Target Audience:
Professional automotive technicians, mechanics, and experienced DIY enthusiasts.
Advantage:
Provides professional-level diagnostic and repair information at an accessible price point, offering a significant cost saving compared to dealership service manuals.
Content Depth:
Contains the same level of detail as used by professional technicians, ensuring accuracy and completeness.
Usability:
Features numbered instructions, bold figure numbers, detailed illustrations, and a logical table of contents for ease of use.
Powertrain:
Engine mechanical, engine management, fuel system, lubrication system, cooling system, exhaust system, ignition system.
Drivetrain:
Manual transmission, automatic transmission (if applicable), transfer case (4WD models), drive shafts, axles, differentials, CV joints.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS and EBD), wheel alignment specifications.
Electrical:
Complete wiring diagrams, electrical component locations, fuse and relay information, charging system, starting system, lighting, instrumentation, body electricals, diagnostic trouble codes (DTCs).
Body:
Body panel removal/installation, interior trim, exterior trim, doors, windows, locks, mirrors, bumpers, hood, tailgate.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair.
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication points, tire rotation, brake inspection.
Diagnostics:
System troubleshooting guides, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation, electrical circuit testing, fuel system pressure testing.
Repair:
Component removal and installation, rebuilding procedures (e.g., engine, transmission, differentials), part replacement, adjustments.
Overhaul:
Detailed instructions for engine, transmission, and other major component overhauls, including specifications and tolerances.
Wiring Diagrams:
Includes comprehensive and detailed wiring diagrams integrated with troubleshooting and electrical service procedures.
Depth:
Comprehensive, covering from basic maintenance to advanced diagnostics and complete rebuilds, suitable for professional technicians and advanced DIYers.
Illustrations:
Features detailed illustrations, drawings, and photos for each procedure.
Troubleshooting:
Dedicated sections for troubleshooting common problems, including symptom-based diagnostics.
Engine Options:
Likely includes 2.5L (4JA1-T or similar turbo-diesel) and potentially 3.0L (4JJ1-TC turbo-diesel) diesel engines common in this generation of D-Max. Specific engine codes would be detailed in the manual.
Horsepower Range:
Typically ranges from 100-140 HP for the 2.5L and 130-170 HP for the 3.0L engines, depending on turbocharging and specific tuning. Exact figures per engine variant will be in the manual.
Torque Range:
Ranges from approximately 250-300 Nm for the 2.5L and 300-360 Nm for the 3.0L engines. Exact figures per engine variant will be in the manual.
Injection System:
Commonly direct injection with turbocharging, likely a high-pressure common rail (HPCR) system for later models within this range. Specifics detailed in the manual.
Engine Layout:
Inline 4-cylinder, turbocharged, intercooled (for most diesel variants).
Body Styles:
Single Cab, Extended Cab (Space Cab), Double Cab.
Ground Clearance:
Typically around 200-235 mm, depending on the specific model and suspension setup.
Curb Weight:
Varies significantly based on cab configuration, drivetrain, and engine, generally ranging from 1600 kg to over 2000 kg.
Audio System:
Base models typically feature a basic AM/FM radio with CD player. Higher trims may include MP3 playback, aux input, and speaker upgrades. Some later models might have basic Bluetooth connectivity.
Traction Control:
Traction Control System (TCS) and Electronic Stability Control (ESC) were less common or optional on earlier models within this range, becoming more prevalent towards 2010. Manual will confirm availability per trim.
Remote Keyless Entry:
Available on higher trim levels. Manual will detail operation and programming.
Engine Oil Change:
Typically every 5,000 km to 10,000 km (3,000 to 6,000 miles) or 6 months, whichever comes first, depending on driving conditions. Specific recommendations in manual.
Transmission Fluid Change:
Manual: Every 40,000 km to 80,000 km (25,000 to 50,000 miles). Automatic: Every 40,000 km to 60,000 km (25,000 to 40,000 miles) or as per manual's severe service schedule. Specifics in manual.
Engine Oil:
Typically API CI-4 or CJ-4 specification for diesel engines. Viscosity grade often 5W-30, 10W-30, or 15W-40. Manual will specify exact grade and API rating.
Coolant:
Ethylene glycol based coolant, typically a red or orange long-life formulation. Manual will specify type and mix ratio (e.g., 50/50). Part numbers like 1819330 or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid. Manual will specify exact type and replacement interval.
Transmission Fluid Manual:
Manual transmission fluid (MTF) specifications, likely GL-4 or GL-5 rated. Specific viscosity grade and capacity detailed in manual.
Transmission Fluid Automatic:
Automatic transmission fluid (ATF) specifications, likely Dexron-III or equivalent. Capacity and change intervals are critical and detailed in the manual.
Common Wear Items:
Clutch wear (especially under heavy load), diesel injector performance issues, turbocharger wear, suspension component wear (bushings, ball joints), EGR valve issues (on later models with DPF).
Electrical Faults:
Wiring harness chafing, sensor failures (e.g., crank/cam position sensors), alternator or starter motor issues.
Manufacturer History:
Isuzu has a long history of producing robust and reliable commercial vehicles and pickups, with a strong reputation for diesel engine technology.
Generation:
The KB P190 represents the second generation of the Isuzu D-Max (also known as Rodeo D-Max in some markets), which was produced from 2002 to 2011/2012, with this manual covering a significant facelift/update period.
Manufacturing Locations:
Primarily manufactured in Thailand, with significant assembly in various global markets.
