2007 ISUZU KB P190 four wheel drive

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

0B-10 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)

Severe driving conditions
MT : Manual transmission
A: Repeated short trips
AT : Automatic transmission
B: Driving on rough roads
4W D : Four wheel drive
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountein frequently

Condition
Item Interval A B C D E A+D
Engine oil Change every 5,000 km (3,000 miles)





Engine oil filter Replace every 5,000 km (3,000 miles)





Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 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 10,000 km (6,000 miles)




Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)


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







4W D Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 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)







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ISUZU KB P190 2007

3B-46 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to lose its centering which will cause damage to the
coil assembly (with SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007

3B-52 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to lose its centering which
will cause damage to the SRS coil assembly (with
SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove the driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007

5A-4 BRAKE CONTROL SYSTEM
General Description
EHCU has controlled ABS (Anti-lock Brake System) and
EBD (Electronic Brake-force Distribution System). ABS
works on all four wheels. EBD system works on rear 2
wheels. A combination of wheel speed sensor and
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking. This system helps the driver maintain greater control of
the vehicle under heavy braking conditions.

Note: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and Control Unit.













This illustration is based on RHD model

RTW 75AMF001101
Legend
(1) Electronic (6) Front Left W heel Speed Sensor
(2) Hydraulic (7) Rear Right W heel Speed Sensor
(3) Hydraulic Unit (H/U) (8) Rear Left W heel Speed Sensor
(4) Control Unit (9) G sensor (4W D only)
(5) Front Right W heel Speed Sensor (10) 2-4W D Control Unit (4W D only)


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ISUZU KB P190 2007

5A-22 BRAKE CONTROL SYSTEM
System Components
Electronic Hydraulic Control Unit (EHCU), four W heel
Speed Sensors, two W arning Lamps, and G sensor.

Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the EHCU according
to the signal from each sensor, cancelling ABS to return
to normal braking when a malfunction has occurred in
the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
left side. It consists of a motor, solenoid valves and a
fail safe relay.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front brake or both rear brakes
according to the signal sent from the EHCU.
Buffer chamber: Temporarily holds the brake fluid that
returns from the front and rear brake so that pressure of
front brake can be reduced smoothly.
Motor: Drives the pump according to the signal from
EHCU.
Fail safe Relay: W hen failure occurs in ABS.
The power supply to solenoid Valve is cut.

ABS Warning Lamp


RTW 75ASH000101
Vehicles equipped with the Anti-lock Brake System
have an amber “ABS” warning lamp on the instrument
panel. The “ABS” warning lamp will illuminate if a
malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In the
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning lamp and disable the anti-lock
braking function.

The “ABS” warning lamp will turn “ON” for
approximately three seconds after the ignition switch is
in the “ON” position.
If the “ABS” warning lamp stays “ON” after the ignition
switch is in the “ON” position, or comes “ON” and stays
“ON” while driving, the Anti-lock Brake System should
be inspected for a malfunction according to the
diagnostic procedure.

Wheel Speed Sensor (WSS)
It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear wheels.
The rotor is press-fit in the axle shaft.

G Sensor
The G sensor detects the vehicle deceleration speed
and sends a signal to the EHCU. In 4W D operation, all
four wheels may be decelerated in almost the same
phase, since all wheels are connected mechanically.
This tendency is noticeable, particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G sensor judges whether the friction coefficient of
the road surface is low or high, and changes the
EHCU's operating system to ensure ABS and EBD
control.

Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal “bump” will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
noise may be heard during brake applications when the
anti-lock feature is being used.
W hen the anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.




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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–8

1 General Information
The HFV6 engine features a closed vee, deep skirt die cast aluminium cylinder block with cast iron cylinder liners,
internally balanced crankcase, full length water jackets and six bolt main bearing caps.
The cylinders are arranged in two banks of three with a 60 degree included angle between the two banks.
The right-hand bank of cylinders consists of number 1-3-5
cylinders and the left-hand bank of cylinders consists of
number 2-4-6.
The engine firing order is 1-2-3-4-5-6.
Each aluminium cylinder head is fitted with hardened valve
seats and four valves per cylinder: two intake and two
exhaust.
The valves are operated by two camshafts (DOHC) per
cylinder bank, one each for intake and exhaust valves.
The crankshaft is manufactured from forged steel. A reluctor
wheel is pressed in place onto the rear of the crankshaft for
the crankshaft position sensor.
The connecting rods are manufactured from powdered
metal and the rod cap is separated during the manufacturing
process using the fractured method. This creates a stronger,
visually seamless rod to cap union.
Figure 6A1 – 1
1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,

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ISUZU KB P190 2007

Engine Mechanical – V6 Page 6A1–22

Crankshaft
The crankshaft is a forged steel design with four main bearings. The number three main bearing controls crankshaft
thrust. A crankshaft position reluctor wheel is pressed onto the rear of the crankshaft, in front of the rear main journal.
The crankshaft is internally balanced with an integral oil pump drive machined into the nose in front of the front main
journal.
Pistons, Pins and Connecting Rods
The piston assembly (1) is fitted with two low tension
compression rings and one multi-piece oil control ring. The
top compression ring is plasma sprayed, while the second
compression ring is cast iron Napier.
The oil control ring incorporates a steel expander and two
chrome plated steel rails.
The connecting rods are sinter forged steel and have full
floating piston pins. The piston pins are a slip-fit type, into
the bronze bushed connecting rods. Round wire retainers
are used to retain the piston pin into the piston.
The cast aluminium pistons incorporate a polymer coated
skirt to reduce friction.
Figure 6A1 – 17
Camshaft Drive System
Three timing chains are fitted:
• primary (1),
• right-hand secondary (2), and
• left-hand secondary (3), refer to Figure 6A1 – 18 for the HFV6 engine.
The primary timing chain connects the crankshaft sprocket (4) with the left-hand and right-hand intermediate drive shaft
sprockets (5).
Each oil pressure fed intermediate sprocket drives the secondary timing chains, which subsequently drive the respective
cylinder head camshaft position actuators (6).
Two stationary timing chain guides (7) and movable timing chain shoes (8) control secondary timing chain backlash.
Each secondary timing chain shoe is under tension from an oil pressure hydraulically operated tensioner (9). To control
backlash on the primary chain, two stationary timing chain guides (10) and an oil pressure hydraulically actuated
tensioner with built in shoe (11) are fitted.
The tensioners minimise timing chain noise and provide accurate valve action by keeping slack out of the timing chains,
while continuously adjusting for timing chain wear. The tensioners incorporate a plunger that adjusts outward with wear,
minimising backlash. The tensioners are equipped with oiling jets to spray oil onto the timing components during engine
operation. Each tensioner is sealed to the head or block using a rubber coated steel gasket. The gasket traps an
adequate oil reserve to ensure quiet start-up.

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ISUZU KB P190 2007