2007 ISUZU KB P190 4JH1

0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Replace the fuel filter (**Mark) when the fuel filter indicator light is lit.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."

I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate


SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
ENGINE
Idling speed and acceleration
(GASOLINE) I I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I * Air cleaner element
(GASOLINE) - I - I - I - R - I - I - I - R - I - I (DIESEL) I I I I I I I R I I I I I I I R I I I I * Engine oil (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - R - R - R - R - R - R - R - R - R - R

(4JA1-T) R R R R R R R R R R R R R R R R R R R R * Engine oil filter (HFV6) - - R - - R - - R - - R - - R - - R - - (C24SE) Replace every 12,000km (4JH1-TC, 4JA1-T) - R - R - R - R - R - R - R - R - R - R (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination (GASOLINE) - I - I - I - I - I - I - I - I - I - I (DIESEL) I I I I I I I I I I I I I I I I I I I I Fuel leakage
I I - I - I - I - I - I - I - I - I - I Fuel tank - - - I - - - I - - - I - - - I - - - I O2 Sensor (C24SE) Replace every 160,000km (HFV6)
MIL diagnostic Indicates O2 Sensor Valve clearances (6VE1) Check and adjust if noisy (4JH1-TC, 4JA1-T) A - - A - - - A - - - A - - - A - - - A (4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - A - - - - - - - A - - - -
Spark plugs (C24SE) (for leaded fuel
use) - R - R - R - R - R - R - R - R - R - R
Spark plugs (C24SE) (for unleaded
fuel use) - - - - - R - - - - - R - - - - - R - -
Spark plugs
(HFV6) Replace every 120,000km Spark plug wire - - - - - - - - - - - - - - - - - - - I Fuel filter (GASOLINE) - - - R - - - R - - - R - - - R - - - R (4JH1-TC, 4JA1-T) - - R - - R - - R - - R - - R - - R - - ** (4JJ1 (Standard Output),
4JJ1 (High Output)) Replace the fuel filter when the fuel filter indicator light is lit.
Fuel pump in fuel tank
(4JJ1 (Standard Output),
4JJ1 (High Output)) - - - - - - - I - - - - - - - I - - - -
Engine / Accessory drive belt
(C24SE) - - - - - - - - - I - - - - - - - - - I

(HFV6) Replace every 100,000km Fan belt tension and damage
(DIESEL) I I I I I I I I I I I I I I I I I I I I
* Exhaust system
I I - I - I - I - I - I - I - I - I - I Engine coolant concentration (HFV6) - I - I - I - I - I - I - I - I - I - R (C24SE) - I - I - I - I - R - I - I - I - I - R (DESEL) - I - I - I - I - I - I - I - I - I - I Engine coolant
(4JJ1 (Standard Output),
4JJ1 (High Output)) Change every 2 years
Cooling system for water leakage - I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clogs or damage - I - I - I - I - I - I - I - I - I - I
Timing belt
(C24SE) - - - - - - - - - - - - - - - I - - - - Replace every 120,000km Timing belt (6VE1) Replace every 160,000km

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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-3


I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate

SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
CLUTCH
Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE

* Automatic transmission fluid (HFV6)
- - I - - I - - I - - I - - I - - I - R (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - - - I - - - I - - - I - - - I - - - I
* Transfer case oil
- - - I - - - I - - - I - - - I - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I

PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve
(4W D) - L - L - L - L - L - L - L - L - L - L

FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I


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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-9
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
C24SE : C24SE Gasoline engine
B : Driving on rough roads
HFV6 : HFV6 Gasoline engine
C : Driving on dusty roads
G : Gasoline engine
D : Driving in extremely cold weather and/or on salted roads
4JA1-T : 4JA1-T Diesel engine
E : Towing trailer or climbing mountain frequently
4JH1-TC : 4JH1-TC Diesel engine
F : Operation in high ambient temperature conditions
4JJ1 (Standard Output):
4JJ1 Standard Output Diesel engine

4JJ1 (High Output): 4JJ1 High Output Diesel engine

D : Diesel engine

MT : Manual transmission

AT : Automatic transmission

4W D : Four wheel drive


Condition
A B C D E F A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month
4JA1-T : Change every 2,500 km (1,500 miles) 4JH1-TC 4JJ1 (Standard Output) 4JJ1 (High Output):

Change every 5,000 km (3,000 miles)




Engine oil filter G : Replace every 5,000 km (3,000 miles) or 3 monthD : Replace every 5,000 km (3,000 miles)



