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2007-2009 Isuzu KP190 Series Service Repair Manual

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🏷️ Basic Information Identification Make: Isuzu Model: KP190 Series Production Years: 2007, 2008, 2009 Chassis Code: KP190 Product Type: Service Repair Manual 👋 Introduction Market Overview Market Position: Essential technical documentation for owners and technicians of the Isuzu KP190 Series vehicles produced between 2007 and 2009. Provides in-depth repair and maintenance information crucial for keeping these vehicles operational and well-maintained. Value Proposition Key Features: Offers detailed diagnostic procedures, repair instructions, and maintenance schedules. Its comprehensive nature, covering all major vehicle systems, makes it an invaluable resource for maximizing vehicle lifespan and ensuring proper functioning. Competitive Edge Manual Uniqueness: The sheer volume of pages (6020) suggests an extremely thorough manual, likely encompassing all engine variants and detailed component breakdowns, distinguishing it from more basic repair guides. Support Customer Support Offer: Customer support available to help acquire specific manuals not listed. 📋 Manual Details Coverage Coverage Areas: General Information, Heating and Airconditioning, Frame and Cab, Steering, Suspension, Wheels and Tyres, Axle, Brakes, Engine, Transmission, Body, Restraints, Cab, Security Pagination Page Count: 6020 Type Manual Type: Workshop Manual / Service Manual Language Language: English Format File Format: PDF, ZIP Digital Accessibility: The PDF/ZIP format ensures high accessibility across various devices and operating systems, offering flexibility for use in a workshop or on the go. Compatibility Operating Systems: Win95/98/ME/XP/vista/7/Linux/MAC Distribution Delivery Method: Instant Download Shipping Info: No shipping cost, no waiting for CD-ROM, instant download. 📖 Manual Coverage Systems Systems Covered: Engine Mechanical, Engine Fuel System, Engine Electrical, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting System, Charging System, Transmission (Manual & Automatic), Drivetrain, Suspension System, Steering System, Brake System (Hydraulic & ABS), Wheel Alignment, Wheels and Tires, Body and Frame, Chassis, Electrical System (Lighting, Instrumentation, Power Accessories), HVAC System, Restraint Systems (Airbags, Seatbelts), Security System, Exterior Body Panels, Interior Trim, Diagnostics and Troubleshooting Brake System Detail: Section 5 'Brakes' will cover hydraulic system components, brake pad and rotor replacement, drum brake service, parking brake operation, and ABS system diagnostics and repair, including wheel speed sensors and hydraulic control units. Suspension Steering Detail: Section 3 'Steering, Suspension, Wheels and Tyres' includes procedures for shock absorber replacement, spring service, ball joint and tie rod end replacement, power steering system repair, wheel bearing service, and tire condition and pressure checks. Axle Drivetrain Detail: Section 4 'Axle' will cover front and rear axle components, differential service, drive shaft maintenance, universal joints, and CV joints, depending on the specific KP190 configuration. Cab And Interior Coverage: Sections 2 'Frame and Cab', 8 'Body', and 10 'Cab' collectively cover the driver and passenger cabin, including seating, dashboard, interior trim panels, sound insulation, door hardware, and potentially cab tilting mechanisms for commercial variants. Procedures Procedures Included: Routine Maintenance, Scheduled Maintenance, Component Removal and Installation, Component Overhaul and Reassembly, Diagnostic Procedures, Troubleshooting Guides, Electrical System Schematics, Wiring Diagrams, Torque Specifications, Fluid Capacities and Specifications, Special Tool Recommendations, Step-by-step Repair Instructions, Inspection Procedures, Adjustment Procedures, Replacement Procedures Troubleshooting Methodology: The manual will provide structured troubleshooting trees and symptom-based diagnostics to help technicians identify the root cause of malfunctions across all vehicle systems. Diagnostic Tools: The manual may list specific diagnostic scan tools or procedures required for accessing vehicle diagnostic trouble codes (DTCs) and performing system tests. Engine Rebuild Steps: Detailed procedures for engine disassembly, cleaning, inspection of critical components (pistons, rings, bearings, cylinder heads), machining specifications, and reassembly with correct clearances and torque sequences will be included. Depth Technical Depth: Comprehensive; covers everything from basic maintenance tasks to complete engine and transmission rebuilds, advanced diagnostics, and body repair. Suitable for professional technicians and advanced DIY enthusiasts. Bodywork Body And Frame Detail: Section 2 'Frame and Cab' and Section 8 'Body' will provide information on chassis structural integrity, cab mounting, door mechanisms, body panel repair, glass replacement, and interior trim removal/installation. Security Security System Detail: Section 11 'Security' likely covers the vehicle's alarm system, immobilizer, keyless entry, and any related electronic control units or sensors. Procedures for diagnostics and potential key programming (if applicable) might be included. Technical Data Torque Specifications: Precise torque values for all fasteners related to engine components, suspension, brakes, and bodywork will be provided, crucial for safe and effective repairs. Wiring Diagrams: Extensive and detailed wiring diagrams for all electrical systems, including engine control, lighting, power accessories, and communication networks, will be a key component of the manual. 📊 Manual Specifications File Characteristics File Quality: High-resolution PDF suitable for printing and screen viewing, likely with searchable text for efficient information retrieval. Searchability: PDF format generally allows for text searching, enabling users to quickly locate specific topics, component names, or diagnostic codes. Zip Format Utility: The ZIP format ensures all related manual files, diagrams, and potentially additional software or documentation are contained in a single, easily transferable package. Physical Attributes Binding Type: N/A (Digital Format) Paper Type: N/A (Digital Format)...
