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Isuzu KP190 Series Truck 2007-2009 Service & Repair Workshop Manual

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🏷️ Basic Information Identification Make: Isuzu Model: KP190 Series Truck Year: 2007-2009 Codes Chassis Code: KP190 Series 👋 Introduction Market Position Vehicle Segment: Light-duty commercial truck, often used for local delivery, trades, and utility services Competitive Analysis Competitors: Mitsubishi Fuso Canter, Hino 300 Series, Ford Transit, Chevrolet Express/GMC Savana (depending on market and specific configuration) Key Features Manual Value Proposition: Authoritative, factory-level repair information for efficient and accurate vehicle maintenance and repair Vehicle Attributes: Known for Isuzu's reputation for durability, fuel efficiency, and reliability in commercial applications. Target Audience: Professional mechanics, truck owners with mechanical aptitude, fleet maintenance departments. 📋 Manual Details Coverage Areas Primary Coverage: Service, Repair, Troubleshooting Page Count Estimated Pages: Hundreds (specific number not provided, but described as very detailed) Manual Type Type: Factory Service & Repair Workshop Manual Language Language: English (implied by product description and typical for this market) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, intake, exhaust, emissions, starting, charging, ignition, engine management (ECU) Drivetrain Systems: Transmission (manual/automatic, depending on specific KP190 variant), clutch, driveshafts, differentials, axles Chassis Systems: Brakes (hydraulic, ABS), steering, suspension (front/rear), wheels, tires Electrical Systems: Wiring diagrams, lighting, instruments, accessories, body electronics, starter, alternator, battery Body Systems: Body panels, doors, windows, interior trim, seats, HVAC (heating, ventilation, air conditioning), body structure Cooling System: Radiator, fan, water pump, thermostat, coolant hoses, heater core, diagnosis and repair. Fuel System Diesel: Fuel tank, fuel lines, fuel pump, fuel filter, injectors, common rail, high-pressure lines, troubleshooting and repair. Procedures Included Maintenance Procedures: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotation, battery maintenance Repair Procedures: Component removal and installation, rebuilds, adjustments, replacement of wear items (e.g., brake pads, belts, hoses) Troubleshooting Procedures: Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation, electrical system diagnostics Engine Rebuild: Detailed procedures for engine disassembly, inspection, component replacement, and reassembly. Brake System Repair: Brake pad/shoe replacement, caliper/wheel cylinder service, rotor/drum replacement, bleeding the brake system. Suspension And Steering Alignment: Alignment specifications, component replacement (ball joints, tie rod ends, control arms), power steering system service. Technical Depth Depth: Comprehensive (covering all repairs, servicing, and troubleshooting) Detail Level: Step-by-step instructions, detailed photos, exploded diagrams Diagnostic Tools: Information on diagnostic connectors, scan tool usage (OBD-II for relevant systems), and interpreting diagnostic trouble codes (DTCs). 📊 Manual Specifications File Format Compatibility: Windows and MAC OS Searchability: Likely searchable text content within the PDF for quick information retrieval. Print Quality Printable: Yes (single page or entire manual) Resolution: High-resolution, clear images and diagrams suitable for printing. Binding Type Binding: Digital (downloadable PDF) Paper Type Paper Type: N/A (digital format) Licensing Usage Rights: Lifetime use on unlimited devices, no expiry dates ⚙️ Engine Specifications Primary Engine Engine Type: Likely a diesel engine, common for Isuzu trucks of this era. Specific engine codes (e.g., 4JJ1, 4HK1) are not provided but would be detailed in the manual. Performance Horsepower: Varies by specific engine and GVWR of the KP190 variant. Typically in the range of 100-150 HP for light-duty trucks. Torque: Varies by specific engine. Diesel engines of this class typically produce between 200-300 lb-ft of torque. Fuel System Fuel Delivery: Likely Common Rail Direct Injection (CRDI) diesel. Manual will detail injection timing, pressures, and components. Fluid Specifications Engine Oil Type: Specific API and SAE viscosity grade for diesel engines (e.g., API CJ-4 or CK-4, SAE 5W-30 or 15W-40) will be detailed in the manual. Coolant Type: Ethylene glycol based coolant with corrosion inhibitors. Specific type and mixture ratio detailed in the manual. Engine Management ECU Identification: The manual will likely provide details on the Engine Control Unit (ECU) or Powertrain Control Module (PCM), including connector pinouts and diagnostic strategies. 🔧 Transmission Standard Transmission Type: Likely a 5-speed or 6-speed manual transmission. Automatic transmissions may also be an option depending on configuration. Optional Optional Transmission: Automatic transmission may be available as an option. Features Transmission Fluid Type: Specific manual transmission fluid (MTF) or automatic transmission fluid (ATF) grade will be specified in the manual. 📐 Dimensions Exterior Body Styles: Typically available as a cab-chassis, allowing for various body applications (e.g., box truck, flatbed, utility body). Weights Gross Vehicle Weight Rating Gvwr: Varies significantly by chassis configuration and intended use, typically within the Class 3 to Class 5 range (10,001 to 26,000 lbs). 🛡️ Safety Features Ratings Crash Test Ratings: Commercial vehicles of this era may have different testing protocols than passenger cars. Specific ratings not publicly available in a standardized format for all variants. Active Features Braking System: Hydraulic disc brakes front and rear are common. ABS (Anti-lock Braking System) is likely standard or optional. Passive Features Occupant Protection: Seat belts, reinforced cab structure. Airbags may be standard or optional depending on the specific model and market. 💡 Technology Features Infotainment Entertainment Features: Base level infotainment,...
