check engine ISUZU KB P190 2007 Workshop User Guide

2B-6 SHEET METAL




RTW 72BSH000301

Important Operations - Removal
2. Intercooler Seal
• Remove the 6 clips.



RUW 52BSH002501
3. Washer Nozzle Tube
1) Open the hood.
2) Support the hood.
3) Remove the windshield washer nozzle tube.




RUW 52BSH002601

4. Hood Hinge Bolt
• Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.









RTW 72BSH000801
8. Engine Hood Bulge
• Remove the 4 nuts.






RTW 72BSH000501

Important Operations - Installation
5. Engine Hood
• Check the engine hood and fender (1).


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ISUZU KB P190 2007

SHEET METAL 2B-9

RUW 52BSH002501

Important Operations - Removal
1. Washer Nozzle Tube
4) Open the hood.
5) Support the hood.
6) Remove the windshield washer nozzle tube.





RUW 52BSH002601
2. Hood Hinge Bolts
• Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.


RTW 72BSH001101

Important Operations - Installation
3. Engine Hood
• Check the engine hood and fender. (1)





• Clearance : 4.0 mm (0.16 in)
• Height (step) : Flushness
• Adjust clearance using the hinges on the engine hood.



RTW 52BSH000301







• Adjust height (step) using the hood rests (1).






Engine Hood Striker
• Apply a light coat of grease to the striker.


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2B-12 SHEET METAL


Important Operations - Installation
4. Control Cable
Reroute the control cable to its original position, and check to
see if the lock assembly and control lever work normally.

2. Engine Hood Lock Assembly

Adjustment
1) Install the engine hood lock assembly (4) and temporaril
y
tighten the bolts securing it.
2) Close the hood.
3) Position the hood so that the stepped portion between the hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
4) Finally tighten the bolts securing the engine hood lock assembly.


5) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified torque.

Torque N ⋅m(kgf ⋅m/lb ⋅in)
10 (1.0 / 87)



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ISUZU KB P190 2007

2B-14 SHEET METAL


Important Operations - Installation
5. Control Cable
Reroute the control cable to its original position, and check to
see if the lock assembly and control lever work normally.

3. Engine Hood Lock Assembly

Adjustment
6) Install the engine hood lock assembly (4) and temporaril
y
tighten the bolts securing it.
7) Close the hood.
8) Position the hood so that the stepped portion between the hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
9) Finally tighten the bolts securing the engine hood lock assembly.


10) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified torque.

Torque N ⋅m(kgf ⋅m/lb ⋅in)
10 (1.0 / 87)



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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-7
Power Steering System Test
Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
(3) Power Steering Unit
(4) Power Steering Pump


The fluid pressure test in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, i
f
necessary, must be made.
・ Inspect pump reservoir for proper fluid level.
・ Inspect pump driver gear condition.
1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses.
2. W ith the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 and
power steering tester adapter 5-8840-2297-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
3. Check the fluid level. Fill the reservoir with powe
r
steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Powe
r
Steering System in this section.
5. Start the engine and check the fluid level. Add power steering fluid if required. W hen the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.


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3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
・ If the pressure recorded is within 9800-10300 kPa
(100-105 kg/cm
2/1422-1493psi), the pump is
functioning within its specifications.
・ If the pressure recorded is higher than 10300 kPa
(105 kg/cm
2/1493psi), the valve in the pump is
defective.
・ If the pressure recorded is lower than 9800 kPa
(100 kg/cm
2/1422psi), the valve or the rotating
assembly in the pump is defective.
7. If the pump pressures are within specifications, leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built up at either side of the
power steering unit, the power steering unit is
leaking internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level and make the needed repairs.
10. If the problem still exists, the steering and front suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean, the fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. W hen a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
・ Inspect gear for looseness or damage.
・ Inspect hoses to insure they are not touching an
y
other parts of the vehicle.
・ Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55 °
C (130 °F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. W hen checking the fluid level after the steering system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding the Power Steering System
W hen a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
W hen bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level remains constant after running the engine.
5. Raise and support the front end of the vehicle so that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to settle for a few minutes, then repeat the above
procedure.

Flushing the Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump.
Direct the line toward a large container to catch the
draining fluid.
3. W hile running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-9
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding the Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. W hile refilling the
reservoir, check the draining fluid for contamination.
If foreign matter is still evident, replace all lines,
disassemble and clean or replace the powe
r
steering system components. Do not re-use any
drained power steering fluid.

Steering Wheel Free Play Inspection
RTW 73BSH000901
1. W ith the tires in the straight-ahead position, check the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running. Free play: 0 - 30 mm (0 - 1.18 in)
2.
Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. W hen test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Front End Alignment Inspection and
Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
431R30006
2. Tighten the lock nut to the specified torque. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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3B-44 POWER-ASSISTED STEERING SYSTEM
13. Align each snap stud of driver air bag to the holes on
steering wheel. (with SRS air bag)

RTW 73BSH001201

RTW 73BSH000401
14. Push the SRS air bag at area-1 (1) and area-2 (2). At
that time confirm the audible noise of each stud.
(with SRS air bag)

RTW 73BSH000301

15. Enable the SRS (Refer to "Enabling the SRS" in this
section). (with SRS air bag)
16. Install driver knee bolster (reinforcement).
17. Install instrument panel lower cover then install the engine hood opening lever.
18. Connect the SRS connector (with SRS air bag).
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)
20. Turn the ignition switch to "ON" while watching warning light and check - the light should flash 7
times and then go off. If lamp does not operate
correctly, refer to Restraints section.




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3B-46 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to lose its centering which will cause damage to the
coil assembly (with SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007

3B-52 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to lose its centering which
will cause damage to the SRS coil assembly (with
SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove the driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007