air suspension ISUZU KB P190 2007 Workshop User Guide

FRONT SUSPENSION 3C-25

P1010005
5. Remove upper ball joint bolt and nut.
6. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
during inspection.
• Inspect the lower end of the boot for damage o
r
grease leaks. Move the ball joint as shown in the
figure to confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.





450R300030
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3-3.2 N ⋅
⋅⋅
⋅
m (0.13-0.33 kgf ⋅
⋅⋅
⋅
m/0.9-
2.4 lb ⋅ft)








450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install upper ball joint bolt and nut, and then tighten them to the specified torque.
Torque: 31 N ⋅
⋅⋅
⋅
m (3.2 kgf ⋅
⋅⋅
⋅
m/23 lb ⋅ft)
3. Install nut and cotter pin then tighten the nut to the specified torque with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅ft)
4. Install link nut, then tighten to the specified torque. Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-27
CAUTION: Be careful not to damage the ball joint
boot.


P1010003
6. Remove lower ball joint nut.
7. Remove lower ball joint bolt.
8. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
during inspection.
• Inspect the lower end of the boot for damage o
r
grease leaks. Move the ball joint as shown in the
figure to confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.






450RS026
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N ⋅
⋅⋅
⋅
m (0.26-0.65 kgf ⋅
⋅⋅
⋅
m/1.9-
4.7 lb ⋅ft)







450RS024
• If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install lower ball joint bolt.
3. Install lower ball joint nut and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅ft)
4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅ft)
5. Install link nut, then tighten to the specified torque. Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅ft)

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ISUZU KB P190 2007

3C-28 FRONT SUSPENSION
Bump Rubber
Bump Rubber and Associated Parts
RTW 340LF002601
Legend
(1) Bolt


(2) Bump Rubber


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
Inspection and Repair
Make the necessary adjustments or parts replacement
if wear, damage, corrosion or any other abnormal
condition is found during inspection.
Check the following parts:
• Bump Rubber
Installation
1. Install bump rubber.
2. Install bolt, then tighten it to the specified torque. Torque: 42 N ⋅
⋅⋅
⋅
m (4.3 kgf ⋅
⋅⋅
⋅
m/31 lb ⋅ft)

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ISUZU KB P190 2007

SECTION 3C
FRONT SUSPENSION
(4 ×
××
×
2 High Ride Suspension, 4 ×
××
×
4)
TABLE OF CONTENTS

Shock Absorber .................................................. 3C - 31 Shock Absorber and Associated Parts............ 3C - 31
Removal .......................................................... 3C - 31
Inspection and Repair ..................................... 3C - 31
Installation ....................................................... 3C - 31
Stabilizer Bar ...................................................... 3C - 32 Stabilizer Bar and Associated Parts ................ 3C - 32
Removal .......................................................... 3C - 32
Inspection and Repair ..................................... 3C - 32
Installation ....................................................... 3C - 33
Torsion Bar ......................................................... 3C - 34 Torsion Bar and Associated Parts................... 3C - 34
Removal .......................................................... 3C - 34
Inspection and Repair ..................................... 3C - 35
Installation ....................................................... 3C - 35
Knuckle............................................................... 3C - 37 Knuckle and Associated Parts ........................ 3C - 37
Removal .......................................................... 3C - 37
Inspection and Repair ..................................... 3C - 39
Installation ....................................................... 3C - 39
Upper Control Arm ............................................. 3C - 40 Upper Control Arm and Associated Parts ....... 3C - 40
Removal .......................................................... 3C - 40