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Sku: 446161
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Isuzu KP190 Series Truck 2007-2009 Service & Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Isuzu
Model:
KP190 Series Truck
Year:
2007-2009
Codes
Chassis Code:
KP190 Series
👋 Introduction
Market Position
Vehicle Segment:
Light-duty commercial truck, often used for local delivery, trades, and utility services
Competitive Analysis
Competitors:
Mitsubishi Fuso Canter, Hino 300 Series, Ford Transit, Chevrolet Express/GMC Savana (depending on market and specific configuration)
Key Features
Manual Value Proposition:
Authoritative, factory-level repair information for efficient and accurate vehicle maintenance and repair
Vehicle Attributes:
Known for Isuzu's reputation for durability, fuel efficiency, and reliability in commercial applications.
Target Audience:
Professional mechanics, truck owners with mechanical aptitude, fleet maintenance departments.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Repair, Troubleshooting
Page Count
Estimated Pages:
Hundreds (specific number not provided, but described as very detailed)
Manual Type
Type:
Factory Service & Repair Workshop Manual
Language
Language:
English (implied by product description and typical for this market)
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, intake, exhaust, emissions, starting, charging, ignition, engine management (ECU)
Drivetrain Systems:
Transmission (manual/automatic, depending on specific KP190 variant), clutch, driveshafts, differentials, axles
Chassis Systems:
Brakes (hydraulic, ABS), steering, suspension (front/rear), wheels, tires
Electrical Systems:
Wiring diagrams, lighting, instruments, accessories, body electronics, starter, alternator, battery
Body Systems:
Body panels, doors, windows, interior trim, seats, HVAC (heating, ventilation, air conditioning), body structure
Cooling System:
Radiator, fan, water pump, thermostat, coolant hoses, heater core, diagnosis and repair.
Fuel System Diesel:
Fuel tank, fuel lines, fuel pump, fuel filter, injectors, common rail, high-pressure lines, troubleshooting and repair.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication, tire rotation, battery maintenance
Repair Procedures:
Component removal and installation, rebuilds, adjustments, replacement of wear items (e.g., brake pads, belts, hoses)
Troubleshooting Procedures:
Diagnostic flowcharts, symptom-based troubleshooting, fault code interpretation, electrical system diagnostics
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, component replacement, and reassembly.
Brake System Repair:
Brake pad/shoe replacement, caliper/wheel cylinder service, rotor/drum replacement, bleeding the brake system.
Suspension And Steering Alignment:
Alignment specifications, component replacement (ball joints, tie rod ends, control arms), power steering system service.
Technical Depth
Depth:
Comprehensive (covering all repairs, servicing, and troubleshooting)
Detail Level:
Step-by-step instructions, detailed photos, exploded diagrams
Diagnostic Tools:
Information on diagnostic connectors, scan tool usage (OBD-II for relevant systems), and interpreting diagnostic trouble codes (DTCs).
📊 Manual Specifications
File Format
Compatibility:
Windows and MAC OS
Searchability:
Likely searchable text content within the PDF for quick information retrieval.
Print Quality
Printable:
Yes (single page or entire manual)
Resolution:
High-resolution, clear images and diagrams suitable for printing.
