trailer ISUZU KB P190 2007 Workshop Repair Manual

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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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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6E-10 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Engine Controls Schematics
Power Distribution (1)
RTW76EXF003601
X-11
X-11 Heater
relay
1
2
Blower
motor Ignition
switchIgnition
switch Starter
relay
SBF1
Main
120A SBF2
ABS-1
40A SBF3
ABS-2
20A SBF5
IG1
40A SBF4
ECM
40A
SBF6
Blower
30A
EB-13
A/C
10A
2
BLU/
RED
3
BLU/
RED 3
BLU/
RED SBF8
Glow
60A
SBF7
Front
Fog
20A
SBF9
IG2
60A
EB-9
Fog
15A
or
Trailer
20AEB-10
Tail/Illumi
10A
or
Condenser
fan
20A EB-4
Engine
10A
EB-14
4WD
10A EB-15
Horn
10A EB-16
Hazard10A EB-1
ACG
(S)
10AEB-2
ECM
(B)
10AEB-3
F/Pump10A
EB-5 H/L HI(RH)10A Fuse
EB-6 H/L HI(LH)10A Fuse
EB-7 H/L LO(RH)10A Fuse
EB-8 H/L LO(LH)10A Fuse
P-6
Body
Generator P-5
8 BLK/
P-1
P-2
Battery
8
BLK 5WHTSrarter
Srarter
C-3
ELEC IG
10A
Fuse
E-92
0.5 WHT
0.3
BLK 3
WHT/
RED 5
WHT
0.3
BLK 5
RED/
BLU
5
RED
3
WHT/
BLK
30
BLK/
RED
30
BLK/
YEL
P-10
Engine
5
4 X-12
X-12
ECM
Fuel pump relay
ECM
ECM
main
relay
1
2 5
4
X-6
X-6
2
RED/
WHT
0.3
RED/
BLU Fuse/ relay box(Engine room)
2
RED
2
RED
0.5
RED
2
WHT
2
RED/
BLU 2
WHT
2
3 1
5
Lighting
switch Head
lamp
relay
C-36 C-36
RED
P-16
P-15
2nd
Battery
30
BLK/
YEL 30
BLK/
RED
P-10

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ENGINE CONTROL SYSTEM (4JK1/4JJ1) 6E-11
Power Distribution (2)
RTW76EXF003701
C-108
5
WHT
3
WHT/
BLK
5
WHT
3
WHT/
BLK
3BLU
3BLK/RED
3
WHT/
BLK
3
BLK/
YEL 3
BLK/
WHT B-62
B-63
2
4
B-62
B-63 1
1
3
C-18
Rr
Def.
20A C-21
Door
lock
20A C-19
Meter
(+B)
10A C-15
Stop
lamp
15A C-22
Anti
theft
10A C-13
Audio
(+B)
15A
C-16
RR
Fog
10A C-17
Room
10A C-20
Power
window
30A Fuse/
relay box
(Cabin)
C-14
Meter
10A C-8
SRS
10AC-7
TCM
10A
or
15A C-9
Front
wiper
20A C-10
Back
up
15A C-6
Engine
10A
C-5
ABS/4WD
10AC-1
Starter
10AC-2
Trailer
10AC-3
ELEC IG
10A C-4
Turn
10AC-12
Cigar
lighter
&
ACC
Socket
20A C-11
Audio
10A
SBF9
IG2
60A Fuse/
relay
box
(Engine
room)
Starter relay
SBF5
IG1
40A
1
2
3 B-62 B1
B2
OFF
ACC
IG2ST
IG1 Ignition
switch

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6-12 ENGINE DIAGNOSIS (C24SE)
Engine Oil Consumption Excessive
Condition Possible cause Correction
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Oil pan setting bolds loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose
or gasket broken Retighten or replace gasket

Head cover retaining bolts loose
or gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace
Oil filter attaching bolt loose or
rubber gasket broken Retighten or replace oil filter

Crankshaft front or rear oil seal
defective Replace oil seal

Oil pressure unit loose or broken Retighten or replace
Blow-by gas hose broken Replace hose
Engine/Transmission coupling
area Replace oil seal
Oil leaking into combustion
chambers due to poor seal in
valve system Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion
chambers due to poor seal in
cylinder parts Cylinders and pistons worn
excessively Rebore cylinder and replace
pistons and others
Piston ring gaps incorrectly
positioned Correct

