body ISUZU KB P190 2007 Workshop Service Manual

5C-54 BRAKES
DISASSEMBLY




RTW 75CMF000701

Disassembly Steps
1. Cap
2. Diaphragm
3. Filter
4. Pin
5. Reservoir tank
6. Grommet
▲ 7. Front seal


8. Guide assembly
▲ 9. Snap ring
▲ 10. Stopper bolt and gasket
▲ 11. Primary piston
▲ 12. Secondary piston
13. Cylinder body


Note:
• Be sure to replace the designated with new ones.
• W ash the disassembled parts in clean brake fluid.
• Use compressed air to clean the ports.
• Do not allow dirt and dust to contaminate the disassembled
parts.



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ISUZU KB P190 2007

BRAKES 5C-55
Important Operations
W hen disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. W ash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.



7. Front Seal
Front seal remain in the vacuum booster side, when removing
master cylinder.
9. Snap Ring
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
10. Stopper Bolt and Gasket
Remove the stopper bolt from the cylinder body with pushing in
the primary and secondary pistons.


RTW 75CSH002201

11. Primary Piston
12. Secondary Piston
Don’t remove the spring from the piston.



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ISUZU KB P190 2007

5C-56 BRAKES
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.




• Cylinder body inside face
• Piston
• Piston cup
• Return port, Supply port
• Return spring
• Guide assembly (O-ring, Cup)
• Front seal



Visual Check
Inspect the following parts for wear, distortion, cuts, nicks,
corrosion, or other abnormal conditions.






RTW 75CSH002401

Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.


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ISUZU KB P190 2007

BRAKES 5C-57
REASSEMBLY



RTW 75CMF000801

Reassembly Steps
▲ 1. Secondary piston
▲ 2. Primary piston
▲ 3. Guide assembly
▲ 4. Cylinder body
▲ 5. Stopper bolt and gasket
▲ 6. Snap ring
▲ 7. Grommet


▲
8. Reservoir tank
▲ 9. Pin
▲ 10. Filter
▲ 11. Diaphragm
▲ 12. Cap
▲ 13. Front seal



1. Secondary Piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note:
Be sure to use a new piston.


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ISUZU KB P190 2007

5C-58 BRAKES




RTW 75CSH002301






























2. Primary Piston
Lubricate the piston cup on the primary piston assemblies with
brake fluid (1).
Note:
Be sure to use a new piston.
3. Guide Assembly
Lubricate the O-ring of guide assembly with brake fluid (2) and
the cup of guide assembly with rubber grease (3) (0.2 ~ 0.3g).



RTW 75CSH002001

4. Cylinder Body
Install the secondary piston and the primary piston to the
cylinder body.
Note:
The secondary piston long hole and the cylinder body stoppe
r
bolt hole must be aligned at installation.










5. Stopper Bolt and Gasket
Install the stopper bolt to the cylinder body (the piston long hole
must be aligned with the cylinder body installation hole).
Tighten the bolts to the specified torque.

Torque N ⋅m (kgf ⋅m/lb ⋅in)
2 - 3 (0.2 - 0.3 / 17 - 26)




6. Snap Ring
Press down on the primary piston and install the snap ring to
the cylinder body groove.
Note:
Be sure to use new snap ring.


7. Grommet
1. Install the grommets to the reservoir tank.
Note:
Be sure to use are new grommets.
2. Install the reservoir tank to the cylinder body.

8. Reservoir Tank
9. Pin


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ISUZU KB P190 2007

BRAKES 5C-63
DISASSEMBLY

VACUUM BOOSTER ASSEMBLY





Disassembly Steps
1. Clevis; Yoke
2. Nut; VLV rod
3. Retainer; Guard
4. Guard; VLV body
5. Silencer
6. Filter








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ISUZU KB P190 2007

5C-64 BRAKES
REASSEMBLY
VACUUM BOOSTER ASSEMBLY




Reassembly Steps
1. Filter
2. Silencer
3. Guard; VLV body
▲ 4. Retainer; Guard
▲ 5. Nut; VLV rod
▲ 6. Clevis; Yoke


RTW 75CSH002901



Important Operations
4. Retainer; Guard
Ensure that the lug of the inner surface is fitted into the groove
of the ROD.

