ABS ISUZU KB P190 2007 Workshop Owner's Manual

FRONT SUSPENSION 3C-11
Installation
1. Install shock absorber.

RTW 340MF000801
NOTE: Paint mark to be on outer side after assembly to
vehicle.
2. Install shock absorber nut, then tighten it to the specified torque.
Torque: 55 N ⋅
⋅⋅
⋅
m (5.6 kgf ⋅
⋅⋅
⋅
m/41lb ⋅ft)
3. Install shock absorber bolt and nut, and then tighten to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅ft)

NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.

















RTW 53ASH000201

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-13
Shock Absorber with Coil Spring

RTW 340LF002101

Legend
1. Nut
2. W asher
3. Bushing; Rubber
4. Mounting Bracket
5. Coil Spring


6. Bushing; Rubber
7. W asher
8. Shock Absorber ASM



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ISUZU KB P190 2007

3C-14 FRONT SUSPENSION
Disassembly

RTW 73CMH000101


1. Install the shock absorber assembly on the strut spring
compressor (5-8840-2842-0).
For the details of the actual operation, follow the steps the
strut spring compressor manufacturer’s instructions.
2. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.



CAUTION:
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.



INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.



Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
• