boot ISUZU KB P190 2007 Workshop User Guide

FRONT SUSPENSION 3C-21
5. Remove link nut.
6. Remove upper ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010005
7. Remove upper control arm nut.
8. Remove upper control arm bolt.
9. Remove upper ball joint bolt and nut.
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
during inspection.
Check the following parts:
• Upper control arm
• Bushing
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.


P1010062
2. Install upper ball joint and tighten it 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 upper control arm assembly.
5. Install upper control arm bolt and nut.
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅ft)




















RTW 53ASH000201
6. Install brake fluid hose nut.
7. Install speed sensor harness nut.

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ISUZU KB P190 2007

3C-24 FRONT SUSPENSION
Upper Ball Joint
Upper Ball Joint and Associated Parts



RTW 340LF001101
Legend
(1) Upper Ball Joint Bolt
(2) Upper Ball Joint

(3) Upper Ball Joint Nut
(4) Nut and Cotter Pin
(5) Link Nut


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove wheel and tire assembly. Refer to wheel in this section.
3. Remove link nut.

4. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2017-0 to remove the uppe
r
ball joint from the knuckle.
CAUTION: Be careful not to damage the ball joint
boot and brake hose.




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ISUZU KB P190 2007

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-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

3C-38 FRONT SUSPENSION
4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to Power Steering Unit in Steering section.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust bolt, and then remove torsion bar. Refer to Torsion
Bar in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840- 2005-0.
CAUTION: Be careful not to damage the ball joint
boot.




901RW 271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.


901RW 272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required. (4×4 Model Only)
14. Remove washer. If replacement required. (4×4 Model Only)
15. Remove needle bearing by using remover 5-8840- 2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4 ×4 Model Only)






(4 ×4 Model Only)
RTW 340SH00401


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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

FRONT SUSPENSION 3C-49
CAUTION: Be careful not to damage the ball joint
boot.



RTW 340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
• Inspect the lower end boot for damage or grease
leak. 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.






450RS023

• 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 bolt and nut, and then tighten them to the specified torque.
Torque: 57 N ⋅
⋅⋅
⋅
m (5.8 kgf ⋅
⋅⋅
⋅
m/42 lb ⋅
⋅⋅
⋅
ft)
3. Install nut and cotter pin, and then tighten the nut to the specified torque with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-51
CAUTION: Be careful not to damage the ball joint
boot.





901RW 271
7. Remove lower ball joint nut.
8. Remove lower ball joint bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
through inspection.
• Inspect the lower end boot for damage or grease
leak. 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 a 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 (0.25-0.65 kgf ⋅
⋅⋅
⋅
m/1.8-
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)

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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-15


Disassembly
NOTE :
For the left side, follow the same steps as right side.

1. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the DOJ side).
CAUTION :
Take care not to damage the bellows during band removal.
2. Remove band (1).







3. Pry off circlip (1) with a screwdriver or equivalent.


4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or equivalent.



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ISUZU KB P190 2007