Isuzu KB P190 Truck 2007-2012 Service & Repair Workshop Manual
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๐ท๏ธ Basic Information Identification Make: Isuzu Model: KB Truck Model Designation: P190 Years Covered: 2007-2012 Codes Chassis Code Identifier: KB Series (Specific P190 chassis codes would be detailed within the manual) ๐ Introduction Market Position Vehicle Segment: Light Commercial Vehicle (LCV) / Pickup Truck Target Audience: Owners seeking to perform maintenance and repairs, Independent repair shops, Fleet maintenance departments Competitive Analysis Competitors: Toyota Hilux, Nissan Navara, Ford Ranger, Mitsubishi Triton (during the 2007-2012 period) Key Features Manual Value: Provides factory-level accuracy for repairs, reducing reliance on external shops and potentially costly mistakes. Download Benefit: Instant access to comprehensive repair information, enabling immediate problem-solving. ๐ Manual Details Coverage Areas Primary Focus: Service, Repair, and Troubleshooting Scope: Comprehensive factory-level procedures Page Count Estimated Page Count: Hundreds (Specific count not provided but described as extensive) Manual Type Type: Workshop Service & Repair Manual Language Language: English (Assumed based on typical market distribution and manual description) Format Format: Downloadable PDF ๐ Manual Coverage Systems Covered Powertrain: Engine (mechanical and electrical), Fuel System, Exhaust System, Cooling System, Lubrication System Drivetrain: Transmission (manual/automatic, if applicable), Clutch, Driveshafts, Differentials, Axles Chassis: Suspension (front and rear), Steering System, Brakes (hydraulic, pneumatic if applicable), Wheels and Tires Body And Frame: Frame structure, Body panels, Doors, Windows, Seats, Interior trim, Exterior trim Electrical: Battery, Starting system, Charging system, Ignition system, Lighting, Instrumentation, Audio system, HVAC controls, Wiring diagrams, ECUs Diagnostics: Troubleshooting guides, Diagnostic trouble codes (DTCs), Symptom-based diagnostics Procedures Included Maintenance: Scheduled maintenance, Oil changes, Filter replacements, Fluid checks and changes, Lubrication points Repair: Component removal and installation, Rebuild procedures, Adjustments, Calibration Troubleshooting: Step-by-step diagnostic flowcharts, Fault finding Specifications: Torque specifications, Clearance measurements, Electrical values Technical Depth Depth: Detailed mechanical and electrical diagnostics, component-level repair, complete system overhauls Visuals: Hundreds of detailed photos, diagrams, and exploded views ๐ Manual Specifications File Format Format: PDF Accessibility: Printable (single pages or entire manual), Multi-device compatibility (computer, tablet, smartphone) Licensing: Lifetime use, No expiry, No renewal fees Platform Compatibility: Windows and macOS Print Quality Print Usability: High-resolution for clear printing of diagrams and text Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Engine Family: Isuzu 4J series (e.g., 4JH1-TC common for this generation of Isuzu trucks) Engine Variants Common Displacements: Likely 2.5L (2500cc) and 3.0L (3000cc) diesel variants Induction: Turbocharged and Intercooled Diesel (common for efficiency and power) Performance Horsepower Range: Typically 80-120 HP (for 2.5L) and 110-145 HP (for 3.0L), depending on specific tune and market Torque Range: Approximately 170-220 Nm (for 2.5L) and 240-330 Nm (for 3.0L) Fuel System Fuel Type: Diesel Injection System: Common Rail Direct Injection (CRDi) likely for models within this range ๐ง Transmission Standard Transmission Type: 5-speed Manual Transmission (MFS5W, RFS6W common Isuzu gearboxes) Optional Transmission Type: 4-speed Automatic Transmission (likely for certain trims/markets) Features Drive Layout: Rear-Wheel Drive (RWD) standard; 4-Wheel Drive (4WD) optional ๐ Dimensions Exterior Body Styles: Single Cab, Extended Cab, Double Cab Bed Lengths: Various bed lengths depending on configuration and market (e.g., standard, long bed) Weights Gross Vehicle Weight Rating: Typically in the 2.5 to 3.5 Tonne range (GVWR specified per variant) Curb Weight: Varies significantly based on configuration (e.g., 1500-2000 kg) ๐ก๏ธ Safety Features Ratings Crash Test Ratings: Varies by market and testing agency (e.g., ANCAP, Euro NCAP). Early models may have had fewer advanced safety features compared to later vehicles. Active Features Braking System: Front Disc / Rear Drum brakes standard; ABS (Anti-lock Braking System) likely optional or standard on higher trims Passive Features Airbags: Driver and passenger airbags likely standard or optional depending on trim and market Seatbelts: 3-point seatbelts with pre-tensioners (front seats) ๐ก Technology Features Infotainment Audio System: Basic AM/FM radio with CD player was common; auxiliary inputs and Bluetooth may have been available on higher trims. Driver Assistance Stability Control: Electronic Stability Control (ESC) was generally not standard on LCVs of this era, but may have been optional on higher trims. Connectivity Connectivity Features: Limited compared to modern vehicles; focus was on utility and reliability. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 5,000 - 10,000 km or 6 months (refer to manual for specific diesel engine type and oil spec) Air Filter Replacement: Typically 20,000 - 40,000 km or annually Fuel Filter Replacement: Typically 30,000 - 60,000 km, or as per manual recommendations for diesel engines Fluid Specifications Engine Oil Type: Diesel Engine Oil: API CF or higher, SAE 10W-30 or 15W-40 recommended (refer to manual for exact viscosity and specification based on ambient temperature) Coolant Type: Ethylene Glycol based antifreeze coolant, typically silicate-free (refer to manual for specific Isuzu coolant specification) Brake Fluid Type: DOT 3 or DOT 4 brake fluid (refer to manual for exact specification) Transmission Fluid Type: Manual: GL-4 or GL-5 gear oil (viscosity typically 75W-90); Automatic: Dexron III or...
Various bed lengths depending on configuration and market (e.g., standard, long bed)
Weights
Gross Vehicle Weight Rating:
Typically in the 2.5 to 3.5 Tonne range (GVWR specified per variant)
Curb Weight:
Varies significantly based on configuration (e.g., 1500-2000 kg)
๐ก๏ธ Safety Features
Ratings
Crash Test Ratings:
Varies by market and testing agency (e.g., ANCAP, Euro NCAP). Early models may have had fewer advanced safety features compared to later vehicles.
Active Features
Braking System:
Front Disc / Rear Drum brakes standard; ABS (Anti-lock Braking System) likely optional or standard on higher trims
Passive Features
Airbags:
Driver and passenger airbags likely standard or optional depending on trim and market
Seatbelts:
3-point seatbelts with pre-tensioners (front seats)
๐ก Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player was common; auxiliary inputs and Bluetooth may have been available on higher trims.
Driver Assistance
Stability Control:
Electronic Stability Control (ESC) was generally not standard on LCVs of this era, but may have been optional on higher trims.
Connectivity
Connectivity Features:
Limited compared to modern vehicles; focus was on utility and reliability.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 10,000 km or 6 months (refer to manual for specific diesel engine type and oil spec)
Air Filter Replacement:
Typically 20,000 - 40,000 km or annually
Fuel Filter Replacement:
Typically 30,000 - 60,000 km, or as per manual recommendations for diesel engines
Fluid Specifications
Engine Oil Type:
Diesel Engine Oil: API CF or higher, SAE 10W-30 or 15W-40 recommended (refer to manual for exact viscosity and specification based on ambient temperature)
Coolant Type:
Ethylene Glycol based antifreeze coolant, typically silicate-free (refer to manual for specific Isuzu coolant specification)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification)
Transmission Fluid Type:
Manual: GL-4 or GL-5 gear oil (viscosity typically 75W-90); Automatic: Dexron III or equivalent (refer to manual)
Known Issues
Common Complaints:
Potential for injector pump issues (common on older diesel CRDi), turbocharger wear, EGR valve problems, clutch wear (manual transmissions), suspension component wear due to load carrying.
Troubleshooting Focus:
The manual would be invaluable for diagnosing and rectifying these common issues efficiently.
๐ Vehicle History
Brand Heritage
Isuzu Legacy:
Isuzu has a long history in producing reliable diesel engines and commercial vehicles, with the KB model line being a significant part of its global LCV offerings.
Model Evolution
Generation:
The KB series is part of Isuzu's long-standing lineage of pickup trucks, often rebadged by other manufacturers (e.g., Holden Rodeo/Colorado in some markets).
Production
Manufacturing Locations:
Primarily manufactured in Thailand and potentially other global assembly plants for Isuzu.
๐ Awards & Recognition
Recognitions
Industry Awards:
While specific awards for the 2007-2012 Isuzu KB P190 are not prominently advertised, Isuzu vehicles are frequently recognized for their diesel engine durability and off-road capability in various markets.