYPOY LSX (90)
ENERGEAR LS-M (90) GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
Automatic transmission
4JH1-TC 4JJ1 (Standard Output)
Power steering
ISUZU GENUINE
CALTEX/TEXACO
SHELL
ELF
TOTAL
CASTROL
BP BESCO ATF III
TEXAMATIC 1888 (DEXRON  III)
SHELL DONAX TG (DEXRON  III)
ELFMATIC G3 (DEXRON  III)
TOTAL FLUID AT42 (DEXRON  III)
TQ DEXRON III (DEXRON  III)
AUTORAN DX3 (DEXRON  III)






Automatic transmission
4JJ1 (High Output)
EXXON MOBIL
MOBIL ATF 3309

Automatic transmission
HFV6
DEXRON III

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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

2B-24 SHEET METAL
B type

RTW 52BMF000301

Removal Steps Installation Steps
1. Battery ground cable
2. Rear combination lamp & license lamp
harness connector
3. Rear wheel housing extension panel
4. Fuel filler door release cable assembly
5. Fuel filler pipe and evaporator hose
6. Bolt; frame to rear body
7. Rear body assembly
7. Rear body assembly
6. Bolt; frame to rear body
5. Fuel filler pipe and evaporator hose
4. Fuel filler door release cable assembly
3. Rear wheel housing extension panel
2. Rear combination lamp & license lamp
connector
1. Battery ground cable


NOTE:
The rear body must be empty before removal.

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ISUZU KB P190 2007

SHEET METAL 2B-25


Important Operations - Removal
5. Fuel Filler Pipe and Evaporator Hose



7. Rear Body Assembly

Attach lifting wires to the rear body hooks and raise the rear
body.

Note:
In lifting up rear body, take care not to strike it against cab
body.



Important Operation – Installation
6. Bolt; Frame to Body

Torque N ⋅m(kgf ⋅m/lb ⋅ft)
54 (5.5 / 40)



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Section 6 Troubleshooting ....................................................................................... ..... 786
PAGE
Section 6A Engine Mechanical .................................................................................... 806
Section 6B Engine Cooling .......................................................................... ................ 945
Section 6C Fuel System .......................................................................... ..................... 96 5
Section 6D Engine Electrical ................................................................ ....................... 1002
Section 6E Engine Control System (4JH1) ....................................................... ......... 1034
Section 6F Exhaust System ....................................................... .............................. ... 1333
Section 6H Accelerator Control ....................................................... ..............................135 3
SECTION 6
ENGINE
TA BLE OF CONTENTS
ENGINE 6
4JA1/4JH1 MODELS

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