torque ISUZU KB P190 2007 Workshop Repair Manual

5D-8 PARKING BRAKE SYSTEM
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bucket Seat)



RTW 35DSF000101

Legend
(1) Rear Floor Console
(2) Parking Brake Cable T-end
(3) Adjust Nut

(4) Switch
(5) Parking Brake Lever Assembly
(6) Bolt
(7) Equalizer


Removal
1. Remove rear floor console.
Refer to section 10.
2. Loosen adjust nut.
3. Remove bolt.
4. Remove switch.
5. Disconnect parking brake cable T-end from parking brake lever assembly.
6. Take out parking brake lever assembly.

Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake rear cable
T-end and parking brake lever equalizer. (arrow
mark).
2. Connect parking brake rear cable T-end to equalizer.
3. Install switch.

4. Tighten the parking brake lever fixing bolt to the
specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
5. Drive adjust nut on parking brake assembly so that parking brake cable T-end fits into equalizer.
6. Install rear floor console.
Refer to section 10.
7. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
8. Adjust nut so that parking brake lever goes through 6 −9 notches, when pulled with an
operation force of 294 N (30 kg/66 lb).
9. Check brake for no drag.


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ISUZU KB P190 2007

5D-10 PARKING BRAKE SYSTEM
Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin and shoe clamp spring.
4. Remove return spring.
5. Remove shoe assembly with parking brake lever.
6. Remove shoe assembly with adjuster lever and spring.
7. Remove parking brake inner cable from parking brake lever.
8. Use offset box wrench (12 mm hex.) to compress locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.




RTW 55CSH000301

Legend
(1) Offset Box W rench (12 mm hex)
9. Remove nut to fix the cable on the leaf spring.
10. Take out parking brake rear cable from the back plate.
11. Remove parking brake cable bolt and nut.
12. Disconnect T-end from the equalizer of front cable.

Installation

NOTE: Be sure to use a new shoe clamp spring and a
new adjuster lever clip.
1. Apply grease (multipurpose type grease) to the connecting portion of the rear cable and equalizer.
(arrow mark).
2. Install parking brake outer cable in back plate and inner cable in parking brake lever.
3. Install return spring.
4. Install shoe clamp spring and tension pin.
5. Install shoe assembly with adjuster lever, shoe assembly with parking brake lever and spring. ----
snap action
6. Install nut and tighten it to the specified torque. Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
7. Connect T-end with equalizer through outer cable retainer.
8. Install parking brake cable nut and tighten it to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
9. Install parking brake cable bolt and tighten it to the specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13.
Adjust parking brake lever adjusting nut so that
parking brake lever goes through 6-9 notches
(Bucket Seat) or 8 −14 notches (Bench Seat), when
pulled with an operation force of 294 N (30 kg/
66 lb).
14. Check brake for no drag.


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PARKING BRAKE SYSTEM 5D-13
Torque Specifications
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)

This illustration is based on the RHD model
RTW 35DSF000201

N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



E05R300006



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ISUZU KB P190 2007

SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
4 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing ...................................................................................................................... .. 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6 A - 24
Lubricating System.................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 2 7
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ..................................................................... 6A - 32
General Description ...................................................................................................... 6A- 3 6
Removal and Installation .............................................................................................. 6A- 37 Removal ...................................................................................................................... 6 A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment ......................................................................................... 6A- 41
Engine Warm-Up .................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A - 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6 A- 43
External Parts ......................................................................................................... 6A- 43
E N GINE MECHA NICA L 6A – 1
Main Dat a and Specif ications ....................................................................................... 6A -
Torque Specif ications ................................................................................................... 6A -

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6A – 8 ENGINE MECHANICAL

TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
N·m (kg·m/lb·ft)
8.8
4.8 (4T) (7T)
Refined Non-Refined 9.8 (9T) Strength
Class
Bolt
Identification


