indicator ISUZU KB P190 2007 Workshop User Guide

4B-58 REAR AXLE

ILLUSTRATION PART NO. PART NAME
5-8840-2163-0
(J-37261)

Installer ( φ220mm)
9-8522-1274-0
(J-24252)

Installer ( φ194mm)
5-8840-2166-0
(J-23597-43)

Gauge Plate ( φ220mm)
5-8840-2087-0
(J-23597-7)

Gauge Plate ( φ194mm)
5-8840-0129-0
(J-23597-12)

Inner Pilot ( φ220mm)
5-8840-0127-0
(J-21777-43)

Stud and Nut ( φ220mm)
5-8840-2089-0
(J-23597-9)

Stud and Nut ( φ194mm)
5-8840-2085-0
(J-21777-42)

Outer Pilot
5-8840-0126-0
(J-8001)

Dial Indicator

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FRONT WHEEL DRIVE 4C1-31








Tighten the nut to the specified torque.
N⋅m (kgf ⋅m/lb ⋅in)
New bearing 2.3 (0.23/20)
Used bearing 0.98 - 1.18
(0.10 – 0.12/9 – 10)
(2) Clean the side bearing bores. Install the dial indicator with the discs and Arbor. Install and tighten the bearing caps to
the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
98 (10.0/72)

1 Dial indicator : 5-8840-0126-0
2 Disc (2 pcs.) : 5-8840-2088-0
3 Arbor : 5-8840-0128-0
4 Gage plate : 5-8840-2087-0




(3) Set the dial indicator to “0”. Place it on the mounting post of
the gaging arbor with the contact button touching the
indicator pad. Force the dial indicator downward until the
needle has made a half turn clockwise. Tighten down the
dial indicator in this position.




(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.


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4C1-32 FRONT WHEEL DRIVE


(5)
After the ZERO setting is obtained, rotate the gaging arbor
until the dial indicator rod does not touch the gaging plate.
Record the number the dial indicator needle points to.


(6) Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a
greater mounting distance (which can be achieved b
y
decreasing the shim thickness). A minus number indicates
the need for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is “nominal”.



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FRONT WHEEL DRIVE 4C1-33
(7) Select the shim using the chart;

mm(in)
Pinion
marking
+10 +8 +6 +4 +2 0 -2 -4 -6 -8 -10 Dial indicator
reading (inches)
0.081 2.18 (0.0858)0.082 2.18 (0.0858) 2.20 (0.0866)0.083 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882)0.084 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890)0.085 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898)0.086 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913)0.087 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921)0.088 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929)0.089 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937 )0.090 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953)0.091 2.18 (0.0858) 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961)0.092 2.20 (0.0866) 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969)0.093 2.24 (0.0882) 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976)0.094 2.26 (0.0890) 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992)0.095 2.28 (0.0898) 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000)0.096 2.32 (0.0913) 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008)0.097 2.34 (0.0921) 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.098 2.36 (0.0929) 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.099 2.38 (0.0937) 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0 2.42 (0.0953) 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.001 2.44 (0.0961) 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.002 2.46 (0.0969) 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.003 2.48 (0.0976) 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.004 2.52 (0.0992) 2.54 (0.1000) 2.56 (0.1008) 0.005 2.54 (0.1000) 2.56 (0.1008) 0.006 2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.








5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.



6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.








9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.


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4C1-34 FRONT WHEEL DRIVE







12. Flange Nut and Washer

(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion flange holder.
Pinion flange holder : 5-8840-0133-0
Torque N ⋅m (kgf ⋅m/lb ⋅ft
)
177 - 275 (18 - 28/130 - 202)
Discard used flange nut and install new one.






(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is obtained.
Starting Torque N⋅m (kgf ⋅m/lb ⋅in
)
0.63 - 1.13 (0.06 – 0.12/5 - 10)


13. Adjust Shim
(1)
Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.

1 Installer : 9-8522-1164-0
2 Drive handle : 5-8840-0007-0
3 Pilot : 9-8521-1743-0




(2) Insert the differential cage assembly with bearing oute
r
races into the side bearing bores of the carrier.



(3) Using two sets of feeler gauges, insert a feeler stock o
f
sufficient thickness between each bearing outer race and
the carrier to remove all end plat. Make certain the feele
r
stock is pushed to the bottom of the bearing bores.
Mount the dial indicator on the carrier so that the indicato
r
stem is at right angles to a tooth on the ring gear.
Dial indicator : 5-8840-0126-0


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4C1-72 FRONT WHEEL DRIVE
ILLUSTRATION PART NO. PART NAME
9-8522-
1274-0
(J-24252) Inner bearing outer race installer
5-8840-2085-0
(J-2 1777-42) Pilot
5-8840-2089-0
(J-23597-9) Nut & bolt
5-8840-2087-0
(J-23597-7) Gauge plate
5-8840-0
126-0
(J-800 1) Dial indicator
5-8840-0
128-0
(J-23597- 1) Arbor
5-8840-2088-0
(J-23597-8) Disc (2 pcs. required)
9-8522-
1165-0
(J-6 133-0 1) Pinion bearing installer (for 4W D)
9-8522-
1275-0
(J-24250) Pinion oil seal installer

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4C2-2 SHIFT ON THE FLY SYSTEM
SHIFT ON THE FLY SYSTEM
Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2W D) and 4 wheel drive (4W D) electrically b
y
driver's pressing the 4W D switch (push button type) on
instrument panel.
This system controls below operations.
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft b
y
motor actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4W D out signal to other Electronic Hydraulic Control Unit.

System Diagrams
RUW 34BLF000201


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BRAKE CONTROL SYSTEM 5A-47
ABS Warning Lamp ON Steady

Step Action Value(s) Yes No
1 1. Check the ABS warning lamp lighting circuit for a
short.
2. If a problem found, repair as necessary. W as a problem found? - Go to Step 3 Go to Step 2
2 1. Check the ABS warning lamp lighting circuit at the
meter for a short. Refer to METER, W ARNING
LIGHT AND INDICATOR LIGHT in 8 section.
2. If a problem is found, repair or replace the meter. W as a problem found? - Go to Step 3 Go to Step 4
3 1. Connect all connectors.
2. Ignition “ON”, engine “OFF”.
3. W ait for about 10 seconds.
4. Observe the ABS warning lamp. Is the ABS warning lamp turned “OFF”? - Verify repair Go to Step 4
4 Replace EHCU.
Note: Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2W D or 4W D Model)
Is the action complete? - Verify repair -


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5C-38 BRAKES


Installation Steps
1. Clip; Pad
2. Pad Assembly with Shim
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side o
f
the outer pad.

RUW 55CSH001701

3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.




RUW 55CSH000201
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
32 - 40 (3.3 – 4.1 / 24 - 30)




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6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several times and check for fuel leakage.
5. Check the water separator indicator light. It should be off.



Except EURO III model
RTW 46ASH002901




For EURO III model
RTW 46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is felt.
2. W ait 1 minute, and operate the priming pump until strong resistance is felt.
3. Once more wait, and operate the priming pump until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. W ait until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

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