Isuzu D-Max Kb P190 2007-2010 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: Isuzu Model: D-Max Generation Code: KB P190 Model Years Covered: 2007, 2008, 2009, 2010 👋 Introduction Market Position Vehicle Segment: Mid-size pickup truck Competitive Analysis Key Competitors: Toyota Hilux, Mitsubishi Triton (L200), Ford Ranger, Nissan Navara Key Features Vehicle Strengths: Known for durability, reliability, and off-road capability Manual Value Proposition Cost Saving: Enables owners to perform maintenance and repairs themselves, saving on labor costs Accessibility: Instant digital access eliminates shipping delays and costs 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive workshop and service repair Target Audience: Professional technicians and DIY mechanics Page Count Estimated Page Count: Hundreds of pages (typical for comprehensive factory manuals) Manual Type Manual Classification: Workshop Service Manual / Repair Manual / Factory Service Manual Language Language Provided: English Format Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Powertrain: Engine, transmission, driveline, fuel system, cooling system, exhaust system Chassis: Suspension (front and rear), steering system, brakes (front and rear), wheels and tires Electrical: Engine control systems, body electrical systems, lighting, instrumentation, power accessories, audio system, wiring diagrams Body: Body structure, exterior panels, interior trim, doors, windows, seats, HVAC system Procedures Included Maintenance: Periodic maintenance charts, fluid changes, filter replacements, lubrication Repair: Step-by-step repair instructions for all major components and systems Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) Overhaul: Detailed overhaul procedures for engines, transmissions, and other major assemblies Technical Depth Diagnostic Capabilities: Advanced diagnostics including component testing and circuit analysis Repair Complexity: Covers everything from basic fluid checks to complete engine and transmission rebuilds Information Detail: Includes detailed torque specifications, clearances, and assembly procedures 📊 Manual Specifications File Format Document Format: PDF Print Quality Printability: Full Printable Zoom Functionality: YES (Zoom IN/OUT) Binding Type Digital Binding: Not Applicable (Digital Download) Paper Type Digital Paper Type: Not Applicable (Digital Download) Software Requirements Required Software: Adobe PDF Reader & WinRAR Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code Common: 4JJ1-TC (common for this generation, though other variants might exist) Engine Type Engine Configuration: 4-cylinder, inline, turbocharged diesel (common) Engine Displacement Displacement: 3.0 Liters (approx. 2999 cc for 4JJ1-TC) Performance Horsepower Range: Typically 130-160 HP (depending on specific engine variant and tuning) Torque Range: Typically 270-350 Nm (depending on specific engine variant and tuning) Fuel System Fuel Delivery: Common Rail Direct Injection (CRDi) Cooling System Cooling Type: Water-cooled, pressurized system Ignition System Ignition Type: Diesel Compression Ignition 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed or 5-speed Automatic Transmission (depending on market and trim) Features Drivetrain Options: Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) with transfer case 📐 Dimensions Exterior Body Styles: Single Cab, Extended Cab (Space Cab), Double Cab Bed Length Options: Varies by cab configuration (e.g., long bed, standard bed) Weights Curb Weight Range: Approx. 1,700 kg to 2,000 kg (depending on configuration) Gross Vehicle Weight Rating Gvwr: Typically around 2,700 kg to 3,000 kg 🛡️ Safety Features Ratings Safety Certification Typical: Refer to specific market crash test results (e.g., ANCAP, Euro NCAP if applicable) Active Features Braking System: Front disc brakes, Rear drum brakes (common), ABS (Anti-lock Braking System) available on some trims Traction Control: Available on some higher trims or 4WD models Passive Features Airbags: Driver and passenger airbags standard on most models, side airbags optional/available on higher trims Seat Belts: 3-point seat belts with pretensioners 💡 Technology Features Infotainment Audio System: Base models typically feature a single-DIN radio with CD player and basic speaker setup. Higher trims may offer 2-DIN units with USB/Aux inputs. Driver Assistance Cruise Control: Available on some higher trim levels. Connectivity Auxiliary Input: Auxiliary audio input jack commonly found on factory-fitted audio systems. Convenience Power Windows: Standard on higher trims, manual or power on lower trims depending on market. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000 to 10,000 km or 6 months, whichever comes first (refer to manual for exact specification) Air Filter Replacement: Every 20,000 to 40,000 km or as needed based on driving conditions Fuel Filter Replacement: Every 20,000 to 40,000 km or as per manual, crucial for diesel engines Fluid Specifications Engine Oil Grade: API CI-4 or higher, SAE 15W-40 or 10W-30 (refer to manual for specific viscosity based on climate) Engine Oil Capacity: Approximately 6.5 to 7.0 Liters (refer to manual for exact capacity) Coolant Type: Isuzu Long Life Coolant (blue or green) or equivalent ethylene glycol-based coolant Transmission Fluid Manual: API GL-4 or GL-5, SAE 75W-90 (gear oil) Transmission Fluid Automatic: Dexron III or equivalent ATF (Automatic Transmission Fluid) Known Issues Common Wear Item: Clutch wear, brake pad and rotor wear, suspension bushings, turbocharger wear (with high mileage/poor maintenance) Diesel Specific: Potential for injector issues or glow plug failures if maintenance is neglected, particularly fuel filter changes. 📚 Vehicle History...
