2007 ISUZU KB P190 towing

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

Engine Control System (4JH1) 6E-257
Checks Action
Electrical Connections or W iring Poor electrical connections, terminal tension or wiring problems cause most intermittent. To perform the following inspections:
• Inspect for poor mating of the connector halves, or terminals improperly seated in the
connector body.
• Inspect for improperly formed or damaged terminals. Test for poor terminal tension.
• Inspect for poor terminal to wire connections including terminals crimped over
insulation. This requires removing the terminal from the connector body.
• Inspect for corrosion/water intrusion. Pierced or damaged insulation can allow
moisture to enter the wiring. The conductor can corrode inside the insulation, with
little visible evidence. Look for swollen and stiff sections of wire in the suspect
circuits.
• Inspect for wires that are broken inside the insulation.
• Inspect the harness for pinched, cut or rubbed through wiring.
• Ensure that the wiring does not come in contact with hot exhaust components.
Control Module Power and Grounds
Component Power and Grounds Poor power or ground connections can cause widely varying symptoms.
• Test all control module power supply circuits. Many vehicles have multiple circuits
supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/component connectors, fuses, and any intermediate connections
between the power source and the module/component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.
• Test all control module ground and system ground circuits. The control module may
have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and in
splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.
Temperature Sensitivity • An intermittent condition may occur when a component/connection reaches normal
operating temperature. The condition may occur only when the
component/connection is cold, or only when the component/connection is hot.
• If the intermittent is related to heat, review the data for a relationship with the
following: - High ambient temperatures
- Under hood/engine generated heat
- Circuit generated heat due to a poor connection, or high electrical load
- Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures–In extremely low temperatures, ice may form in a connection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern
that is temperature related.

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ISUZU KB P190 2007

6E-326 ENGINE CONTROL SYSTEM (4JK1/4JJ1)
Temperature Sensitivity• An intermittent condition may occur when a component/ connection reaches normal
operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.
• Freeze Frame, Failure Records or Snapshot Data may help with this type of intermittent conditions, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the following:
- High ambient temperatures.
- Underhood/ engine generated heat.
- Circuit generated heat due to a poor connection, or high electrical load.
- Higher than normal load conditions, towing, etc..
• If the intermittent is related to cold, review the data for the following: - Low ambient temperatures-In extremely low temperatures, ice may form in aconnection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern that is temperature related.
Electromagnetic Interference (EMI)
and Electrical Noise Some electrical components/ circuits are sensitive to EMI or other types of electrical
noise. Inspect the following conditions:
• A misrouted harness that is too close to high voltage/ high current devices such as injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the ECM driven solenoid or switch. These conditions can cause a sharp electrical surge. Normally,
the problem will occur when the malfunctioning component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test for any open diodes. Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
- An ECM from another vehicle is installed.
- Revised software/ calibration files have been released for this vehicle.
Important: DO NOT reprogram the ECM with the SAME software/ calibration files that
are already present in the ECM. This is not an effective repair for any type of driveability
problem.
• Verify that the ECM contains the correct software/ calibration. If incorrect programming is found, reprogram the ECM with the most current software/
calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/ or capture the failure conditions.
• Freeze Frame/ Failure Records data, where applicable, contains the conditions that were present when the DTC set.
- Review and record Freeze Frame/ Failure Records data.
- Operate the vehicle under the same conditions that were noted in Freeze Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.
• An alternate method is to drive the vehicle with the DMM connected to a suspected circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
Checks
Action

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ISUZU KB P190 2007

6-12 ENGINE DIAGNOSIS (C24SE)
Engine Oil Consumption Excessive
Condition Possible cause Correction
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Oil pan setting bolds loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose
or gasket broken Retighten or replace gasket

Head cover retaining bolts loose
or gasket broken Retighten or replace gasket

Oil filter adapter cracked Replace
Oil filter attaching bolt loose or
rubber gasket broken Retighten or replace oil filter

Crankshaft front or rear oil seal
defective Replace oil seal

Oil pressure unit loose or broken Retighten or replace
Blow-by gas hose broken Replace hose
Engine/Transmission coupling
area Replace oil seal
Oil leaking into combustion
chambers due to poor seal in
valve system Valve stem oil seal defective Replace

Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion
chambers due to poor seal in
cylinder parts Cylinders and pistons worn
excessively Rebore cylinder and replace
pistons and others
Piston ring gaps incorrectly
positioned Correct

Piston rings set with wrong side
up Correct

Piston rings sticking Rebore cylinder and replace
pistons and others
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Crank case ventilation, Positive
Crankcase Ventilation System
malfunctioning Positive Crankcase Ventilation
Hose clogged Clean
Others
Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving
and or severe usage such as
trailer towing Continuous high speed operation
and or severe usage will normally
cause increased oil consumption


