torque ISUZU KB P190 2007 Workshop Repair Manual

5B-10 ANTI-LOCK BRAKE SYSTEM
Installation
1. Install the speed sensor in the knuckle and take
care not to hit the speed sensor head during
installation.
2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque.
Torque: 8 N ⋅m (0.8 kgf ⋅m /69 lb·in)
3. Connect the cable clips at the arrow mark places.
4. Install the cable fixing bolt and tighten the fixing bolt to the specified torque.
Torque:
Bolt 8 N ⋅m (0.8 kgf ⋅m /69 lb·in)

NOTE: Confirm that the cable is not twisted when
connecting the speed sensor cable.
5. Connect the speed sensor connector.



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ISUZU KB P190 2007

5B-12 ANTI-LOCK BRAKE SYSTEM
3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check fo
r
cable short or open, bend or stretch the cable while
checking for continuity.
Installation
1. Install the speed sensor.
2. Tighten the sensor fixing bolts to the specified torque.
Torque: 8 N ⋅m (0.8 kgf ⋅m / 69 lb·in)
3. Connect the cable fixing clips (arrow marked).
4. Install the cable fixing bolts and tighten it to the specified torque.
Torque: 8 N ⋅m (0.8 kgf ⋅m / 69 lb·in)
5. Connect the harness connector.


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ANTI-LOCK BRAKE SYSTEM 5B-13
Front Sensor Rotor
Front Sensor Rotor and Associated Parts
411R300010
Legend
(1) Sensor Rotor
(2) Hub and Disc


(3) Disc Rotor fixing Bolt
(4) Hub and Disc Assembly
Removal
1. Remove the hub and disc assembly. (Refer to the
section Front wheel Drive).
2. Remove two disc rotor fixing bolts on a diagonal.
3. Drive out the sensor rotor using a metal bar and hammer through the two bolt holes.
• Discard the used sensor rotor.
4. Install disc rotor fixing bolts and tighten them to the specified torque.
Torque: 103 N ⋅m (10.5 kgf ⋅m / 76 lb·ft)



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ANTI-LOCK BRAKE SYSTEM 5B-19
G-Sensor
G-Sensor and Associated Parts


This illustration is based on the RHD model
RTW 75BLF000101
Legend
(1) G-Sensor


(2) Nut
Removal
1. Remove the front floor console. (Refer to the section Floor Console)
2. Disconnect the connector.
3. Remove the nuts.
4. Take out the G-sensor.

Installation
1. Set the G-sensor.
2. Install the nut and tighten it to specified torque.
Torque: 8 N·m (0.8 kgf·m / 69 lb·in)
3. Connect the connector.
4. Install the front floor console. (Refer to the section Floor Console)



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ISUZU KB P190 2007

BRAKES 5C-1
SECTION 5C
BRAKES
TABLE OF CONTENTS
PAGE
General Description ........................................................................................................ 5C- 2
Main Data and Specifications ......................................................................................... 5C- 9
Torque Specifications ..................................................................................................... 5C-1 0
Servicing ...................................................................................................................... .... 5C-19
Front Disc Brake Assembly ............................................................................................ 5C-33 Removal and Installation............................................................................................ 5C-33
Removal and installation of Disc Pad ....................................................................... 5C-37
Disassembly ................................................................................................................ 5C- 39
Inspection and Repair ................................................................................................ 5C-40
Reassembly ................................................................................................................. 5C- 42
Rear Drum Brake Assembly ........................................................................................... 5C-45 Disassembly ................................................................................................................ 5C- 45
Inspection and Repair ................................................................................................ 5C-46
Reassembly ................................................................................................................. 5C- 48
Brake Control.................................................................................................................. . 5C-52
Removal and Installation............................................................................................ 5C-52
Master Cylinder................................................................................................................ 5C-53
Removal and Installation............................................................................................ 5C-53
Disassembly ................................................................................................................ 5C- 54
Inspection and Repair ................................................................................................ 5C-56
Reassembly ................................................................................................................. 5C- 57
Vacuum Booster .............................................................................................................. 5C -60
Removal and Installation............................................................................................ 5C-60
Disassembly ................................................................................................................ 5C- 63
Reassembly ................................................................................................................. 5C- 64
Special Tools ................................................................................................................. . 5C-70