Bolt
Diameter ×
Pitch (mm)
M 6 ×
××
×
1.0

M 8 ×
××
×
1.25

M 10 ×
××
×
1.25

M 12 ×
××
×
1.25

M 14 ×
××
×
1.5

M 16 ×
××
×
1.5

M 18 ×
××
×
1.5

M 20 ×
××
×
1.5

M 22 ×
××
×
1.5

M 24 ×
××
×
2.0

* M 10 ×
××
×
1.5

* M 12 ×
××
×
1.5

* M 14 ×
××
×
2.0

* M 16 ×
××
×
2.0
5.88 ± 1.96
(0.60 ± 0.20/4.33 ± 1.44)
12.74 ± 4.90
(1.30 ± 0.50/9.40 ± 3.62)
27.44 ± 6.86
(2.80 ± 0.70/20.25 ± 5.06)
61.25 ± 12.25
(6.25 ± 1.25/45.21 ± 9.04)
95.55 ± 19.11
(9.75 ±1.95/70.52 ± 14.10)
130.34 ± 26.46
(13.30 ± 2.70/96.20 ± 19.53)
188.16 ± 37.24
(19.20 ± 3.80/138.87 ± 27.49)
257.74 ± 51.94
(26.30 ± 5.30/190.23 ± 38.33)
332.22 ± 81.34
(33.90 ± 8.30/245.20 ± 60.03)
448.84 ± 90.16
(45.80 ± 9.20/331.27 ± 66.54)
26.46 ± 6.86
(2.70 ± 0.70/19.53 ± 5.06)
56.84 ± 11.76
(5.80 ± 1.20/41.95 ± 8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
124.46 ± 24.50
(12.70 ± 2.50/91.86 ± 18.08) 7.35 ± 2.45
(0.75 ± 0.25/5.43 ± 1.80)
17.15 ± 5.39
(1.75 ± 0.55/12.66 ± 4.00)
36.75 ± 9.31
(3.75 ± 0.95/27.12 ± 6.87)
75.95 ± 15.19
(7.75 ± 1.55/56.06 ± 11.21)
116.13 ± 23.03
(11.85 ± 2.35/85.71 ± 17.00)
169.54 ± 34.30
(17.30 ± 3.50/125.13 ± 25.32)
244.02 ± 49.00
(24.90 ± 5.00/180.10 ± 36.17)
337.12 ± 67.62
(34.40 ± 6.90/248.82 ± 49.41)
453.25 ± 90.65
(46.25 ± 9.25/334.53 ± 66.91)
570.36 ± 140.14
(58.20 ± 14.30/420.96 ± 103.43)
36.26 ± 8.82
(3.70 ± 0.90/26.76 ± 6.50)
70.56 ± 13.72
(7.20 ± 1.40/52.08 ± 10.13)
109.76 ± 21.56
(11.20 ± 2.20/81.01 ± 15.91)
161.70 ± 32.34
(16.50 ± 3.30/119.34 ± 23.87) -

23.52 ± 6.86
(2.40 ± 0.70/17.36 ± 5.06)
49.98 ± 12.74
(5.10 ± 1.30/36.89 ± 9.40)
94.57 ± 19.11
(9.65 ± 1.95/69.80 ± 14.10)
142.10 ± 28.42
(14.50 ± 2.90/104.88 ± 21.00)
199.92 ± 40.18
(20.40 ± 4.10/147.55 ± 29.66)
287.14 ± 57.82
(29.30 ± 5.90/211.93 ± 42.67)
395.92 ± 79.38
(40.40 ± 8.10/292.21 ± 58.59)
530.18 ± 105.84
(54.10 ± 10.80/391.30 ± 78.12)
691.88 ± 138.18
(70.60 ± 14.10/510.65 ± 101.99)
48.02 ± 11.76
(4.90 ± 1.20/35.44 ±8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
133.28 ± 26.46
(13.60 ± 2.70/98.37 ± 19.53)
191.10 ± 38.22
(19.50 ± 3.90/141.04 ± 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS N·m (kg·m/lb·ft)
Pipe diameter mm
(in) Torque Pipe diameter mm
(in) Torque
4.76 (0.187)
6.35 (0.250)
8.00 (0.315) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8)
26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1)
44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 10.00 (0.394)
12.00 (0.472)
15.00 (0.591) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

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ENGINE MECHANICAL 6A – 23

LOCTITE APPLICATION PROCEDURE
LOCTITE Type LOCTITE Color Application Steps
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 270 Green
LOCTITE 271 Red 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.
2. Apply LOCTITE to the bolts.

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

LOCTITE 515 Violet 1. Completely remove lubricant and moisture from the connecting
surfaces.
The surfaces must be perfectly dry.
2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting surfaces.
There must be no gaps in the bead.
3. Tighten the bolts to the specified torque.
4. Let the joined parts set for at least thirty minutes.


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ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4 cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


014RY00015
8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness between the rocker arm and the valve stem end.

014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360 °.
14. Realign the crankshaft damper pulley TDC notched line with the timing pointer.
15. Adjust the clearances for the remaining valves as shown in the illustration.



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6A – 32 ENGINE MECHANICAL









































COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 °C (158 – 176 °F).
2. Remove the following parts.
• Leak off pipe
• Injection nozzle holder bracket
• Injection nozzle holder
3. Install the following parts.
• Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
• Injection nozzle holder bracket

Injection nozzle holder bracket Bolt Torque
N·m (kg·m /lb·ft)
37 (3.8/27)

Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0


4. Turn the engine over with the starter motor and take the compression gauge reading.

Compression Pressure MPa (kg/cm
2 /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)




5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
F06XL056
901R100003

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6A – 34 ENGINE MECHANICAL



RTW 46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8 °)
is aligned with the pointer.

Injection Timing : BTDC 8 ° ± 2 °

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket bolts.
11. Adjust the injection pump setting angle.
W hen large than standard value W hen smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.
12. Install the distributor head bolt.
Distributor head bolt torque N·m (kg·m /lb·ft)
29 (3.0/22)



ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant temperature reaches 70 - 80 °C (158 - 176 °F).


4. Disconnect the engine control cable from the control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 ± 25 rpm



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6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model) Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model) Remove the shift lever from the floor.

14. Transmission member 1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model) 1) Remove the under cover under the torque converter housing.
2) Rotate the flywheel by using tire lever or some other tool, and then remove the torque converter bolts.
16. Transmission coupling bolt 1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer) Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007
P1010025


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