Exhaust pipes and mounting Inspect every 5,000 km (3,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)


Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000 miles)




Transmission or transmission
with transfer case oil MTC24SE D Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)
MT HFV6 Change every 40,000 km (24,000 miles)

AT Transmission:
Change every 20,000 km (12,000 miles)








4W D Transfer:
Change every 20,000 km (12,000 miles)


Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and di
scs
wear Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)





Interval
Item

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ISUZU KB P190 2007

MAINTENANCE AND LUBRICATION 0B-11
Recommended Fluids and Lubricants (For GENERAL EXPORT)
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly the best lubricants and diesel fuels.
W hen lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
The lubrication intervals in the maintenance schedule and coverage and period of new vehicle warranty are based
on the use of ISUZU genuine lubricants or recommended lubricants listed in the chart, which will serve as a guide
for selecting lubricants of the correct brand name.

GRADE
LUBRICATION MAKE BRAND/TYPE API ACEA JASO
Gasoline engine
crankcase C24SE
ISUZU GENUINE
ISUZU GENUINE
CALTEX
SHELL
ELF
TOTAL
CASTROL
BP BESCO RACING ACE TYPE SJ (5W-30)
BESCO MULTI ACE (7.5W-30)
HAVOLINE FORMULA (15W-40, 10W-30, 20W-50) HELIX PLUS (15W-50)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
GTX-7 (15W-40)
VISCO 3000 (15W-40) SJ
SG SL
SJ/CF SG
SJ/CF
SG/SH
SG/SH


A3/B3
A2/B2


Gasoline engine
crankcase HFV6

CALTEX 10W-30

HAVOLINE FORMULA (10W-30) SL
SL
Diesel engine crankcase
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
CALTEX/CHEVRON
CALTEX/CHEVRON
SHELL
SHELL
ELF
TOTAL
CASTROL
CASTROL
BP BESCO MULTI-Z TYPE CF-4 (10W-30)
BESCO MULTI-Z SUV (5W-30)
BESCO S-3 (10W, 20W, 30, 40)
DELO CXJ (15W-40, 20W-50, 40)
DELO 400 MULTIGRADE (15W-40)
RIMULA X (15W-40)
RIMULA D (15W-40, 30, 40)
PERFO 3F (15W-40)
RUBIA XT (15W-40)
RX SUPER PLUS (15W-40)
TECTION J PLUS (15W-40)
BP VANELLUS C6 (15W-40) CF-4
CD
CD
CD/CF
CD/CE/CF/CI-4 CH-4
CD/CF
CF-4/CE CF-4
CH-4
CH-4
CH-4



E3/E5 E3
B2/E2 E2
E3
E3/B3 E3


DH-1
DH-1
DH-1



DH-1
Manual transmission
C24SE D
Transfer case
ISUZU GENUINE
CALTEX/CHEVRON
SHELL
ELF
TOTAL
CASTROL
BP

BESCO GEAR OIL TRANSAXLE (5W-30)
DELO 400 MULTIGRADE (15W-40)
HELIX PLUS (15W-50)
SUPER SPORTI (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
RX SUPER PLUS (15W-40)
BP VANELLUS C6 (15W-40)

SG CD/CE/CF/CI-4 SJ/CF
SG/CD SJ/CF
CD/CE/CF
CD/CE/CF


E3/E5
A3/B3
A2/B2

DH-1




Manual transmission
HFV6
MOBIL 75W-90
MOBIL XHP (75W-90) GL-3



Differential
Shift on the fly system
(GL-5 only) ISUZU GENUINE
ISUZU GENUINE
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL
BP
BP BESCO GEAR OIL SH (80W-90, 90, 140)
BESCO SHIFT ON THE FLY (75W-90)
THURBAN GL-5 EP (80W-90, 85W-140)
SPIRAX A (140)
TRANSELF TYPE B (80W-90, 85W-140)
TRANSMISSION TM (80W-90, 85W-140)
EPX90 (90)
DYNA DRIVE (80W-90)
ENERGEAR HYPO (90)
ENERGEAR EP (80W-90) GL-5
GL-5 GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5