Piston rings set with wrong side
up Correct

Piston rings sticking Rebore cylinder and replace
pistons and others
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Crank case ventilation, Positive
Crankcase Ventilation System
malfunctioning Positive Crankcase Ventilation
Hose clogged Clean
Others
Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving
and or severe usage such as
trailer towing Continuous high speed operation
and or severe usage will normally
cause increased oil consumption


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ENGINE DRIVEABILITY AND EMISSIONS 6E–31
RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAYNo. Relay Name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 —
X-6 RELAY; STARTER
X-7 RELAY; H/LAMP (Except AUSTRALIA)
RELAY; COND FAN
(AUSTRALIA)
X-8 —
X-9 RELAY; FRT FOG LIGHT
X-10 —
X-11 RELAY; HEATER
X-12 RELAY; STARTER CUT (AUSTRALIA)
X-13 RELAY; STARTER CUT (Except
AUSTRALIA)
REPLAY; H/LAMP
(AUSTRALIA)
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
SLOW BLOW FUSE
NO. Slow Blow Fuse Name
SBF-1 100A MAIN
SBF-2 —
SBF-3 —
SBF-4 20A COND, FAN
SBF-5 40A IG 1
SBF-6 —
SBF-7 —
SBF-8 30A BLOWER
SBF-9 50A IG 2
* 1 AUSTRALIA
* 2 WITH HEADLIGHTS LEVELING
FUSE
NO. Fuse Name
EB-1 15A ECM
EB-2 —
EB-3 15A FRT FOG 20A TRAILER *1
EB-4 15A ACG (S)
EB-5 10A ILLUMI 10A ILLUMI & TAIL-RF
* 1
EB-6 10A TAIL
EB-7 10A H/LIGHT-RH 10A H/LIGHT-RH-LOW
* 2
EB-8 10A H/LIGHT-LH 10A H/LIGHT-LH-LOW
* 2
EB-9 20A FUEL PUMP
EB-10 10A O
2 SENSOR
EB-11 10A H/LIGHT-RH- HIGH *2
EB-12 10A H/LIGHT-LH- HIGH *2
EB-13 10A A/C
EB-14 10A 4WD
EB-15 10A HORN
EB-16 10A HAZARD

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6E–32 ENGINE DRIVEABILITY AND EMISSIONS
FUSE AND RELAY LOCATION (LHD & RHD)
FUSE
SLOW BLOW FUSE
RELAY No. Capacity Indication on label No. Capacity Indication on label
1— — 1 215A CIGER/ACC
SOCKET
2 10A ABS/4WD 13 15A AUDIO (+B)
3 10A TRAILER 14 20A DOOR LOCK
4 15A BACK UP 15 10A METER (+B)
5 15A METER16 10A ROOM
6 10A TURN17 10A ANTI THEFT
7 15A ELEC.IG 18 15ASTOP
815A ENGINE 19 — —
9 20A FRT WIPER 20 10A STARTER
10 15A EGR (RHD)
IG.COIL (LHD) 21 10A
SRS
11 10A AUDIO
No. Capacity Indication on label 22 20A RR DEF
23 30A POWER WINDOW
Connector No. B-7B-8B-40
C24SE REAR DEFOGGER POWER WINDOW (NO RELAY)
FUSE BOX

