brake rotor ISUZU KB P190 2007 Workshop User Guide

FRONT WHEEL DRIVE 4C1-59


13. Wheel Pin
( 1 ) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats completely.



(3) Align index marks and install hub to disc.



14. Bolt
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
1 03 ( 10.5/76)


15. ABS sensor rotor
( 1 ) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.




16. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2 119-0
Grip : 5-8840-0007-0


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

5A-22 BRAKE CONTROL SYSTEM
System Components
Electronic Hydraulic Control Unit (EHCU), four W heel
Speed Sensors, two W arning Lamps, and G sensor.

Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the EHCU according
to the signal from each sensor, cancelling ABS to return
to normal braking when a malfunction has occurred in
the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
left side. It consists of a motor, solenoid valves and a
fail safe relay.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front brake or both rear brakes
according to the signal sent from the EHCU.
Buffer chamber: Temporarily holds the brake fluid that
returns from the front and rear brake so that pressure of
front brake can be reduced smoothly.
Motor: Drives the pump according to the signal from
EHCU.
Fail safe Relay: W hen failure occurs in ABS.
The power supply to solenoid Valve is cut.

ABS Warning Lamp


RTW 75ASH000101
Vehicles equipped with the Anti-lock Brake System
have an amber “ABS” warning lamp on the instrument
panel. The “ABS” warning lamp will illuminate if a
malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In the
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning lamp and disable the anti-lock
braking function.

The “ABS” warning lamp will turn “ON” for
approximately three seconds after the ignition switch is
in the “ON” position.
If the “ABS” warning lamp stays “ON” after the ignition
switch is in the “ON” position, or comes “ON” and stays
“ON” while driving, the Anti-lock Brake System should
be inspected for a malfunction according to the
diagnostic procedure.

Wheel Speed Sensor (WSS)
It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear wheels.
The rotor is press-fit in the axle shaft.

G Sensor
The G sensor detects the vehicle deceleration speed
and sends a signal to the EHCU. In 4W D operation, all
four wheels may be decelerated in almost the same
phase, since all wheels are connected mechanically.
This tendency is noticeable, particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G sensor judges whether the friction coefficient of
the road surface is low or high, and changes the
EHCU's operating system to ensure ABS and EBD
control.

Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal “bump” will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
noise may be heard during brake applications when the
anti-lock feature is being used.
W hen the anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.




BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

5A-40 BRAKE CONTROL SYSTEM
Basic Inspection Procedure
1. Basic Inspection of Service Brake
Step Action
Value(s) Yes No
1 Is the fluid level normal?
- Go to Step 2 Replenish with
fluid
Go to Step 2
2 Does fluid leak? - Repair
Go to Step 3 Go to Step 3
3 Is the booster function normal? - Go to Step 4 Repair
Go to Step 4
4 Is the pad and rotor normal? - Go to Step 5 Repair
Go to Step 5
5 Reconnect all components. Ensure all components are properly mounted.
Is this step finished? - Finished Go to Step 5

2. Ground Inspection
Step Action
Value(s) Yes No
1 Are ABS related ground points normal?
- Go to Step 2 Repair
Go to Step 2
2 Reconnect all components. Ensure all component are properly mounted.
Is this step finished? - Finished Go to Step 2



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

5A-42 BRAKE CONTROL SYSTEM
Symptom Diagnosis
The symptoms that cannot be indicated by warning
lamp can be divided into the following six categories:
1. ABS works frequently but vehicle does not decelerate.
2. Uneven braking occurs while ABS works.
3. The wheels are locked.

4. Brake pedal feel is abnormal.
5. Braking sound (from EHCU) is heard while not braking.
6. No ABS warning lamp
These are all attributable to problems which cannot be
detected by EHCU self-diagnosis. Use the customer
complaint and a test to determine which symptom is
present.
ABS Works Frequently But Vehicle Does Not Decelerate

Step Action Value(s) Yes No
1 Is braking force distribution normal between front and
rear of vehicle?
- Go to Step 2 Repair brake
parts.
Go to Step 7
2 Are axle parts installed normally?
- Go to Step 3 Repair axle
parts.
Go to Step 7
3 Is there play in each or any wheel speed sensor?
- Repair wheel
speed sensor.
Go to Step 7 Go to Step 4
4 Is there damage, or powered iron sticking to each or any wheel speed sensor/sensor rotor?
- Replace
wheel speed sensor or
sensor rotor.
Go to Step 7 Go to Step 5
5 Is the speed sensor of each wheel output normal?
- Go to Step 6 Replace
wheel speed sensor or repair
harness.
Go to Step 7
6 Is the 4W D control system function normal?
- 2-4W D Repair
or Go to Step 7 Repair or
replace 2-
4W D control System.
Go to Step 7
7 Reconnect all components, ensure all components are properly mounted.
Is this step finished? - Repeat the
“Basic
diagnostic
flow chart” Go to Step 7



BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-43
Uneven Braking Occurs While ABS Works

Step Action Value(s) Yes No
1 Is there play in each or any sensor?
- Repair.
Go to Step 5 Go to Step 2
2 Damage or powdered iron sticking to each or any
sensor/sensor rotor? - Repair.
Go to Step 5 Go to Step 3
3 Is the output normal for each sensor?
- Go to Step 4 Replace
sensor or repair
harness.
Go to Step 5
4 Is brake pipe connecting order correct? Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification; 2W D Model or 4W D Model) - Replace
EHCU.
Go to Step 5 Reconnect
brake pipe correctly.
Go to Step 5
5 Reconnect all components, ensure all components are properly mounted.
Is this step finished? - Repeat the
“Basic
diagnostic
flow chart” Go to Step 5

The Wheels Are Locked

Step Action Value(s) Yes No
1 Is ABS working?
- Go to Step 2 Go to Step 4
2 Is vehicle speed under 5 km/h? - Go to Step 3 Normal.
3 Is the output for each normal?
- Go to Step 4 Replace
sensor or repair
harness.
Go to Step 6
4 Is 2-4W D system function normal?
- Go to Step 5 Replace 2-
4W D control
unit or repair harness.
Go to Step 6
5 Is EHCU grounded properly? Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification; 2W D Model or 4W D Model) - Replace
EHCU.
Go to Step 6 Repair.
Go to Step 6
6 Reconnect all components, ensure all components are properly mounted.
Is this step finished? - Repeat the
“Basic
diagnostic
flow chart” Go to Step 6


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-45
Braking Sound (From EHCU) Is Heard While Not Braking

Step Action Value(s) Yes No
1 Is this the first vehicle start after engine start?
- It is self
checking sound
Normal. Go to Step 2
2 Is vehicle speed at 15 km/h or 30 km/h?
- It is self
checking sound
Normal. Go to Step 3
3 Check for the following condition: • At the time of shift down or clutch operation.
• At the time of low road friction drive (ice or snow on road) or rough road drive.
• At the time of high-speed turn.
• At the time of passing curb.
• At the time of operating electrical equipment switches.
• At the time of racing the engine. Did it occur under any of the conditions above? - ABS may
sometimes be
actuated even when brake pedal is not applied. Go to Step 4
4 Is there play in each or any sensor/wheel speed sensor rotor? - Repair.
Go to Step 7 Go to Step 5
5 Damage or powdered iron sticking to each or any sensor/wheel speed sensor rotor? - Repair.
Go to Step 7 Go to Step 6
6 Is each sensor normal? Note: Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2W D or 4W D Model)

- Check
harness/
connector for suspected
disconnection
If no
disconnection is found,
replace EHCU
Go to Step 7 Repair.
Go to Step 7
7 Reconnect all components, ensure all components are properly mounted.
Is this step finished? - Repeat the
“Basic
diagnostic
flow chart” Go to Step 7


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

5A-50 BRAKE CONTROL SYSTEM
DTC C0222 (Flash Code 22) Front Right Wheel Speed Sensor Signal
Malfunction



RTW 75AMF001301

Step Action Value(s) Yes No
1 W ere the steps of the “Basic Diagnostic Flow Chart” performed?
- Go to Step 2 Go to Basic
Diagnostic
Flow Chart
2 1. Check the tire for the following conditions.
• Tire specification
• W ear of the outer surface
2. If a problem is found, repair as necessary. W as a problem found? - Verify repair Go to Step 3
3 Note:
This DTC is set when certain tire is rotated alone.