Binding Type
Binding:
Digital (downloadable PDF)
Paper Type
Paper Type:
N/A (digital format)
Licensing
Usage Rights:
Lifetime use on unlimited devices, no expiry dates
⚙️ Engine Specifications
Primary Engine
Engine Type:
Likely a diesel engine, common for Isuzu trucks of this era. Specific engine codes (e.g., 4JJ1, 4HK1) are not provided but would be detailed in the manual.
Performance
Horsepower:
Varies by specific engine and GVWR of the KP190 variant. Typically in the range of 100-150 HP for light-duty trucks.
Torque:
Varies by specific engine. Diesel engines of this class typically produce between 200-300 lb-ft of torque.
Fuel System
Fuel Delivery:
Likely Common Rail Direct Injection (CRDI) diesel. Manual will detail injection timing, pressures, and components.
Fluid Specifications
Engine Oil Type:
Specific API and SAE viscosity grade for diesel engines (e.g., API CJ-4 or CK-4, SAE 5W-30 or 15W-40) will be detailed in the manual.
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors. Specific type and mixture ratio detailed in the manual.
Engine Management
ECU Identification:
The manual will likely provide details on the Engine Control Unit (ECU) or Powertrain Control Module (PCM), including connector pinouts and diagnostic strategies.
🔧 Transmission
Standard
Transmission Type:
Likely a 5-speed or 6-speed manual transmission. Automatic transmissions may also be an option depending on configuration.
Optional
Optional Transmission:
Automatic transmission may be available as an option.
Features
Transmission Fluid Type:
Specific manual transmission fluid (MTF) or automatic transmission fluid (ATF) grade will be specified in the manual.
📐 Dimensions
Exterior
Body Styles:
Typically available as a cab-chassis, allowing for various body applications (e.g., box truck, flatbed, utility body).
Weights
Gross Vehicle Weight Rating Gvwr:
Varies significantly by chassis configuration and intended use, typically within the Class 3 to Class 5 range (10,001 to 26,000 lbs).
🛡️ Safety Features
Ratings
Crash Test Ratings:
Commercial vehicles of this era may have different testing protocols than passenger cars. Specific ratings not publicly available in a standardized format for all variants.
Active Features
Braking System:
Hydraulic disc brakes front and rear are common. ABS (Anti-lock Braking System) is likely standard or optional.
Passive Features
Occupant Protection:
Seat belts, reinforced cab structure. Airbags may be standard or optional depending on the specific model and market.
💡 Technology Features
Infotainment
Entertainment Features:
Base level infotainment, likely including AM/FM radio, CD player, and possibly auxiliary input. Advanced features would be rare for a commercial truck of this period.
Driver Assistance
Assistance Systems:
ABS is the most probable driver assistance system. Cruise control might be optional.
Connectivity
Connectivity Options:
Limited to basic 12V power outlets or cigarette lighter sockets for device charging.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 to 10,000 miles or 6-12 months, depending on operating conditions. The manual will provide precise intervals.
Air Filter Replacement:
Recommended at regular intervals (e.g., 15,000-30,000 miles) or if visually dirty. Manual will specify.
Fuel Filter Replacement:
Crucial for diesel engines. Intervals typically range from 10,000 to 25,000 miles. Manual will provide exact specification.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, as specified by Isuzu. Manual will confirm.
Power Steering Fluid:
Specific hydraulic fluid or ATF, depending on the system. Manual will provide specification.
Known Issues
Common Wear Items:
Brake components (pads, rotors), suspension bushings, exhaust system components, and glow plugs (for diesel) are common wear items.
Diesel Specific Considerations:
Fuel system cleanliness, EGR system maintenance, and DPF (Diesel Particulate Filter) regeneration/service are critical for diesel engines of this era.
Fluid Capacities
Engine Oil Capacity:
Specific oil capacity in quarts or liters will be detailed based on engine variant.
Coolant Capacity:
Total engine cooling system capacity will be specified.
Torque Specifications
Engine Component Torque:
Precise torque values for cylinder head bolts, crankshaft main bearings, connecting rod bolts, etc., will be provided.
Wheel Lug Nut Torque:
Correct torque specification for wheel lug nuts to ensure proper wheel mounting.
📚 Vehicle History
Brand Heritage
Isuzu Truck Legacy:
Isuzu has a long-standing reputation for producing reliable and durable commercial vehicles, particularly in the light and medium-duty segments globally.
Model Evolution
Kp Series Lineage:
The KP190 likely represents an evolution of Isuzu's earlier NPR or N-Series trucks, adapted for specific markets and emissions standards of the late 2000s.
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