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Automatic Transmission – 4L60E – Electrical Diagnosis Page 7C2–34
• The TCM records the operating conditions when the conditions for setting the DTC are met. The TCM stores this
information as Failure Records.
• The TCM stores DTC P0218 in TCM history.
Conditions for Clearing the DTC
• Tech 2 can clear the DTC.
• The TCM clears the DTC from TCM history if the vehicle completes 40 warm-up cycles without a non-emission
related diagnostic fault occurring.
• The TCM cancels the DTC default actions when the fault no longer exists and the DTC passes.
Diagnostic Aids
• Tech 2’s Transmission Fluid Temp. should rise steadily to a normal operating temperature, then stabilise.
• Ask about the customer's driving habits, trailer towing, etc. Trailer towing should occur in D3.
• Refer to Symptoms - Automatic Transmission in 7C3 Automatic Transmission – 4L60E – Hydraulic and Mechanical
Diagnosis.
Test Description
The following numbers refer to the step numbers in the diagnostic table:
2 Low transmission fluid can cause the transmission to overheat.
3 This step inspects for airflow restrictions or damage, which may result in the transmission overheating.
4-5 Decreased line pressure will cause the transmission to overheat. The torque converter stator is the pump for the transmission fluid. If the torque converter is damaged, it may not be producing the required pressure.
DTC P0218 Diagnostic Table
Step Action Yes No
1 Has the Diagnostic System Check been performed?
Go to Step 2 Refer to
4.7 Diagnostic System Check
2 1 Connect Tech 2 to the DLC.
2 Turn on the ignition, with the engine off.
NOTE
Before clearing the DTC, use the Tech 2 Freeze
Frame/Failure Record to record the transmission
parameters at the time the DTC set. Using Tech 2 to clear
the DTC(s) erases the Freeze Frame/Failure Record
records from the TCM.
3 On Tech 2 select: Transmission / Automatic Transmission / Diagnostic
Trouble Codes / Freeze Frame.
4 Select the relevant DTC and note the parameters at the time of the DTC setting.
5 On Tech 2 select:
Diagnostic Trouble Codes / Clear Engine & Transmission
DTCs.
6 Follow the instructions on Tech 2 and clear the DTCs.
7 Inspect for correct transmission fluid level, refer to 7C4 Automatic Transmission – 4L60E – On-vehicle Servicing.
Did you perform the fluid checking procedure? Go to Step 3 Perform the
transmission fluid
checking procedure, refer to
7C4 Automatic
Transmission –
4L60E – On-vehicle Servicing

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Automatic Transmission – 4L60E – Electrical Diagnosis Page 7C2–45
Diagnostic Aids
• Tech 2 displays the transmission fluid temperature in degrees. After the transmission is operating, the fluid
temperature should rise steadily to a normal operating temperature, then stabilise.
• Verify the customer's driving habits, trailer towing, etc. Trailer towing should occur in D3.
Test Description
The following numbers refer to the step numbers in the diagnostic table:
3 Checks the hardware components that affect the transmission fluid temperature.
4 Checks there is power supplied to the TFT sensor.
5 Checks the TFT sensor high reference circuit for serviceability.
6 Check the TFT sensor for serviceability.
7 Checks the TFT sensor low reference circuit for serviceability.
DTC P0711 to P0713 Diagnostic Table
Step Action Yes No
1 Has the Diagnostic System Check been performed?
Go to Step 2 Refer to
4.7 Diagnostic System Check
2 1 Connect Tech 2 to the DLC.
2 Turn on the ignition, with the engine off.
NOTE
Before clearing the DTC, use the Tech 2 Freeze
Frame/Failure Record to record the transmission
parameters at the time the DTC set. Using Tech 2 to clear
the DTC(s) erases the Freeze Frame/Failure Record
records from the TCM.
3 On Tech 2 select: Transmission / Automatic Transmission / Diagnostic
Trouble Codes / Freeze Frame.
4 Select the relevant DTC and note the parameters at the time of the DTC setting.
5 On Tech 2 select:
Diagnostic Trouble Codes / Clear Engine & Transmission
DTCs.
6 Follow the instructions on Tech 2 and clear the DTCs.
7 On Tech 2 select: Data Display / Transmission Data
8 Drive the vehicle and observe Tech 2 for either of the following conditions:
• The Trans. Fluid Temp . does not change more than
2.25°C in 409 seconds since start-up
• The Trans. Fluid Temp . changes more than 20°C in
200 milliseconds 14 times within 7 seconds
• The Trans. Fluid Temp . less than -39°C?
Does Tech 2 display any of the above conditions? Go to Step 4 Go to Step 3

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ELECTRICAL-BODY AND CHASSIS 8A-3
PAGE
Power Window ............................................................................................................8A- 41 5
Audio, Clock and Cigarette Lighter ...........................................................................8A- 440
Power Door Mirror ......................................................................................................8A- 464
Rear Defogger .............................................................................................................8A- 480
Supplemental Restraint System (SRS)-Air Bag ........................................................8A- 491
Transfer Case Control Module ...................................................................................8A- 498
Anti-Lock Brake System .............................................................................................8A- 514
Immobilizer ..................................................................................................................8 A- 519
Keyless Entry ..............................................................................................................8A- 529
Data Link Connector ...................................................................................................8A- 553
Anti Theft ..................................................................................................................... .8A- 561
Key Inter Lock .............................................................................................................8A- 588
DRM ........................................................................................................................... ...8A- 592
Trailer Hitch ................................................................................................................. 8A- 595
Power Train Interface Module (PIM) ..........................................................................8A- 600
Connector List ................................................................................................................ .8A- 606

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