Detailed overhaul procedures for engines, transmissions, and other major assemblies
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics including component testing and circuit analysis
Repair Complexity:
Covers everything from basic fluid checks to complete engine and transmission rebuilds
Information Detail:
Includes detailed torque specifications, clearances, and assembly procedures
📊 Manual Specifications
File Format
Document Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Functionality:
YES (Zoom IN/OUT)
Binding Type
Digital Binding:
Not Applicable (Digital Download)
Paper Type
Digital Paper Type:
Not Applicable (Digital Download)
Software Requirements
Required Software:
Adobe PDF Reader & WinRAR
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4JJ1-TC (common for this generation, though other variants might exist)
Engine Type
Engine Configuration:
4-cylinder, inline, turbocharged diesel (common)
Engine Displacement
Displacement:
3.0 Liters (approx. 2999 cc for 4JJ1-TC)
Performance
Horsepower Range:
Typically 130-160 HP (depending on specific engine variant and tuning)
Torque Range:
Typically 270-350 Nm (depending on specific engine variant and tuning)
Fuel System
Fuel Delivery:
Common Rail Direct Injection (CRDi)
Cooling System
Cooling Type:
Water-cooled, pressurized system
Ignition System
Ignition Type:
Diesel Compression Ignition
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed or 5-speed Automatic Transmission (depending on market and trim)
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) with transfer case
📐 Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Space Cab), Double Cab
Bed Length Options:
Varies by cab configuration (e.g., long bed, standard bed)
Weights
Curb Weight Range:
Approx. 1,700 kg to 2,000 kg (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Typically around 2,700 kg to 3,000 kg
🛡️ Safety Features
Ratings
Safety Certification Typical:
Refer to specific market crash test results (e.g., ANCAP, Euro NCAP if applicable)
Active Features
Braking System:
Front disc brakes, Rear drum brakes (common), ABS (Anti-lock Braking System) available on some trims
Traction Control:
Available on some higher trims or 4WD models
Passive Features
Airbags:
Driver and passenger airbags standard on most models, side airbags optional/available on higher trims
Seat Belts:
3-point seat belts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Base models typically feature a single-DIN radio with CD player and basic speaker setup. Higher trims may offer 2-DIN units with USB/Aux inputs.
Driver Assistance
Cruise Control:
Available on some higher trim levels.
Connectivity
Auxiliary Input:
Auxiliary audio input jack commonly found on factory-fitted audio systems.
Convenience
Power Windows:
Standard on higher trims, manual or power on lower trims depending on market.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 to 10,000 km or 6 months, whichever comes first (refer to manual for exact specification)
Air Filter Replacement:
Every 20,000 to 40,000 km or as needed based on driving conditions
Fuel Filter Replacement:
Every 20,000 to 40,000 km or as per manual, crucial for diesel engines
Fluid Specifications
Engine Oil Grade:
API CI-4 or higher, SAE 15W-40 or 10W-30 (refer to manual for specific viscosity based on climate)
Engine Oil Capacity:
Approximately 6.5 to 7.0 Liters (refer to manual for exact capacity)
Coolant Type:
Isuzu Long Life Coolant (blue or green) or equivalent ethylene glycol-based coolant
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 (gear oil)
Transmission Fluid Automatic:
Dexron III or equivalent ATF (Automatic Transmission Fluid)
Known Issues
Common Wear Item:
Clutch wear, brake pad and rotor wear, suspension bushings, turbocharger wear (with high mileage/poor maintenance)
Diesel Specific:
Potential for injector issues or glow plug failures if maintenance is neglected, particularly fuel filter changes.
📚 Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long history in commercial vehicles and robust utility trucks, translating into D-Max's reputation for toughness.
Model Evolution
D Max Platform:
The KB P190 is part of the second generation Isuzu D-Max, a platform known for its shared development with General Motors (GM) vehicles in certain markets.
Production
Manufacturing Locations:
Primarily manufactured in Thailand, with assembly plants in other regions for specific markets.
🏆 Awards & Recognition
Recognitions
Brand Reputation:
Isuzu D-Max is globally recognized for its ruggedness and reliability in challenging conditions, often winning 'Best Pickup' awards in various automotive publications.
Ratings
Durability Ranking:
Consistently ranks high in long-term reliability and durability surveys within the pickup truck segment.
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