2009 Isuzu D-Max Kb P190 Service and Repair Manual

This 2009 Isuzu D-Max KB (P190) Service & Repair Manual Covers

• Complete factory workshop procedures
• Factory diagnostic information
• Component removal and installation
• Repair and overhaul procedures
• Technical specifications
• Factory maintenance schedules
• Factory wiring diagrams
• Torque specifications
• Fuse and relay information
• Diagnostic flow charts

Engine Options

• 2.5L 4JK1-TC Common Rail Turbo Diesel
• 3.0L 4JJ1-TC Common Rail Turbo Diesel

Transmission Options

• 5-speed Manual Transmission
• 5-speed Automatic Transmission

Engine and Drivetrain Repair Coverage

• Engine overhaul procedures
• Cylinder head servicing
• Timing gear system servicing
• Diesel common rail injection diagnostics
• Fuel injector coding and testing
• High-pressure fuel pump servicing
• Turbocharger diagnostics
• Variable Geometry Turbo diagnostics
• Charge-air system inspection
• Intercooler servicing
• EGR system diagnostics
• Diesel particulate filter diagnostics (where equipped)
• Cooling system repairs
• Lubrication system servicing
• Emissions system diagnostics
• Manual transmission servicing
• Automatic transmission diagnostics
• Transfer case servicing
• Front differential servicing
• Rear differential servicing
• Driveshaft servicing
• Universal joint servicing
• CV joint inspection and repair

Turbocharged and Diesel Technologies

• Common rail diesel injection diagnostics
• Turbocharger diagnostics
• Variable Geometry Turbo diagnostics
• Charge-air system inspection
• Intercooler servicing
• EGR valve diagnostics
• Diesel particulate filter diagnostics (where equipped)
• Fuel pressure regulator testing

4WD and AWD Technologies

• Shift-on-the-Fly 4WD diagnostics
• Transfer case diagnostics
• Front axle engagement system servicing
• Front differential diagnostics
• Rear differential diagnostics
• Free-wheel hub servicing (where equipped)
• 4WD control system diagnostics

Chassis, Steering and Suspension

• Double wishbone front suspension servicing
• Rear leaf spring suspension servicing
• Power steering system diagnostics
• Steering gear servicing
• Steering column servicing
• Shock absorber replacement
• Wheel bearing servicing
• Suspension bush inspection
• Wheel alignment specifications

Braking Systems

• ABS diagnostics
• Electronic Brakeforce Distribution diagnostics
• Brake Assist diagnostics
• Brake hydraulic system bleeding
• Front disc brake servicing
• Rear drum brake servicing
• Parking brake adjustment
• Wheel speed sensor diagnostics

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine management system
• Diesel fuel injection wiring
• Glow plug system diagnostics
• Charging system diagnostics
• Starting system diagnostics
• Immobiliser diagnostics
• Instrument cluster diagnostics
• CAN communication network diagnostics
• Lighting system diagnostics
• Airbag system wiring
• Audio system wiring
• Power window diagnostics
• Central locking diagnostics
• Trailer wiring diagnostics

Air Conditioning and HVAC

• Air conditioning system diagnostics
• Compressor servicing
• Refrigerant system repairs
• HVAC control panel diagnostics
• Blower motor servicing
• Air distribution system servicing

Body, Interior and Restraint Systems

• Body panel removal and installation
• Door servicing
• Dashboard removal procedures
• Interior trim servicing
• Seat servicing
• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Tailgate servicing
• Wiper and washer system servicing

Diagnostics and Troubleshooting

• Factory diagnostic flow charts
• Symptom-based troubleshooting
• Scan tool diagnostics
• Sensor testing procedures
• Actuator testing
• CAN communication diagnostics
• Electrical fault isolation
• ECU programming procedures
• Component inspection procedures

Common Error Codes Covered

Engine Codes

• P0087 — Fuel Rail/System Pressure Too Low
• P0093 — Fuel System Large Leak Detected
• P0101 — Mass Air Flow Sensor Range/Performance
• P0113 — Intake Air Temperature Sensor Circuit High Input
• P0234 — Turbocharger Overboost Condition
• P0299 — Turbocharger Underboost Condition
• P0401 — Exhaust Gas Recirculation Flow Insufficient
• P0402 — Exhaust Gas Recirculation Flow Excessive
• P0671 — Cylinder 1 Glow Plug Circuit
• P2002 — Diesel Particulate Filter Efficiency Below Threshold (where equipped)

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input/Turbine Speed Sensor Circuit Malfunction
• P0722 — Output Speed Sensor No Signal
• P0741 — Torque Converter Clutch Performance or Stuck Off

ABS and Chassis Codes

• C0035 — Left Front Wheel Speed Sensor Circuit
• C0040 — Right Front Wheel Speed Sensor Circuit
• C0045 — Left Rear Wheel Speed Sensor Circuit
• C0050 — Right Rear Wheel Speed Sensor Circuit

Network Communication Codes

• U0100 — Lost Communication With Engine Control Module
• U0121 — Lost Communication With ABS Control Module

Body Control Codes

• B1000 — Control Module Configuration Error
• B1370 — Ignition Relay Circuit Fault

Plus many other codes included in the manual.

Fuse Box Diagram

• Engine compartment fuse box layout
• Cabin fuse box layout
• Relay locations
• Fuse identification charts
• Fuse amperage specifications
• Power distribution diagrams

Wiring Diagrams

• Engine management system
• Common rail diesel injection system
• Turbocharger control system
• Glow plug system
• Manual transmission
• Automatic transmission
• 4WD control system
• ABS system
• Air conditioning system
• SRS airbag system
• Instrument cluster
• Immobiliser system
• CAN communication network
• Lighting system
• Audio system
• Power windows
• Central locking
• Trailer electrical system

Serpentine Belt and Timing System Information

• Accessory drive belt routing
• Serpentine belt inspection procedures
• Serpentine belt replacement procedures
• Timing gear train inspection
• Timing gear alignment procedures
• Timing component specifications

Torque Specifications

• Engine fastener torque values
• Cylinder head torque specifications
• Main bearing torque values
• Connecting rod torque values
• Flywheel torque specifications
• Transmission torque specifications
• Transfer case torque specifications
• Differential torque specifications
• Suspension torque specifications
• Steering component torque values
• Brake system torque values
• Wheel nut torque specifications

Maintenance and Service Information

• Factory scheduled maintenance intervals
• Engine oil and filter replacement
• Fuel filter replacement
• Manual transmission oil servicing
• Automatic transmission fluid servicing
• Transfer case oil replacement
• Differential oil replacement
• Engine coolant replacement
• Brake fluid replacement
• Air filter replacement
• Cabin air filter replacement (where fitted)
• Drive belt inspection
• Tyre rotation procedures
• Wheel alignment checks

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Diesel specialists
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions