engine mount ISUZU KB P190 2007 Workshop Repair Manual

MAINTENANCE AND LUBRICATION 0B-9
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
C24SE : C24SE Gasoline engine
B : Driving on rough roads
HFV6 : HFV6 Gasoline engine
C : Driving on dusty roads
G : Gasoline engine
D : Driving in extremely cold weather and/or on salted roads
4JA1-T : 4JA1-T Diesel engine
E : Towing trailer or climbing mountain frequently
4JH1-TC : 4JH1-TC Diesel engine
F : Operation in high ambient temperature conditions
4JJ1 (Standard Output):
4JJ1 Standard Output Diesel engine

4JJ1 (High Output): 4JJ1 High Output Diesel engine

D : Diesel engine

MT : Manual transmission

AT : Automatic transmission

4W D : Four wheel drive


Condition
A B C D E F A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month
4JA1-T : Change every 2,500 km (1,500 miles) 4JH1-TC 4JJ1 (Standard Output) 4JJ1 (High Output):

Change every 5,000 km (3,000 miles)




Engine oil filter G : Replace every 5,000 km (3,000 miles) or 3 monthD : Replace every 5,000 km (3,000 miles)



Exhaust pipes and mounting Inspect every 5,000 km (3,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)


Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)


Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000 miles)




Transmission or transmission
with transfer case oil MTC24SE D Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)
MT HFV6 Change every 40,000 km (24,000 miles)

AT Transmission:
Change every 20,000 km (12,000 miles)








4W D Transfer:
Change every 20,000 km (12,000 miles)


Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and di
scs
wear Inspect every 5,000 km (3,000 miles)




Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)





Interval
Item

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ISUZU KB P190 2007

0B-10 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)

Severe driving conditions
MT : Manual transmission
A: Repeated short trips
AT : Automatic transmission
B: Driving on rough roads
4W D : Four wheel drive
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountein frequently

Condition
Item Interval A B C D E A+D
Engine oil Change every 5,000 km (3,000 miles)





Engine oil filter Replace every 5,000 km (3,000 miles)





Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)





Air cleaner element
Replace every 20,000 km (12,000 miles)



Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)


Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)




Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)


AT
Transmission:
Inspection every 20,000 km (12,000 miles)







4W D Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)


Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)


Front brake pads and di
scs wear Inspect every 5, 000 km (3,000 miles)




Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)







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1-38 HEATER AND AIR CONDITIONING
8) Charge the system to the specified amount and then close the low-pressure hand valve.
Refrigerant Amount g(lbs)
4JA1-T, 4JH1-TC, C24SE 720 (1.59)
4JJ1-TC (Standard Output)
4JJ1-TC (High Output)
4JK1-TC (High Output)
650 (1.43)

9) Check for refrigerant leaks by using a HFC-134a leak detector.
• A fully charged system is indicated by the sight glass on
the receiver/drier being free of any bubbles (Refer to
"Reading Sight Glass").
• Check the high and low pressure value of the manifold
gauge. (Refer to “CHECKING REFRIGERANT SYSTEM
W ITH MAINFOLD GAUGE” in SERVICE
INFORMATION.)
Immediately after charging refrigerant, both high and low
pressures are slightly high and to the left of the gauge, but they
settle down to the guide pressure valves as shown below:
• Ambient temperature; 30 ∼35 °C (86 ∼95 °F)
• Guide pressure
High-pressure side;
Approx. 1373 ∼1670 kPa (14 ∼17 kg/cm
2 / 199 ∼242 psi)
Low-pressure side;
Approx. 127 ∼245 kPa (1.3 ∼2.5 kg/cm
2 / 18 ∼36 psi)
10) Close the low pressure hand valve and charge valve of the refrigerant container.
11) Stop the air conditioning and the engine.
12) Disconnect the high and low pressure hoses from the manifold gauge fittings.





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HEATER AND AIR CONDITIONING 1-39
Reading Sight Glass

High and low
pressure pipe
temperature The high pressure
pipe is hot and the
low pressure pipe
is cold. There is a
distinct difference
in temperature
between them. The high pressure
pipe is warm and
the low pressure
pipe is cool. There
is no great
difference in
temperature
between them. There is little
difference in
temperature
between the high
pressure pipe and
the low pressure
pipe. The high pressure
pipe is hot and the
low pressure pipe
is slightly warm.
There is a
difference in
temperature
between them.
Sight glass
condition Almost transparent.
A flow of bubbles
can be seen, but
they disappear
when the throttle is
opened.

A flow of bubbles
always can be
seen. It appears
sometimes
transparent, and
sometimes frothy.
Something like fog
faintly can be seen.
Even at idle with
the fan at "HI" (with
the window fully
open), the bubbles
cannot be seen.



