2007 ISUZU KB P190 engine mount

ON-VEHICLE SERVICE (JR405E) 7A3-19
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
43ASSY119
2. Install the control valve assembly and tighten the 12 fixing bolts to the specified torque.
Number of bolts Length Color
10 (A) 40 mm (1.57 in) Gold
2 (B) 30 mm (1.18 in) Gold

Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
3. Connect the 2 harness connectors.
4. If removed, install the oil strainer.
Refer to “Solenoids, Oil Pressure Switch and Oil Temperature Sensor” previously in this section.
5. Install the new gasket and oil pan.
Bolt torque : 8 N·m (0.8 kgf·m/69 lb·in)
6. Fill with the fluid.
Refer to “ATF CHANGE” in this section.
7. Connect the negative battery cable.
8. Remove the wheel blocks.

FLUSHING THE TRANSMISSION FLUID COOLER AND LINE
The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. W hen an abnormal amount of debris is found.
2. W hen an abnormal wear or chips on gears and shafts is found while overhauling.
3. W hen there is abnormal clutch facing wear and oil contamination found.

Procedures
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with suitable safet
y
stands.
4. Disconnect the fluid cooler lines at the transmission case and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using solvent and compressed air.
Note:
DO NOT exceed (200 kPa/2.0 kgf/cm
2/28 psi) air
pressure, or damage may result to oil cooler.

6. Remove all remaining solvent from the system with
compressed air.
7. Flush the cooling system again with Automatic Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 N·m (4.5 kgf·m/33 lb·ft)
8. Replenish the ATF.
9. Start the engine to test the system for the free flow o
f
fluid. If the flow is restricted, the cooler assembly o
r
lines must be replaced.
Repeated cleaning and flushing may not remove all the debris from the fluid cooler circuit.
Move the select lever through the various ranges and return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF must be added.
10. Connect the negative battery cable.
11. Remove the safety stands.
12. Remove the wheel blocks.

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ISUZU KB P190 2007

7A3-20 ON-VEHICLE SERVICE (JR405E)
TRANSMISSION ASSEMBLY

RUW 57ALF000201
Legend
1. Shift Cable
2. Propeller Shaft
3. Engine Harness
4. ATF Level Dipstick & Filler Tube
5. Under Cover
6. Bolt

7. ATF Pipe
8. Crossmember
9. Transmission Mount
10. Starter Motor
11. Bolt
12. Automatic Transmission

Remove or Disconnect
1. Block the wheels.
2. Disconnect the negative battery cable.
3. Raise the vehicle and support it with the suitable safety stands.




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ISUZU KB P190 2007

ON-VEHICLE SERVICE (JR405E) 7A3-21
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.
6. Loosen (do not remove) the nuts securing the exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the transmission.
8. Remove the fuel pipe bracket.
P1010013

P1010014
9. Remove the ATF level dipstick and tube.
10. Remove the undercover.
11. Rotate the ring gear and remove the 6 torque
converter bolts.
P1010016
12. Remove the automatic transmission fluid cooling pipe.
P1010060
13. Place a jack beneath the engine to support it.
14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the engine and transmission. Do not allow the radiato
r
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the engine.
18. Lower the transmission from beneath the vehicle. Take care not to damage the breathers.

Install or Connect
1. Install the transmission to the engine and tighten the bolts.
Bolt torque : M10 40 N·m (4.1 kgf·m/30 lb·ft)
M12 76 N·m (7.7 kgf·m/56 lb·ft)
2. Install the cable bracket to the transmission.
3. Connect the engine harness connectors.

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ISUZU KB P190 2007

MSG MODEL 7B-9
Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.




Starter Motor
Remove the starter motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the No.3
crossmember
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-7
Transmission (4×
××
×
2)
Disassembled View



RTW 77BLF003201
Legend
(1) Gear Control Lever Knob (9) Slave Cylinder
(2) Rear Floor Console (bucket seat) (10) Nut: rear mount to Crossmember
(3) Front Floor Console (11) Transmission Crossmember
(4) Grommet Assembly (12) Nut: rear mount to transmission
(5) Gear Control Lever (13) Rear Mount Rubber
(6) Rear Propeller Shaft (14) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only) (15) Transmission Retaining Nut and Bolt
(8) Fuel Pipe Bracket (16) Transmission Assembly




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ISUZU KB P190 2007

7B1-10 MANUAL TRANSMISSION
12. Remove slave cylinder and put it aside.
Diesel engine
220LV019
13. Support the transmission with a transmission jack.
220RS001
14. Remove engine rear mount nuts fixing on cross
member, from the transmission crossmember.
15. Remove engine rear mount nuts fixing on the
transmission.
220R300029
Legend
(1) Transmission
(2) Nut: rear mount to transmission
(3) Rear Mount Rubber
(4) Nut: rear mount to crossmember
(5) Transmission Crossmember
16. Remove the middle part of the transmission crossmember by removing four fixing bolts and nuts.
501R300008


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ISUZU KB P190 2007

MANUAL TRANSMISSION 7B1-11
17. Take out the rear mount rubber.
18. Remove the starter (Diesel engine only).
060L100070
19. Remove transmission retaining nuts and bolts. Remove the transmission assembly from the
vehicle.

Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front of the transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must be the same.
3.
Align the top gear shaft spline with the clutch driven
plate spline.
4. Install the transmission assembly to the engine. Tighten the transmission nuts and bolts as shown in
the figure.



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ISUZU KB P190 2007

7B1-14 MANUAL TRANSMISSION
5. Install the starter. (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
6. Install the rear support rubber on the transmission and tighten the nuts to the specified torque.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
7. Install the middle part of the transmission crossmember and the bolts.
Tighten the nuts to the specified torque.
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)
8. Install the engine rear mount nuts fixing on the transmission crossmember.
Torque: 52 N ⋅
⋅⋅
⋅
m (5.3 kgf ⋅
⋅⋅
⋅
m/38 lb ⋅
⋅⋅
⋅
ft)
Remove the transmission jack from transmission
side.
9. Apply grease to the top hole portion of the shift fork. Install the slave cylinder and tighten the bolts to the
specified torque.
Torque: 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
10. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N ⋅
⋅⋅
⋅
m (7.7 kgf ⋅
⋅⋅
⋅
m/56 lb ⋅
⋅⋅
⋅
ft)
Nut 37 N ⋅
⋅⋅
⋅
m (3.8 kgf ⋅
⋅⋅
⋅
m/27 lb ⋅
⋅⋅
⋅
ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly






C24SE
Scan-1
11. Connect the transmission harness connectors and
clip. Connector: neutral switch, car speed sensor,
and backup switch.
12. Tighten the exhaust pipe fixing nuts to the specified torque. (Diesel engine only)
Torque: 67 N ⋅
⋅⋅
⋅
m (6.8 kgf ⋅
⋅⋅
⋅
m/49 lb ⋅
⋅⋅
⋅
ft)





RTW 67BSH000101



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ISUZU KB P190 2007