Isuzu D-Max P190 2007-2010 Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Isuzu Model: D-Max Generation Code: P190 Model Years Covered: 2007-2010 ๐ Introduction Market Position Target Audience: Mechanical technicians, professional mechanics, and advanced DIY enthusiasts familiar with automotive service procedures. Competitive Analysis Value Proposition: Provides dealership-level technical information, enabling accurate repairs and maintenance, potentially saving significant costs compared to dealership labor. Key Features Emphasis On Safety: Highlights the importance of safety equipment and precautions, including the use of torque wrenches for critical fasteners. Special Tools: Identifies and illustrates specific Isuzu special tools required for certain adjustments and repairs. Proprietary Components: Includes instructions for proprietary components, integrating manufacturer guidance for proper function and performance assessment. Warning Symbols: Utilizes specific wording and symbols (WARNING, CAUTION, NOTE) to convey critical information and procedural emphasis. ๐ Manual Details Coverage Areas Manual Scope: Comprehensive workshop service and repair Page Count Total Pages: 6020 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF ๐ Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, disassembly/assembly, overhaul, internal components, cooling system, lubrication system, fuel system, intake and exhaust systems. Engine Management: Ignition system, fuel injection systems, emissions control systems, engine control module (ECM) diagnostics and troubleshooting. Transmission Drivetrain: Manual and automatic transmission overhaul, repair, removal/installation, clutch system, driveshafts, differentials, axles. Chassis Suspension: Front and rear suspension systems, shock absorbers, springs, control arms, steering system, power steering, wheel alignment. Braking System: Brake system overhaul, hydraulic components, disc brakes, drum brakes, parking brake, ABS (Anti-lock Braking System) diagnostics and repair. Electrical System: Complete electrical system diagrams, charging system (alternator, battery), starting system, lighting, instrumentation, power windows, door locks, accessories, fuses and relays. Body Exterior Interior: Body panel repair, doors, hood, tailgate, bumpers, interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) system. Procedures Included Routine Maintenance: Oil changes, fluid checks and top-offs, filter replacements, tire rotation, brake inspection, battery maintenance. Diagnostic Troubleshooting: Systematic diagnostic procedures for common and uncommon issues, fault code interpretation, wiring diagrams for troubleshooting. Repair Overhaul: Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Technical Specifications: Torque specifications for fasteners, fluid capacities, fluid types, electrical resistance values, component tolerances. Technical Depth Depth: Advanced diagnostics and complete overhaul procedures, suitable for professional technicians and experienced DIY mechanics. ๐ Manual Specifications File Format Format: PDF Searchability: Likely text-searchable within the PDF viewer, enhancing usability. Print Quality Printability: Yes, printable pages. Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper: Not applicable (Digital PDF) โ๏ธ Engine Specifications Primary Engine Engine Options: The manual covers various engine options likely present in the P190 D-Max range from 2007-2010, typically including diesel engines. Specific engine codes are not provided in the product description but would be detailed within the manual (e.g., 4JJ1, 4JK1 variants for diesel). Performance Performance Details: The manual provides specifications for horsepower, torque, and other performance metrics pertinent to each engine variant, crucial for diagnostics and tuning. Fuel System Fuel System Types: Covers diesel fuel injection systems, fuel pumps, injectors, fuel filters, and related components. ๐ง Transmission Standard Standard Transmission Type: Likely manual transmission, with detailed procedures for gear shifting mechanisms and components. Optional Optional Transmission Type: Likely automatic transmission, with comprehensive coverage of hydraulic systems, torque converters, and electronic controls. Features Transmission Fluid Specs: Details specific transmission fluid types and capacities required for optimal performance and longevity. ๐ Dimensions Exterior Body Styles: The D-Max P190 was available in various body styles including single cab, extended cab (space cab), and double cab, with potential variations in dimensions. Weights Gross Vehicle Weight: The manual will contain Gross Vehicle Weight (GVW) ratings and curb weights for different configurations, essential for payload calculations and safety. ๐ก๏ธ Safety Features Ratings Crash Safety: While the manual itself doesn't provide crash ratings, it covers safety-critical systems like brakes, airbags, and seatbelts, which contribute to overall vehicle safety. Active Features ABS System: Detailed information on the Anti-lock Braking System (ABS), including component testing, diagnostics, and repair procedures. Passive Features Airbag System: Procedures for airbag system diagnostics, inspection of SRS (Supplemental Restraint System) components, and safety precautions when working near airbag modules. ๐ก Technology Features Infotainment Audio System: Details related to the factory-installed audio system, including speaker configurations and potential troubleshooting for head units. Driver Assistance ABS And Traction Control: Information on the operation and maintenance of ABS and potential traction control systems present on some models. Connectivity Electrical Component Diagnostics: The manual's extensive electrical diagrams are crucial for diagnosing and repairing any electronic control modules, sensors, or wiring harnesses related to vehicle functions. ๐ง Maintenance Service Intervals Scheduled Maintenance: The manual provides detailed scheduled maintenance charts outlining intervals for oil changes, filter replacements, fluid checks, and component inspections, typically based on mileage or time. Fluid Specifications Engine Oil Type: Specifies the correct viscosity grade and API specification for engine oil (e.g.,...
