clock ISUZU KB P190 2007 Workshop Repair Manual

GENERAL INFORMATION 0A-5
7. Measurement criteria are defined by the terms "standard" and "limit".
A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.
"Limit" is an absolute value.
A measurement falling outside the "limit" indicates that the applicable part or parts must be repaired or replaced.
8. Components and parts are listed in the singular form throughout the W orkshop Manual.
9. The following directional criteria are used throughout the W orkshop Manual:
Front:
The cooling fan side of the engine.
Right:
The right-hand side of the engine viewed from the flywheel.
Left:
The left-hand side of the engine viewed from the flywheel.
Rear:
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine towards the rear.
The engine's rotation is clockwise viewed from the front of the engine.


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ISUZU KB P190 2007

1-36 HEATER AND AIR CONDITIONING
F06R300013



•
••
•
Direct charging with a manifold gauge charging
station method.
Handling the charging valve handle when installing refrigerant
container.
1) Before attaching the charge valve to the refrigerant container, turn the charge valve handle counterclockwise
until the needle is fully retracted.
2) Turn the plate nut counterclockwise until it reaches its highest position relative to the charge valve.
3) Install the charge valve onto the refrigerant container.
4) Turn the plate nut clockwise and connect the center hose of the manifold gauge to the charge valve.
5) Tighten the plate nut sufficiently by hand. Then turn the charge valve handle clockwise to lower the needle and bore
a hole in the refrigerant container.
6) Turn the charge valve handle counterclockwise to raise the needle. The refrigerant in the refrigerant container is
charged into the air conditioning system by the operation of
the manifold gauge.
•
••
•
Be absolutely sure not to reuse the emptied

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HEATER AND AIR CONDITIONING 1-37
refrigerant container.


1) Make sure the evacuation process is correctly completed.
2) Connect the center-hose of the manifold gauge to the refrigerant container. •
••
•
Turn the charge valve handle counterclockwise to purge
to the charging line and purge any air exiting in the
center-hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the refrigerant about 200 g (0.44 lbs.). •
••
•
Make sure the high-pressure hand valve is closed.
•
••
•
Avoid charging the refrigerant by turning the refrigerant
container upside down.
4) Close the low-pressure hand valve of the manifold gauge. •
••
•
Check to ensure that the degree of pressure does not
change.
5) Check the refrigerant leaks by using a HFC-134a leak detector. •
••
•
If a leak occurs, repair the leak connection, and start all
over again from the first step of evacuation.
6) If no leaks are found, open the low-pressure hand valve of the manifold gauge. Then continue charging refrigerant to
the system. •
••
•
W hen charging the system becomes difficult:
(1) Run the engine at Idling and close the all vehicle doors.
(2) A/C switch is "ON".
(3) Set the fan control knob (fan switch) to its highest position.
(4) Set air source selector lever to “RECIRC”



WARNING
BE ABSOLUTELY SURE NOT TO OPEN THE HIGH-
PRESSURE HAND VALVE. SHOULD THE HIGH-
PRESSURE HAND VALVE BE OPENED, THE HIGH-
PRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT
CONTAINER TO BURST.
7) W hen the refrigerant container is emptied, use the following procedure to replace it with a new refrigerant container.
(1) Close the low-pressure hand valve.
(2) Raise the needle upward and remove the charge valve.
(3) Reinstall the charge valve to the new refrigerant container.
(4) Purge any air existing in the center hose of the manifold gauge.






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1-80 HEATER AND AIR CONDITIONING


RTW 710MH000101
Important Operations - Removal
1. Control lever assembly
Refer to “CONTROL LEVER ASSEMBLY” in this section.

2. Illumination Bulb
To remove the illumination bulb, insert a pliers (long nose) into
the cap at the back of the bulb. Turn the bulb counterclockwise
and pull it free.



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2B-12 SHEET METAL


Important Operations - Installation
4. Control Cable
Reroute the control cable to its original position, and check to
see if the lock assembly and control lever work normally.

2. Engine Hood Lock Assembly

Adjustment
1) Install the engine hood lock assembly (4) and temporaril
y
tighten the bolts securing it.
2) Close the hood.
3) Position the hood so that the stepped portion between the hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
4) Finally tighten the bolts securing the engine hood lock assembly.


5) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified torque.

Torque N ⋅m(kgf ⋅m/lb ⋅in)
10 (1.0 / 87)



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2B-14 SHEET METAL


Important Operations - Installation
5. Control Cable
Reroute the control cable to its original position, and check to
see if the lock assembly and control lever work normally.

3. Engine Hood Lock Assembly

Adjustment
6) Install the engine hood lock assembly (4) and temporaril
y
tighten the bolts securing it.
7) Close the hood.
8) Position the hood so that the stepped portion between the hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
9) Finally tighten the bolts securing the engine hood lock assembly.


10) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified torque.

Torque N ⋅m(kgf ⋅m/lb ⋅in)
10 (1.0 / 87)



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3B-42 POWER-ASSISTED STEERING SYSTEM
CAUTION: When turning the SRS coil fully
counterclockwise, stop turning if resistance is felt.
Further forced turning may damage the cable in the
SRS coil (with SRS air bag).
826RW 014
Legend
(1) Neutral mark


RTW 73BSH001301
16. Remove steering column cover.
17. Disconnect the wiring harness connectors located under the steering column then remove combination
switch and SRS coil assembly (with SRS air bag).
NOTE: The SRS coil is a part of the combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly (with SRS air bag).

RTW 73BSH001001

Installation
1. Install the combination switch assembly with SRS coil (with SRS air bag).
2. Turn the SRS coil fully counterclockwise, return about 3 turns and align the neutral mark (with SRS
air bag).


3. Connect the wiring harness connectors located at the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil will not catch
wiring (with SRS air bag).
825RS048


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ISUZU KB P190 2007

3B-48 POWER-ASSISTED STEERING SYSTEM
430R300007
17. Remove steering column cover.
18. Disconnect the wiring harness connectors located under the steering column.
19. Remove the combination switch assembly with SRS coil.
NOTE: The SRS coil is a part of the combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly (with SRS air bag).

RTW 73BSH001001
20. Turn the ignition switch to the ACC position.

21. Insert a pin (1) into the hole and push on it. Pull the
key cylinder free.







RUW 53BSH000101

Installation
1. Install lock cylinder assembly.
2. Install the combination switch assembly with SRS coil (with SRS air bag).
3. Turn the SRS coil fully counterclockwise, return about 3 turns and align the neutral mark (with SRS
air bag).
CAUTION: When turning the SRS coil fully
counterclockwise, stop turning if resistance is felt.
Further forced turning may damage the cable in the
SRS coil (with SRS air bag).
826RW 014
Legend
(1) Neutral mark


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ISUZU KB P190 2007

3B-56 POWER-ASSISTED STEERING SYSTEM
9. Turn the SRS coil fully counterclockwise, return
about 3 turns and align the neutral mark (1). (with
SRS air bag)
CAUTION: When turning the SRS coil fully
counterclockwise, stop turning if resistance is felt.
Further forced turning may damage to the cable in
the SRS coil.
826RW 014
10. W hen installing the steering column cover, be sure to
route each wiring harness as illustrated so that the
harnesses do not catch any moving parts.
825RW 017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing. Refer to the adjustment method in case a mark has
not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701

CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
12. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
ft)
13. Support the module and carefully connect the module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 3 N ⋅
⋅⋅
⋅
m (0.3 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn lead located under the steering column.
19. Connect the battery "-" terminal cable (with SRS ai
r
bag).


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ISUZU KB P190 2007

REAR AXLE 4B-25
b. Tighten the nut to the specified torque.
Torque:
φ220mm : 2.7 N ⋅m (0.28 kgf ⋅m/24 lb ⋅in)
φ194mm : 2.3 N ⋅m (0.23 kgf ⋅m/20 lb ⋅in)



425RW 030

c. Clean the side bearing bores. Place discs and
dial indicator on to arbor, and place tool into
position in side bearing bores. Install and
tighten the bearing caps to the specified
torque.
Torque : φ220mm : 108N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 94N ⋅m (10 kgf ⋅m/72 lb ⋅ft)

425RW 031
Legend
φ
φφ
φ
220mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2166-0
3. Disc (2 pcs.) : 5-8840-2167-0
4. Arbor : 5-8840-0128-0
φ
φφ
φ
194mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2087-0
3. Disc (2 pcs.) : 5-8840-2088-0
4. Arbor : 5-8840-0128-0



Note :
The scale on the dial indicator (5-8840-0126-0) is
inch unit.
d. Set the dial indicator 5-8840-0126-0 to “0”.
Place it on the mounting post of the gauging
arbor with the contact button touching the
indicator pad. Force the dial indicato
r
downward until the needle has made a hal
f
turn clockwise. Tighten down the dial indicato
r
in this position.




425RS020
Legend
1. Dial Indicator
2. Gauging Arbor
3. Plunger
4. Gauge Plate


e. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicato
r
shows the greatest deflection. At this point,
once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.

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