5. Nut; VLV Rod
Install the nut.

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TROUBLESHOOTING 6 – 9
6. Overheating
Step Action Value(s) Yes No
1 Was the engine coolant level OK? —
Go to Step 2 Replenish the
coolant
2 Was the water leakage or the radiator restriction found? (Include radiator cap) —
Repair or
replace the
leakage part. Go to Step 3
3 Was the fan belt slippage found? — Tension or
replace the fan belt. Go to Step 4
4 Was the fan clutch working completely? —
Go to Step 5 Replace the fan
clutch
assembly.
5 Was the oil leakage found from fan clutch? — Replace the fan
clutch
assembly Go to Step 6
6 Was the thermostat working normally? —
Go to Step 7 Replace the
thermostat.
7 Was the water pump working OK? —
Go to Step 8 Replace the
water pump assembly.
8 Was the restriction by the foreign materials in the cooling system found? For example, clog the water
hose between the cylinder body and radiator etc.. —
Clean or
replace the clog part. Go to Step 9
9 Was the water leakage found from the sealing cap
on the cylinder body? —
Replace the
sealing cap or replace the
cylinder body. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC. Solved

7. White Exhaust Smoke
Step Action Value(s) Yes No
1 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at 200 rpm
Go to Step 2 Readjust the
valve clearance or replace the cylinder head gasket or
cylinder liner or
piston or piston ring or valve and relation parts.
2 Was the PCV (Positive Crankcase Ventilation) valve working completely? —

Go to Step 3 Repair or
replace the
PCV valve.
3 Was the turbocharger working completely? —
Go to Step 4 Replace the
turbocharger.
4 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

TROUBLESHOOTING 6 – 13
10–3 Continuous noise
Step Action Value(s) Yes No
1 Was the fan belt tension OK? 9 – 13 mm
(0.35 – 0.51
in)
Go to Step 2 Adjust the fan
belt tension.
2 Was the cooling fan loose? — Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? — Repair or
replace the generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? — Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? — Readjust the
valve
clearance. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

10-4 Slapping noise
Step Action Value(s) Yes No
1 Was noise coming from the cylinder head cover? — Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in)
both intake
and exhaust Adjust the
valve
clearances Go to Step 3
3 Were the rocker arms damaged? — Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? — Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? — Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft.
Was the crankshaft bearing and/or crankshaft worn? —
Replace the
worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin.
Was the connecting rod bearing and/or crankpin
worn? —

Replace the worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or
piston pin.
Was the connecting rod small end bushing and/or
piston pin worn? —

Replace the worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner.
Was the piston and/or cylinder liner worn or
damaged? —
Replace the
worn or
damaged parts Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved


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ISUZU KB P190 2007

6A – 2 ENGINE MECHANICAL
Disassembly ............................................................................................................... 6A- 47
Internal Parts .......................................................................................................... 6A- 47
Major Components ............................................................................................. 6A- 47
Minor Components ............................................................................................. 6A- 56 Rocker Arm Shaft and Rocker Arm ............................................................... 6A- 56
Cylinder Head .................................................................................................. 6A- 57
Piston and Connecting Rod ........................................................................... 6A- 59
Inspection and Repair ............................................................................................... 6A- 61 Cylinder Head ......................................................................................................... 6A- 61
Rocker Arm Shaft and Rocker Arm....................................................................... 6A- 68
Cylinder Body ......................................................................................................... 6A- 69
Camshaft ................................................................................................................. 6A- 7 7
Crankshaft and Bearing ......................................................................................... 6A- 79
Crankshaft Bearing Selection ............................................................................... 6A- 83
Crankshaft Pilot Bearing ....................................................................................... 6A- 85
Flywheel and Ring Gear......................................................................................... 6A- 85
Piston ...................................................................................................................... 6A - 86
Cylinder Head Gasket Selection ........................................................................... 6A- 88
Connecting Rod...................................................................................................... 6A- 90
Idler Gear Shaft and Idler Gear ............................................................................. 6A- 91
Timing Gear Case Cover........................................................................................ 6A- 91
Reassembly ................................................................................................................ 6A- 93
Internal Parts .......................................................................................................... 6A- 93
Minor Component ............................................................................................... 6A- 93 Rocker Arm Shaft and Rocker Arm ............................................................... 6A- 93
Cylinder Head .................................................................................................. 6A- 94
Piston and Connecting Rod ........................................................................... 6A- 96
Positive Crankcase Ventilation (PCV) Valve ................................................. 6A- 99
Major Component ............................................................................................... 6A- 101
Installation .................................................................................................................. 6A- 118
External Parts ......................................................................................................... 6A- 118
Lubrication System ....................................................................................................... 6A- 1 26

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ISUZU KB P190 2007