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5C-10 BRAKES
TORQUE SPECIFICATIONS
FRONT WHEEL BRAKE N⋅m (kgf ⋅m/lb ⋅ft)

RTW 55CMF000401


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5C-24 BRAKES
RTW 35CSH000201
3) Rear wheel cylinder fluid pressure measurement
Step on the brake pedal until the fluid pressure of the front wheel cylinder gets to 9.8Mpa (100kg/cm
2), and
check the rear wheel cylinder fluid pressure. (Read the
value of the front wheel cylinder fluid pressure 2
seconds after the measurement. W hen measuring the
LSPV fluid pressure, keep the brake pedal pressed
down without stepping it down twice or releasing it.)
Rear W heel Cylinder Fluid Pressure MPa (kg/cm
2)
2W D 6.77 ±0.83 (69.0 ±8.5)
2W D (W ith High Ride
Suspension), 4W D 6.77
±0.83 (69.0 ±8.5)

RTW 35CSH000401
2. Oil Pressure Adjustment
1) LSPV spring length adjustment
Loosen the adjust nut of the LSPV spring joint, and adjust the length of the LSPV spring.
W hen the oil pressure is insufficient, turn the adjust nut clockwise to extend the span “A”. W hen the oil pressure
is too high, turn the adjust nut counterclockwise to
reduce the span “A”.


2) After adjustment, tighten the lock nut securely.
Lock Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
11-20 (1.1-2.0/8-14)


















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BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW 35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal. mm (in)
Pedal free play (L1) 6 - 10 (0.24 - 0.39)
M/T 174 - 186 (6.85 - 7.32) Height (L2)
A/T 176 - 188 (6.93 - 7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque
N⋅m (kgf ⋅m/lb ⋅
⋅⋅
⋅
ft)
15 - 25 (1.5 – 2.5 / 11 - 18)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 57 mm (2.24 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005

How to connect the CLEVICE of the BOOSTER ROD with the
PEDAL ARM and how to adjust the PEDAL SW .
After connecting the CLEVIS of the BOOSTER ROD to the
PEDAL ARM, adjust the PEDAL SW mounted (PDA) to the
PEDAL BRACKET using the procedure explained below.
1. Set the hole of the CLEVIS of the BOOSTER & M/CYL
ROD with the hole in the PEDAL ARM.
2. Enter the PIN; PUSH ROD to the PEDAL to the holes from the left side of the PEDAL.
3. Enter and fix the PIN; SNAP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SW ITCH counter- clock-wise.

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BRAKES 5C-35


9. Front Hub and Disc Assembly
For the removal procedure, refer to Section 4C “FRONT
W HEEL DRIVE”.



Important Operations - Installation
9. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C “FRONT W HEEL
DRIVE”.




RUW 55CSH000101







8. Support Bracket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
206 - 245 (21.0 – 25.0 / 152 - 181)
Set up the clip and pad before installation of the support
bracket.
7. Boot
6. Slide Pin • Be sure to install the boots to the slide pin and the
support bracket securely.
•
Apply rubber grease to the sliding surface of the slide
pin before installation of the slide pin. (Don’t use mineral
type grease.)



















1) Assemble a slide pin boot to a slide pin.
2) Use 0.6g to apply grease to the slide pin entirely as shown bellow.
3) Insert the slide pin to the housing and make sure the boot is also inserted to the housing tightly.


5. Clip; Pad
Install new parts if necessary.




RUW 55CSH000201
2. Lock Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)


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5C-36 BRAKES





1. Brake Flexible Hose
Attach the bolt and new gasket
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
29 -39 (3.0 - 4.0 / 22 - 29)

After installation, the bleeding and replenishing procedure must
be performed.
W ipe the circumference of the hose clean.
Note:
•
••
•
Always use new gaskets.
• Be sure to put the hooked edge of the flexible hose end
into the anti-rotation cavity.

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