Differential
(Limited Slip Differential) ISUZU GENUINE
CALTEX
SELL
ELF
TOTAL
CASTROL
BP BESCO GEAR OIL LSD (140)
GEAR OIL LSD (90)
SPIRAX A LS 90 (90)
TRANSELF TYPE BLS (90)
TRANSMISSION DA (85W-90)
HYPOY LSX (90)
ENERGEAR LS-M (90) GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
Automatic transmission
4JH1-TC 4JJ1 (Standard Output)
Power steering
ISUZU GENUINE
CALTEX/TEXACO
SHELL
ELF
TOTAL
CASTROL
BP BESCO ATF III
TEXAMATIC 1888 (DEXRON  III)
SHELL DONAX TG (DEXRON  III)
ELFMATIC G3 (DEXRON  III)
TOTAL FLUID AT42 (DEXRON  III)
TQ DEXRON III (DEXRON  III)
AUTORAN DX3 (DEXRON  III)






Automatic transmission
4JJ1 (High Output)
EXXON MOBIL
MOBIL ATF 3309

Automatic transmission
HFV6
DEXRON III

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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description ........................................................................................................ 1- 3
Main Data and Specifications ......................................................................................... 1- 21
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 23
On-Vehicle Service .......................................................................................................... 1- 30
Precautions For Replacement or repair of air conditioning parts .......................... 1- 30
Condenser...................................................................................................................... .. 1- 40
Removal and Installation (4JH1-TC, 4JJ1-TC Standard Output)............................. 1- 40
Removal and Installation (4JJ1-TC High Output, 4JK1-TC High Output, 4JA1-T) ........................................ 1- 41
Removal and Installation (C24SE) ............................................................................. 1- 42
Condenser Fan Motor ..................................................................................................... 1- 43 Removal and Installation............................................................................................ 1- 43
Receiver/drier ................................................................................................................. . 1- 44
Removal and Installation............................................................................................ 1- 44
Compressor ..................................................................................................................... 1- 45
Removal and Installation (4JA1-T, 4JH1-TC) ............................................................ 1- 45
Removal and Installation (4JJ1-TC Standard Output, 4JJ1-TC High Output, 4JK1-TC High Output) ......... 1- 47
Removal and Installation (C24SE) ............................................................................. 1- 49
Disassembly ................................................................................................................ 1- 55
Reassembly ................................................................................................................. 1- 57
Heater Unit .................................................................................................................... ... 1- 59
Removal and Installation............................................................................................ 1- 59
Disassembly and Reassembly................................................................................... 1- 61
Vent Unit (Without Heater) ............................................................................................. 1- 62 Removal and Installation............................................................................................ 1- 62
Disassembly and Reassembly................................................................................... 1- 64
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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-7

(4JA1-T, 4JH1-TC LHD MODEL)


RTW 710LF002201



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ISUZU KB P190 2007

1-14 HEATER AND AIR CONDITIONING
(4JH1-TC)


RTW 78AXF007901



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ISUZU KB P190 2007

HEATER AND AIR CONDITIONING 1-21
MAIN DATA AND SPECIFICATIONS

COMPRESSOR

Model CR-14
Type 5 Vane rotary type
Displacement cm3 (lmp fl oz) 144 (4.03)
Oil type DH-PR
Oil capacity cm3 (lmp fl oz) 180 (5.07)
Magnetic clutch mm (in) Type: Dry single disc dia. 109 (4.3)

HEATING UNIT (VENT UNIT)

Type Reheat air mix
Core dimension mm (in) (L×H ×W ) 180 (7.09) × 182.3 (7.18) × 27 (1.06)
Capacity (kcal/h) 4200

BLOWER UNIT

Type Sirocco fan type

COOLING UNIT

Type Fin and tube evaporator
Evaporator element dimensions mm (in) (L×H ×W ) 222 (8.74) × 213 (8.39) × 56 (2.2)
Air volume / Heat absorption m3/H / W
300/3440
500/5140
• Expansion Valve type External pressure equalizer type
• Thermo Switch type (Cooler) Variable electronic thermostat
• Maximum Cool position °C ( °F) OFF 3± 0.5 (37.4 ±0.9)
DIFF 1.5 ±0.5 (34.7 ±0.9)
• Minimum Cool position °C ( °F)
OFF 11.6
±2 (52.9 ±3.6)
DIFF 2.9 ±2 (37.2 ±3.6)
• Thermo Switch type (A/C) °C ( °F) Fixed electronic thermostat
OFF 3 ± 0.5 (37.4 ± 0.9)
DIFF 1.5 ± 0.5 (34.7 ± 0.9)

CONDENSER
Type Aluminum louvered fins
Capacity kW (kcal/h) •
4JA1-T, 4JH1-TC, C24SE
14 (12300)
• 4JJ1-TC (Standard Output),
4JJ1- TC (High Output), 4JK1-TC (High Output),
17 (14620)

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ISUZU KB P190 2007