Installation ....................................................... 3C - 42
Lower Control Arm ............................................. 3C - 44 Lower Control Arm and Associated Parts ....... 3C - 44
Removal .......................................................... 3C - 45
Inspection and Repair ..................................... 3C - 46
Installation ....................................................... 3C - 46
Upper Ball Joint .................................................. 3C - 48 Upper Ball Joint and Associated Parts ............ 3C - 48
Removal .......................................................... 3C - 48
Inspection and Repair ..................................... 3C - 49
Installation ....................................................... 3C - 49
Lower Ball Joint .................................................. 3C - 50 Lower Ball Joint and Associated Parts ............ 3C - 50
Removal .......................................................... 3C - 50
Inspection and Repair ..................................... 3C - 51
Installation ....................................................... 3C - 51
Bump Rubber ..................................................... 3C - 52 Bump Rubber and Associated Parts ............... 3C - 52
Removal .......................................................... 3C - 52
Inspection and Repair ..................................... 3C - 52
Installation ....................................................... 3C - 52
Special Tools ..................................................... 3C - 53


Ins
pec tion and Repair ..................................... 3C - 41
Service Precaution ................................ ............ 3C - 30

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ISUZU KB P190 2007

3C-30 FRONT SUSPENSION

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNECESSARY SRS
SYSTEM REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require
a replacement after removal. ISUZU/GM will also
call out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.

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FRONT SUSPENSION 3C-31
Shock Absorber
Shock Absorber and Associated Parts
RTW 340MF000901
Legend
(1) Shock Absorber Nut
(2) Rubber Bushing and W asher

(3) Shock Absorber Bolt and Nut
(4) Shock Absorber
(5) Rubber Bushing and W asher


Removal
1. Raise the vehicle and support it with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel Replacement in this section.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.
Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Shock absorber
• Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install shock absorber nut, then tighten it to the specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
5. Install shock absorber bolt and nut, and then tighten to the specified torque.
Torque: 93 N ⋅
⋅⋅
⋅
m (9.5 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

3C-32 FRONT SUSPENSION
Stabilizer Bar
Stabilizer Bar and Associated Parts



RTW 340MF000401
Legend
(1) Rubber Bushing
(2) Bracket and Bolt
(3) Link


(4) Link Nut
(5) Stabilizer Bar
(6) Link Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove the stone guard.
3. Remove wheel and tire assembly. Refer to W heel Replacement in this section.
4. Remove link nut.
CAUTION: Be careful not to break the ball joint
boot.
5. Remove link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing.

Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Stabilizer bar
• Rubber bushing
• Link ball joint


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ISUZU KB P190 2007

FRONT SUSPENSION 3C-35
3. Apply the setting marks (2) to the height control
arm and torsion bar, then remove height control
arm.
NOTE: “Besco chassis grease” should be applied on
contact area of height control arm with frame.
(RH & LH Both side)






410RS005
4. Apply the setting marks (3) to the torsion bar and
lower control arm, and then remove torsion bar.



RTW 340SH000301

Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Torsion bar
• Height control arm
• Adjust bolt
• Rubber seat
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks (3).







410RS007




RTW 340SH000301


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ISUZU KB P190 2007

FRONT SUSPENSION 3C-39
Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Knuckle
• Thrust washer (4 ×4 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g (0.18 oz))
and install needle bearing by using installer 5-
8840-2128-0 and grip 5-8840-0007-0. (4 ×4 Model
Only)






(4 ×4 Model Only)
901RW 275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (4 ×4 Model Only)

3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g (0.07 oz)). Then use installer 5-8840-2851-0 (2)
and grip 5-8840-0007-0 (1) to install oil seal. Afte
r
fitting the oil seal to the installer, drive it to the
knuckle using a hammer or bench press until the
tool front face contacts with the thrust washer.
(4 ×4 Model Only)





RTW 73CSH000101
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
6. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅
⋅⋅
⋅
ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar; refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-41
4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.


RTW 340SH000401
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and number of shims.
11. Remove caster shims and note the positions and number of shims.
12. Remove upper control arm assembly.
13. Remove upper control arm nut.
14. Remove plate.

15. Remove bushing by using remover 5-8840-0256-0.


RTW 340SH000501




RTW 340SH000601
16. Remove fulcrum pin.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
• Upper control arm
• Bushing
• Fulcrum pin


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ISUZU KB P190 2007