ISUZU KB P190 2007 Workshop Repair Manual

CLUTCH 7C-33
MASTER CYLINDER
DISASSEMBLY



Disassembly Steps
1. Bolt : reservoir tank
2. Reservoir tank
3. Yoke
4. Lock nut
5. Body sub assembly






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ISUZU KB P190 2007

7C-34 CLUTCH
REASSEMBLY



Reassembly Steps
1. Body sub assembly
2. Lock nut
3. Yoke
4. Reservoir tank
5. Bolt : Reservoir Tank







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CLUTCH 7C-35
SLAVE CYLINDER (MSG, MUA)
DISASSEMBLY



Disassembly Steps

1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body




Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.



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7C-36 CLUTCH
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.





Cylinder Bore and piston Clearance
1. Clean the cylinder body and the piston.
2. Use an inside dial indicator to measure the cylinder bore.
3. Use a micrometer to measure the piston diameter.
4. Calculate the clearance between the cylinder bore and the piston diameter.
If the clearance exceeds the limit, the entire slave cylinde
r
assembly must be replaced.
Cylinder Bore and Piston Clearance mm(in)
Standard Limit
0.07 (0.0028)0.15 (0.006)



Piston and Piston Cup
Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.



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ISUZU KB P190 2007

CLUTCH 7C-37
REASSEMBLY



Reassembly Steps

1. Cylinder body
2. Spring

3. Piston and piston cup


4. Push rod
5. Boot







Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.


3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the illustration.
3) Install the piston and piston cup to the cylinder body.



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ISUZU KB P190 2007

7C-38 CLUTCH
SLAVE CYLINDER (MUX)
DISASSEMBLY

RTW 77CSF000501

Disassembly Steps
1. Push rod
2. Boot
3. Piston and piston cup


4. Spring
5. Cylinder body
6. Clutch damper valve


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ISUZU KB P190 2007

CLUTCH 7C-39
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.



RTW 77CSH000901
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it i
f
necessary.
206RS004
Piston and Piston Cup
1. Visually inspect the disassembled piston and piston cup for
excessive wear and damage.
2. Replace the inner parts with new parts shown in the illustration.
206RS005
3. Measure the clearance between slave cylinder wall and
piston.
4. If the measured value exceeds the specified limit, the slave cylinder assembly must be replaced.
mm(in)
Standard Limit
0.07 (0.0028) 0.15 (0.006)



Clutch Damper Valve
1. Visually inspect the entire clutch damper valve housing or
connector for cracking and other damage.
The slave cylinder assembly must be replaced if any o
f
these conditions are present.
2. Measure resistance between terminals.
Replace slave cylinder assembly if less than standard value.
Standard: 14.3 Ω



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ISUZU KB P190 2007

7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:



RTW 77CSH001001
1. Before installing the parts, apply a thin coat of rubber
grease.
2. Install cup in groove in piston with the lip turned to the front of cylinder. Use care so as not to scratch the cylinder.



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ISUZU KB P190 2007

CLUTCH 7C-41
HYDRAULIC DAMPER CYLINDER
INSPECTION AND REPAIR

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




Visually check for oil leakage and other damage.
If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.






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ISUZU KB P190 2007

7C-42 CLUTCH
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right. (1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise 1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage


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ISUZU KB P190 2007