Front and rear suspension systems, shock absorbers, springs, control arms, steering system, power steering, wheel alignment.
Braking System:
Brake system overhaul, hydraulic components, disc brakes, drum brakes, parking brake, ABS (Anti-lock Braking System) diagnostics and repair.
Electrical System:
Complete electrical system diagrams, charging system (alternator, battery), starting system, lighting, instrumentation, power windows, door locks, accessories, fuses and relays.
Body Exterior Interior:
Body panel repair, doors, hood, tailgate, bumpers, interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) system.
Advanced diagnostics and complete overhaul procedures, suitable for professional technicians and experienced DIY mechanics.
๐ Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable within the PDF viewer, enhancing usability.
Print Quality
Printability:
Yes, printable pages.
Binding Type
Binding:
Not applicable (Digital PDF)
Paper Type
Paper:
Not applicable (Digital PDF)
โ๏ธ Engine Specifications
Primary Engine
Engine Options:
The manual covers various engine options likely present in the P190 D-Max range from 2007-2010, typically including diesel engines. Specific engine codes are not provided in the product description but would be detailed within the manual (e.g., 4JJ1, 4JK1 variants for diesel).
Performance
Performance Details:
The manual provides specifications for horsepower, torque, and other performance metrics pertinent to each engine variant, crucial for diagnostics and tuning.
Fuel System
Fuel System Types:
Covers diesel fuel injection systems, fuel pumps, injectors, fuel filters, and related components.
๐ง Transmission
Standard
Standard Transmission Type:
Likely manual transmission, with detailed procedures for gear shifting mechanisms and components.
Optional
Optional Transmission Type:
Likely automatic transmission, with comprehensive coverage of hydraulic systems, torque converters, and electronic controls.
Features
Transmission Fluid Specs:
Details specific transmission fluid types and capacities required for optimal performance and longevity.
๐ Dimensions
Exterior
Body Styles:
The D-Max P190 was available in various body styles including single cab, extended cab (space cab), and double cab, with potential variations in dimensions.
Weights
Gross Vehicle Weight:
The manual will contain Gross Vehicle Weight (GVW) ratings and curb weights for different configurations, essential for payload calculations and safety.
๐ก๏ธ Safety Features
Ratings
Crash Safety:
While the manual itself doesn't provide crash ratings, it covers safety-critical systems like brakes, airbags, and seatbelts, which contribute to overall vehicle safety.
Active Features
ABS System:
Detailed information on the Anti-lock Braking System (ABS), including component testing, diagnostics, and repair procedures.
Passive Features
Airbag System:
Procedures for airbag system diagnostics, inspection of SRS (Supplemental Restraint System) components, and safety precautions when working near airbag modules.
๐ก Technology Features
Infotainment
Audio System:
Details related to the factory-installed audio system, including speaker configurations and potential troubleshooting for head units.
Driver Assistance
ABS And Traction Control:
Information on the operation and maintenance of ABS and potential traction control systems present on some models.
Connectivity
Electrical Component Diagnostics:
The manual's extensive electrical diagrams are crucial for diagnosing and repairing any electronic control modules, sensors, or wiring harnesses related to vehicle functions.
๐ง Maintenance
Service Intervals
Scheduled Maintenance:
The manual provides detailed scheduled maintenance charts outlining intervals for oil changes, filter replacements, fluid checks, and component inspections, typically based on mileage or time.
Fluid Specifications
Engine Oil Type:
Specifies the correct viscosity grade and API specification for engine oil (e.g., 5W-30, 10W-40 diesel engine oil).
Coolant Type:
Details the type of engine coolant and antifreeze mixture required, often specifying an ethylene glycol-based coolant.
Brake Fluid Type:
Specifies the required brake fluid standard, typically DOT 3 or DOT 4.
Known Issues
Common D Max P190 Concerns:
While not explicitly stated in the product description, a comprehensive manual would address common issues such as potential turbocharger problems, EGR valve issues in diesel engines, or driveline wear, providing diagnostic and repair guidance.
Filter Part Numbers
Oil Filter P N:
The manual would list specific Isuzu or equivalent part numbers for oil filters, air filters, fuel filters, and cabin air filters.
๐ Vehicle History
Brand Heritage
Isuzu Truck Heritage:
Isuzu has a long history of producing robust and reliable trucks and commercial vehicles, a heritage reflected in the D-Max's engineering.
Model Evolution
D Max Generation P190:
The P190 represents a significant generation of the Isuzu D-Max, known for its durability and capability, building upon previous iterations.
Production
Manufacturing Locations:
Isuzu vehicles, including the D-Max, are manufactured in various locations globally, reflecting Isuzu's international presence.
๐ Awards & Recognition
Recognitions
Durability Reputation:
The Isuzu D-Max is widely recognized for its robust construction and reliability, often earning accolades in various international markets for its durability and off-road capability.