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ISUZU KB P190 2007

Engine Management – V6 – Diagnostics Page 6C1-2–24

Checks Actions
Temperature Related Temperature related intermittent fault condition occurs only when the engine or ambient
temperature is hot, or only when it is cold.
• If the intermittent fault is heat related, review Tech 2 data in relationship to the
following:
• high ambient temperature,
• engine generated heat,
• circuit generated heat due to a poor electrical connection or high electrical
load, and
• higher than normal load conditions (towing, etc.).
• If the intermittent fault is related to cold ambient or engine temperature, review
Tech 2 data in relationship to the following:
• low ambient temperature, and
• the fault condition that occurs only on a cold start situation.
Additional Tests
• Incorrect installation of aftermarket electrical equipment such as the following:
• mobile phones,
• theft deterrent alarms,
• lights, or
• radio equipment.
• Electromagnetic interference (EMI) caused by a faulty relay, ECM controlled
solenoid or switch. The fault is triggered when the relay or solenoid is activated.
• Test the A/C compressor clutch and some relays that contain a clamping diode or
resistor for an open circuit.
• Test the generator for a faulty rectifier bridge that may allow the A/C noise into the
ECM electrical circuit.
When all diagnosis and repairs are completed, check the system for correct operation.
5.3 Backfire
Description
The air / fuel mixture in the intake manifold or in the exhaust system ignites which produces a loud popping noise.
Checks Actions
Preliminary Perform the Preliminary Checks. Refer to 4.3 Preliminary Checks in this
Section.
Sensor / System • Check the air intake system and crankcase for air leaks.
• Check the PCV System for correct operation. Refer to 6A1 Engine Mechanical –
V6.
• Use Tech 2 to monitor the knock sensor system for excessive spark retard
activity. Check for items that cause spark retard activity.

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ISUZU KB P190 2007

Engine Management – V6 – Diagnostics Page 6C1-2–32

Checks Actions
Ignition System
• Inspect for moisture or corrosion around the spark plug / ignition coil area.
• Test the ignition coil voltage output. Refer to 6C1-3 Engine Management – V6 –
Service Operations.
• Remove and inspect the spark plugs. Refer to 6C1-3 Engine Management – V6 –
Service Operations.
NOTE
If the spark plugs are fouled, determine the cause of the fouling before
replacing the spark plugs, refer to 6C1-3 Engine Management – V6 –
Service Operations.
• Check for loose ignition coil ground circuit.
Engine Mechanical
• Check for the following engine mechanical fault condition. Refer to 6A1 Engine
Mechanical – V6.
• low engine compression, and
• worn valve train components.
Additional Checks
• Check the exhaust system for possible restrictions. Refer to 6F Exhaust System –
V6.
• Test for other TCM related faults that may cause the transmission to operate in
the default mode.
• Check for transmission mechanical faults that may produce similar symptoms
such as slipping clutch.
When all diagnosis and repairs are completed, check the system for correct operation.
5.11 Poor Fuel Economy
Description
As confirmed by an actual road test, the fuel economy as compared to the previous fuel consumption of the same
vehicle is noticeably lower.
Checks Actions
Preliminary • Perform the preliminary checks. Refer to 4.3 Preliminary Checks in this
Section.
• Check the air filter element and intake air ducts for blockages.
• Check for correct tyre pressure. Refer to the Owners Manual.
• Check the recent driving conditions are the same compared to the previous when
the fuel consumption is normal. The following are list of driving conditions that
may affect fuel consumption:
− vehicle load,
− acceleration rate,
− A/C or other electrical equipment use, and
− vehicle used for towing.

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ISUZU KB P190 2007

Powertrain Interface Module – V6 Page 6E1–30

Checks Actions
Temperature Related The Tech 2 Freeze Frame / Failure Records or Snapshot data may be used if applicable
to the fault condition. Refer to 4.1 Diagnostic General Descriptions for information on
Tech 2 ECU diagnostic tests.
• If the intermittent fault is heat related, review the Tech 2 data in relationship to the
following:
• high ambient temperature,
• underhood / engine generated heat,
• circuit generated heat due to a poor electrical connection or high electrical
load, and
• higher than normal load conditions (towing, etc.).
• If the intermittent fault is related to cold ambient or engine temperature, review the
Tech 2 data in relationship to the following:
• low ambient temperature, and
• the fault condition that occurs only on a cold start situation.
Additional Tests
• Check for incorrect installation of aftermarket electrical equipment such as the
following:
• mobile phones,
• theft deterrent alarms,
• lights, or
• radio equipment.
• Check for electromagnetic Interference (EMI) caused by a faulty relay, ECM
controlled solenoid or switch. The fault is triggered when the relay or solenoid is
activated.
• Check the A/C compressor clutch and some relays that contain a clamping diode
or resistor for an open circuit.
• Check the generator for a faulty rectifier bridge that may allow A/C noise into the
PIM electrical circuit.
When all diagnosis and repairs are completed, check the engine management system for correct operation.

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ISUZU KB P190 2007