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Taper: Truck
Distributeur:
UGS: 194726
Collections: ALL Isuzu

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2007-2009 Isuzu KP190 Series Service Repair Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
KP190 Series
Production Years:
2007, 2008, 2009
Chassis Code:
KP190
Product Type:
Service Repair Manual
👋 Introduction
Market Overview
Market Position:
Essential technical documentation for owners and technicians of the Isuzu KP190 Series vehicles produced between 2007 and 2009. Provides in-depth repair and maintenance information crucial for keeping these vehicles operational and well-maintained.
Value Proposition
Key Features:
Offers detailed diagnostic procedures, repair instructions, and maintenance schedules. Its comprehensive nature, covering all major vehicle systems, makes it an invaluable resource for maximizing vehicle lifespan and ensuring proper functioning.
Competitive Edge
Manual Uniqueness:
The sheer volume of pages (6020) suggests an extremely thorough manual, likely encompassing all engine variants and detailed component breakdowns, distinguishing it from more basic repair guides.
Support
Customer Support Offer:
Customer support available to help acquire specific manuals not listed.
📋 Manual Details
Coverage
Coverage Areas:
General Information, Heating and Airconditioning, Frame and Cab, Steering, Suspension, Wheels and Tyres, Axle, Brakes, Engine, Transmission, Body, Restraints, Cab, Security
Pagination
Page Count:
6020
Type
Manual Type:
Workshop Manual / Service Manual
Language
Language:
English
Format
File Format:
PDF, ZIP
Digital Accessibility:
The PDF/ZIP format ensures high accessibility across various devices and operating systems, offering flexibility for use in a workshop or on the go.
Compatibility
Operating Systems:
Win95/98/ME/XP/vista/7/Linux/MAC
Distribution
Delivery Method:
Instant Download
Shipping Info:
No shipping cost, no waiting for CD-ROM, instant download.
📖 Manual Coverage
Systems
Systems Covered:
Engine Mechanical, Engine Fuel System, Engine Electrical, Cooling System, Lubrication System, Exhaust System, Ignition System, Starting System, Charging System, Transmission (Manual & Automatic), Drivetrain, Suspension System, Steering System, Brake System (Hydraulic & ABS), Wheel Alignment, Wheels and Tires, Body and Frame, Chassis, Electrical System (Lighting, Instrumentation, Power Accessories), HVAC System, Restraint Systems (Airbags, Seatbelts), Security System, Exterior Body Panels, Interior Trim, Diagnostics and Troubleshooting
Brake System Detail:
Section 5 'Brakes' will cover hydraulic system components, brake pad and rotor replacement, drum brake service, parking brake operation, and ABS system diagnostics and repair, including wheel speed sensors and hydraulic control units.
Suspension Steering Detail:
Section 3 'Steering, Suspension, Wheels and Tyres' includes procedures for shock absorber replacement, spring service, ball joint and tie rod end replacement, power steering system repair, wheel bearing service, and tire condition and pressure checks.
Axle Drivetrain Detail:
Section 4 'Axle' will cover front and rear axle components, differential service, drive shaft maintenance, universal joints, and CV joints, depending on the specific KP190 configuration.
