ISUZU KB P190 2007 Workshop Repair Manual

3B-10 POWER-ASSISTED STEERING SYSTEM
Torque Specification
N⋅m (kgf ⋅m/Ib ⋅ft)

RTW 53BLF001001

Special Tools

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION

TOOL NO.
TOOL NAME
5-8840-0135-0
(J-29877-A) Tester;
Power steering 5-8840-2297-0
(J-39213) Adapter;
Power steering tester


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-11
Power Steering Unit
Power Steering Unit and Associated Parts


431R300016
Legend
(1) Crossmember
(2) Power Steering Unit Assembly
(3) Bracket
(4) Universal joint (Steering shaft)


Removal
1. Remove the universal joint assembly. Make a setting mark across the coupling flange and
steering unit to insure reassembly of the parts in the
original position.
2. Drain power steering fluid.

3. Remove the tie rod end assembly from knuckle.
Use tie rod end remover 5-8840-2005-0.


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3B-12 POWER-ASSISTED STEERING SYSTEM
901RW 270
4. Disconnect the feed line and return line from
steering unit.
Remove the clips on the crossmember and frame.
W ire the power steering line to frame.
NOTE: Take care to prevent foreign matter from
entering when disconnecting the power steering line.
5. Remove the power steering unit from the crossmember.

Installation
1. Install power steering unit on crossmember.
Tighten fixing bolt and nut to specified torque.
Torque:
116 N ⋅
⋅⋅
⋅
m (11.8 kgf ⋅
⋅⋅
⋅
m/85 lb ⋅
⋅⋅
⋅
ft)
Torque:
220 N ⋅
⋅⋅
⋅
m (22.4 kgf ⋅
⋅⋅
⋅
m/162 lb ⋅
⋅⋅
⋅
ft)
2. Connect the feed line and return line. Torque:
25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)
3. Install tie-rod end assembly on knuckle. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
4.
Align the setting marks on the universal joint
(applied at disassembly) with the setting marks on
the power steering unit. Connect the universal joint
assembly to the power steering unit.
5. Tighten the universal joint bolt to the specified torque.
Torque:
31 N ⋅
⋅⋅
⋅
m (3.2 kgf ⋅
⋅⋅
⋅
m/23 lb ⋅
⋅⋅
⋅
ft)
6. Install the stone guard.
7. Bleed the system. Refer to Bleeding the Power Steering System in this
section.



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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-13
Power Steering Unit Disassembled View

RTW 53BLF000401
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line
(8) Rack Bar
(9) Tab W asher
(10) Mounting Rubber
(11) Housing Assembly
(12) Dust Cover



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ISUZU KB P190 2007

3B-14 POWER-ASSISTED STEERING SYSTEM
Disassembly
NOTE : The valve hosing is made of aluminum and care
should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
For the left side, follow the same steps as right side.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
• Use a pair of pliers to open the clip. Slide the cliptoward the tie-rod end.





RUW 53BSH000401
• Remove band from the bellows by using
screwdriver.





RUW 53BSH000501


CAUTION :
For 4 ×
××
×
2 except High ride suspension models;
The band is not reusable. If removed, it must be
replaced with a new one.
Take care not to damage the bellows during band
removal.
For 4 ×
××
×
4 and 4 ×
××
×
2 High ride suspension models;
The band and bellows are not reusable. If removed,
they must be replaced with a new one.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end, then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.

Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found during inspection.
Check the following parts.
1. Tie-rod end
2. Lock nut
3. Clip
4. Bellows
5. Band
Tie-Rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.

Tie-Rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Rubber Parts
For 4 ×2 except High ride suspension models;
If wear or damage is found during inspection, replace
with new ones.
For 4 ×4 and 4 ×2 High ride suspension models;
Even if wear or damage is not found after removal,
replace with new ones.

Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line. Torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kgf ⋅
⋅⋅
⋅
m/104 lb ⋅
⋅⋅
⋅
in)


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-15
3. Install tie-rod assembly with tab washer, then tighten
to specified torque. For 4 ×2 except High ride suspension models;
Torque: 83 N ⋅
⋅⋅
⋅
m (8.5 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
ft)
For 4 ×4 and 4 ×2 High ride suspension models;
Torque: 108 N ⋅
⋅⋅
⋅
m (11.0 kgf ⋅
⋅⋅
⋅
m/80 lb ⋅
⋅⋅
⋅
ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply grease to the tie-rod groove. Install bellows on housing assembly.
CAUTION :
Make sure that there are no bulges or dents in the
bellows.
After installation, confirm the small end of the
bellows is inserted into the tie-rod groove.











RUW 53BSH000301

5. Caulk the band using clamp pliers 5-8840-2745-0.
For 4 ×2 except High ride suspension models;
Caulk gap(A): less than 2.0mm(0.08in).
For 4 ×4 and 4 ×2 High ride suspension models;
Caulk gap(A): 2.6 – 3.3mm(0.10 – 0.13in).

CAUTION :
Be sure to use a new band.





RUW 53BSH000601
6. Install clip.
7. Install tie-rod end and tighten lock nut.
Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)


Main Data and Specifications
General Specifications
2W D 4W D
Power steering W ithout W ith
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.23


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ISUZU KB P190 2007

3B-16 POWER-ASSISTED STEERING SYSTEM
Torque Specifications
N⋅m (kgf ⋅m/Ib ⋅ft)





RTW 73BLF000801

Special Tools

ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION

TOOL NO.
TOOL NAME



5-8840-2005-0
(J-29107)
Tie rod end remover






5-8840-2745-0 Clamp plier


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-17
Power Steering Pump (4JH1-TC, 4JA1-T)
Power Steering Pump and Associated Parts


RTW 53BMF000401
Legend (1) Pump Assembly
(2) Suction Hose
(3) Flexible Hose
(4) Bolt
(5) Bracket


Removal
1. Remove the drive belt.
2. Remove the pulley
3. Place a drain pan below the pump.
4. Disconnect the suction hose.
5. Disconnect the flexible hose.
6. Remove the power steering fixing bolt and remove the pump assembly.

Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
Torque: 40 N·m (4.1 kgf·m/30 lb·ft)
2. Install the flexible hose.
Tighten the nut to specified torque.
Torque: 20 N·m (2.0 kgf·m/14 lb·ft)
3. Install the pulley and tighten the bolt to the specified torque.
Torque: 28 N·m (2.9 kgf·m/21 lb·ft)
4. Install the drive belt.
5. Connect the suction hose, then fill and bleed system.
Refer to Bleeding the Power Steering System in this section.

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ISUZU KB P190 2007

3B-18 POWER-ASSISTED STEERING SYSTEM
Power Steering Pump Disassembled View






RTW 63BLF000301
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Cam
(12) Pump Cartridge Assembly
(13) O-ring
(14) Snap Ring
(15) Rear Housing
(16) Bolt
(17) Spring
(18) Relief Valve
(19) O-ring
(20) Connector
(21) Bush
(22) Pulley
(23) O-ring




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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-19
Disassembly
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft
assembly to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and spring.
4. Remove the bolt, rear housing and O-ring.
5. Remove the snap ring.
6. Remove the shaft assembly.
7. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
8. Remove the pump cartridge assembly from the front housing.
9. Remove two O-rings.

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. W hen part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.



Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). W hen
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam
The inner face of the cam should have a uniform
contact pattern without a sign of step wear. W hen part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm (0.0004 in)), which can be felt b
y
the finger nail.
The parts with minor scores may be reused after lapping
the face.

Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.

O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.


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ISUZU KB P190 2007