Air conditioning
cycle condition
OK NG
(Not enough refrigerant) NG
(Almost no
refrigerant) NG
(Too much
refrigerant)

The sight glass provides accurate diagnosis only under the following conditions.
If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart.
* Engine speed Idling
* A/C switch "ON"
* Blower fan operating at highest speed
* Air source selector lever at "RECIRC"
* Temperature control knob at coldest position
* Ambient temperature below 35 °C (95 °F) and humidity below 70% (See NOTE 1)
* High side pressure less than 1470 kPa (15 kg/cm
2 / 213 psi) (See NOTE 2)

NOTE 1
If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be
used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified
amount of refrigerant. Then continue checking the system performance.

NOTE 2
If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue
checking system performance.



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HEATER AND AIR CONDITIONING 1-53
Checking and Adjusting for Compressor
Replacement
180 cm3 (5.07 lmp fl oz) of oil is charged in compressor
(service parts). So it is necessary to drain the proper amount
of oil from the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the compressor.
3) Drain the compressor oil and measure the extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.
Amount of oil drained
From used compressor Draining amount of oil
From new compressor
less than
90 cm
3 (2.53 lmp fl oz) Some as drained
amount
more than
90 cm
3 (2.53 lmp fl oz) 90 cm
3 (2.53 lmp fl oz)

6) Evacuate, charge and perform oil return operation.
7) Check system operation.


CONTAMINATION OF COMPRESSOR OIL
Unlike engine oil, no cleaning agent is added to the
compressor oil. Even is the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
• The capacity of the oil has increased.
• The oil has changed color to red.
• Foreign substances, metal powder, etc., are present in the
oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.


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1-54 HEATER AND AIR CONDITIONING
OIL RETURN OPERATION
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the
refrigerant in the system.
W hen checking the amount of oil in the system, or replacing
any component of the system, the compressor must be run in
advance for oil return operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is "ON" and Set the fan control knob at its highest position.
3) Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4) Stop the engine.


REPLACEMENT OF COMPONENT PARTS
W hen replacing system component parts, supply the following
amount of oil to the component parts to be installed.
Component parts to be installed Amount of oil
Evaporator 50 cm3 (1.41 lmp fl oz)
Condenser 30 cm3 (0.84 lmp fl oz)
Receiver/drier 30 cm3 (0.84 lmp fl oz)
Refrigerant line (One piece) 10 cm3 (0.28 lmp fl oz)

Refrigeration oil must be replenished if more than two parts
are removed at the same time. After installing these
components, check compressor oil.



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SHEET METAL 2B-1
SECTION 2B
SHEET METAL

This section includes items of front end sheet metal that are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance.
W hen servicing these panels, areas on which this material has been disturbed, should be properly recoated with
service-type anticorrosion material.
TABLE OF CONTENTS
PAGE
Engine Hood Assembly (A type) ...................................................................................... 2B- 2
Engine Hood Assembly (B type) ..................................................................................... 2B- 8
Engine Hood Lock (A type) .............................................................................................. 2B- 11
Engine Hood Lock (B type) .............................................................................................. 2B- 13
Front Fender Panel (A type) ............................................................................................. 2B- 15
Front Fender Panel (B type) ............................................................................................. 2B- 18
Radiator Grille (A type) ..................................................................................................... 2 B- 21
Radiator Grille (B type) .................................................................................................... 2B - 22
Rear Body...................................................................................................................... ..... 2B- 23
Body Mounting .................................................................................................................. 2B- 26
Body Dimensions .............................................................................................................. 2B - 32


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POWER-ASSISTED STEERING SYSTEM 3B-9
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding the Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. W hile refilling the
reservoir, check the draining fluid for contamination.
If foreign matter is still evident, replace all lines,
disassemble and clean or replace the powe
r
steering system components. Do not re-use any
drained power steering fluid.

Steering Wheel Free Play Inspection
RTW 73BSH000901
1. W ith the tires in the straight-ahead position, check the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running. Free play: 0 - 30 mm (0 - 1.18 in)
2.
Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. W hen test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Front End Alignment Inspection and
Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
431R30006
2. Tighten the lock nut to the specified torque. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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4B-6 REAR AXLE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV* Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
W ater Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poo
r
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262
Red 2. Apply LOCTITE to the bolts.


LOCTITE 270
Green

LOCTITE 271
Red
3. Tighten the bolts to the specified torque.
4. W ait at least one hour before continuing the installation procedure.



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REAR AXLE 4B-7
REAR AXLE ASSEMBLY
General Description
A03R300001

The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the cente
r
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The φ220 mm (8.6 in) or φ194mm (7.6 in) ring gea
r
rear axle uses a conventional ring and pinion gear set
to transmit the driving force of the engine to the rea
r
wheels. This gear set transfers this driving force at a
90 degree angle from the propeller shaft to the drive
shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered rolle
r
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with
12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings, which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing.

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