Cab And Interior Coverage:
Sections 2 'Frame and Cab', 8 'Body', and 10 'Cab' collectively cover the driver and passenger cabin, including seating, dashboard, interior trim panels, sound insulation, door hardware, and potentially cab tilting mechanisms for commercial variants.
Procedures
Procedures Included:
Routine Maintenance, Scheduled Maintenance, Component Removal and Installation, Component Overhaul and Reassembly, Diagnostic Procedures, Troubleshooting Guides, Electrical System Schematics, Wiring Diagrams, Torque Specifications, Fluid Capacities and Specifications, Special Tool Recommendations, Step-by-step Repair Instructions, Inspection Procedures, Adjustment Procedures, Replacement Procedures
Troubleshooting Methodology:
The manual will provide structured troubleshooting trees and symptom-based diagnostics to help technicians identify the root cause of malfunctions across all vehicle systems.
Diagnostic Tools:
The manual may list specific diagnostic scan tools or procedures required for accessing vehicle diagnostic trouble codes (DTCs) and performing system tests.
Engine Rebuild Steps:
Detailed procedures for engine disassembly, cleaning, inspection of critical components (pistons, rings, bearings, cylinder heads), machining specifications, and reassembly with correct clearances and torque sequences will be included.
Depth
Technical Depth:
Comprehensive; covers everything from basic maintenance tasks to complete engine and transmission rebuilds, advanced diagnostics, and body repair. Suitable for professional technicians and advanced DIY enthusiasts.
Bodywork
Body And Frame Detail:
Section 2 'Frame and Cab' and Section 8 'Body' will provide information on chassis structural integrity, cab mounting, door mechanisms, body panel repair, glass replacement, and interior trim removal/installation.
Security
Security System Detail:
Section 11 'Security' likely covers the vehicle's alarm system, immobilizer, keyless entry, and any related electronic control units or sensors. Procedures for diagnostics and potential key programming (if applicable) might be included.
Technical Data
Torque Specifications:
Precise torque values for all fasteners related to engine components, suspension, brakes, and bodywork will be provided, crucial for safe and effective repairs.
Wiring Diagrams:
Extensive and detailed wiring diagrams for all electrical systems, including engine control, lighting, power accessories, and communication networks, will be a key component of the manual.
📊 Manual Specifications
File Characteristics
File Quality:
High-resolution PDF suitable for printing and screen viewing, likely with searchable text for efficient information retrieval.
Searchability:
PDF format generally allows for text searching, enabling users to quickly locate specific topics, component names, or diagnostic codes.
Zip Format Utility:
The ZIP format ensures all related manual files, diagrams, and potentially additional software or documentation are contained in a single, easily transferable package.
Physical Attributes
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Variants
Engine Options:
4JA1-T, 4JH1-TC, 4JJ1, 4JK1, C24SE, HFV6. These represent a range of diesel and potentially gasoline engines, indicating versatility in the KP190 series, possibly including light commercial vehicles or SUVs.
General Notes
Engine Coverage Detail:
The manual will provide detailed specifications, diagnostic procedures, and repair instructions for each listed engine variant, including potential differences in fuel injection, turbocharging, and emission control systems.
Diesel Engines
Diesel Engine Common Features:
The 4JA1-T, 4JH1-TC, 4JJ1, and 4JK1 engines are all known Isuzu diesel powerplants, often featuring turbocharging and direct injection. They are renowned for their durability and fuel efficiency in light-duty applications. The 'T' signifies turbocharging.
Gasoline Engine
Gasoline Engine Identifier:
C24SE is likely a 2.4L gasoline engine. HFV6 indicates a V6 gasoline engine, potentially a GM-derived unit given Isuzu's historical ties.
Turbocharging
Turbocharger Service:
For turbocharged variants (4JA1-T, 4JH1-TC), the manual will detail turbocharger inspection, lubrication requirements, and common failure modes.
Emissions Control
Emission System Service:
The manual will likely include procedures for servicing emission control systems such as EGR (Exhaust Gas Recirculation) valves, catalytic converters, and diesel particulate filters (if equipped on later models).
🔧 Transmission
Types
Transmission Options:
The manual likely covers both manual and automatic transmission options for the KP190 series. Specific details on gear ratios, clutch operation, torque converter function, and transmission fluid specifications will be included.
📐 Dimensions
Vehicle Class
Vehicle Type:
The KP190 designation, along with the range of diesel engines, suggests the Isuzu KP190 Series likely falls into categories such as light commercial trucks, pickups, or rugged SUVs, common for Isuzu's global offerings.