Has certain tire been rotated alone by performing for
lift-up or roller tester? - Verify repair Go to Step 4
4 Is the front right wheel bearing rattling?
- Go to Step 11 Go to Step 5
5 Is the front right wheel speed sensor or the sensor
rotor rattling? - Go to Step 12 Go to Step 6
6 Is iron powder attached to the front right wheel speed
sensor or the sensor rotor? - Go to Step 13 Go to Step 7

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-51
Step Action Value(s) Yes No
7 Check the front right wheel speed sensor. Refer to
"W heel Speed Sensor Inspection procedure"
W as a problem found? - Go to Step 10 Go to Step 8
8 Does the sensor rotor have missing tooth or saw- toothed? - Go to Step 14 Go to Step 9
9 1. Clear the DTC.
2. Test run the vehicle, and check the DTC. Is the DTC displayed repeatedly? - Go to Step 18 Go to Step 17
10 Is the wheel speed sensor damaged or saw-toothed?
- Go to Step 15 Go to Step 16
11 Adjust the preload of the wheel bearing.
Is the action complete? - Verify repair -
12 Repair or replace the front right speed sensor or the
sensor rotor.
Is the action complete? - Verify repair -
13 Repair the front right speed sensor or the sensor rotor.
Is the action complete? - Verify repair -
14 Replace the sensor rotor. Is the action complete? - Verify repair -
15 Replace the front right wheel speed sensor.
Is the action complete? - Verify repair -
16 Repair or replace the front right speed sensor
circuits.
Is the action complete? - Verify repair -
17 Check the connection btween the EHCU and the front right wheel speed sensor and repair as
necessary Refer to "Note on Intermittents".
Is the action complete? - Verify repair -
18 Replace EHCU.
Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2W D model or 4W D model)
Is the action complete? - Verify repair -


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

5A-54 BRAKE CONTROL SYSTEM
DTC C0226 (Flash Code 26) Front Left Wheel Speed Sensor Signal
Malfunction



RTW 75AMF001301

Step Action Value(s) Yes No
1 W ere the steps of the “Basic Diagnostic Flow Chart” performed?
- Go to Step 2 Go to Basic
Diagnostic
Flow Chart
2 1. Check the tire for the following conditions.
• Tire specification
• W ear of the outer surface
2. If a problem is found, repair as necessary. W as a problem found? - Verify repair Go to Step 3
3 Note:
This DTC is set when certain tire is rotated alone.

Has certain tire been rotated alone by performing for
lift-up or roller tester? - Verify repair Go to Step 4
4 Is the front right wheel bearing rattling?
- Go to Step 11 Go to Step 5
5 Is the front right wheel speed sensor or the sensor
rotor rattling? - Go to Step 12 Go to Step 6
6 Is iron powder attached to the front left wheel speed
sensor or the sensor rotor? - Go to Step 13 Go to Step 7

BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007

BRAKE CONTROL SYSTEM 5A-55
Step Action Value(s) Yes No
7 Check the front left wheel speed sensor. Refer to
"W heel Speed Sensor Inspection procedure"
W as a problem found? - Go to Step 10 Go to Step 8
8 Does the sensor rotor have missing tooth or saw- toothed? - Go to Step 14 Go to Step 9
9 1. Clear the DTC.
2. Test run the vehicle, and check the DTC. Is the DTC displayed repeatedly? - Go to Step 18 Go to Step 17
10 Is the wheel speed sensor damaged or saw-toothed?
- Go to Step 15 Go to Step 16
11 Adjust the preload of the wheel bearing.
Is the action complete? - Verify repair -
12 Repair or replace the front left speed sensor or the
sensor rotor.
Is the action complete? - Verify repair -
13 Repair the front left speed sensor or the sensor rotor. Is the action complete? - Verify repair -
14 Replace the sensor rotor.
Is the action complete? - Verify repair -
15 Replace the front left wheel speed sensor.
Is the action complete? - Verify repair -
16 Repair or replace the front left speed sensor circuits.
Is the action complete? - Verify repair -
17 Check the connection btween the EHCU and the
front left wheel speed sensor and repair as
necessary Refer to "Note on Intermittents".
Is the action complete? - Verify repair -
18 Replace EHCU.
Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2W D model or 4W D model)
Is the action complete? - Verify repair -


BACK TO CHAPTER INDEX
TO MODEL INDEX
ISUZU KB P190 2007