🛡️ Safety Features
Features Coverage
Restraint Systems:
Section 9 'Restraints' confirms coverage of safety systems such as airbags, seatbelt pre-tensioners, and potentially passive safety features. The manual will detail their operation, inspection, and replacement.
Active Safety Features:
While ABS is mentioned under brakes, the manual will detail its operation and troubleshooting. Other active safety features, if present, will also be covered.
Passive Safety Features:
Beyond airbags and seatbelts, passive features like body structure design for crash energy absorption and head restraints will be implicitly covered in structural and body repair sections.
💡 Technology Features
Vehicle Systems
HVAC Coverage:
Section 1 'Heating and Airconditioning' indicates comprehensive coverage of the HVAC system, including component testing, refrigerant handling (with appropriate safety warnings), diagnosis of cooling and heating performance issues, and repair of ducting and blower systems.
Electrical Coverage
Electrical System Detail:
Sections on Engine Electrical, Charging System, Starting System, and general Electrical System within the Body section, along with detailed wiring diagrams, will cover all aspects of the vehicle's electrical components, sensors, actuators, ECUs, and control modules.
Infotainment
Infotainment System Coverage:
Basic infotainment systems of the era (radio, CD player, potentially auxiliary inputs) will be covered under the electrical systems section, detailing their power supply, speakers, and control units.
🔧 Maintenance
Intervals
Service Intervals Coverage:
The manual will detail recommended service intervals for oil changes, filter replacements, fluid checks, belt inspections, and other critical maintenance tasks, tailored to each engine variant and driving conditions.
Fluids
Fluid Specifications:
Expect detailed specifications for engine oil (viscosity grades like 5W-30, 10W-30, and API classifications), transmission fluid (ATF types, manual gear oil grades), coolant (type and mixture), brake fluid (DOT specifications), and power steering fluid.
Common Issues
Known Issues Diagnostics:
While specific common issues are not listed, the manual's extensive coverage implies it will address typical wear-and-tear components, potential diesel-specific issues (e.g., glow plugs, injection systems), and common electrical or HVAC problems encountered in vehicles of this era.
Engine Oil
Engine Oil Specification:
Likely to recommend API CI-4 or CJ-4 for diesel engines, with viscosity grades such as 15W-40 or 10W-30 depending on climate. Gasoline engines may require API SN/SM with 5W-30 or 10W-30.
Cooling System
Coolant Specification:
Typically a heavy-duty coolant with a long-life formulation, often ethylene glycol-based, with specific freeze protection and corrosion inhibitor packages. May require a specific color or type for Isuzu vehicles.
Brake Fluid
Brake Fluid Specification:
Standard DOT 3 or DOT 4 brake fluid is usually specified for most vehicles of this era.
Service Intervals
Tire Rotation Interval:
Likely recommends tire rotation every 5,000 to 7,500 miles (8,000 to 12,000 km) to ensure even wear.
Engine Air Filter Replacement:
Recommended replacement typically every 15,000 to 30,000 miles (24,000 to 48,000 km) or sooner if operating in dusty conditions.
Fuel Filter Replacement:
Diesel fuel filter replacement intervals are critical and will be specified, often around 15,000 to 30,000 miles (24,000 to 48,000 km).
Transmission Fluid Change:
Manual transmission fluid change typically every 50,000 to 100,000 miles (80,000 to 160,000 km). Automatic transmission fluid service is often more frequent, potentially every 30,000 to 60,000 miles (48,000 to 96,000 km), depending on usage.
📚 Vehicle History
Brand Context
Brand Heritage:
Isuzu has a long history of producing robust diesel engines and durable vehicles, particularly in the commercial and utility segments. This manual reflects Isuzu's focus on reliability and serviceability.
Model Context
Model Evolution:
The KP190 series likely represents a specific generation or platform within Isuzu's light-duty vehicle lineup during the late 2000s, known for its workhorse capabilities.
Production Details
Manufacturing Locations:
Isuzu vehicles are manufactured globally. Specific manufacturing locations for the KP190 series during 2007-2009 would typically be in Japan, Thailand, or other Asian markets where Isuzu has significant production facilities.
🏆 Awards & Recognition
Vehicle Recognition
Industry Ratings:
While specific awards for the KP190 series are not detailed here, Isuzu vehicles are often recognized for their durability, fuel efficiency (especially diesel variants), and utility in commercial and off-road applications.
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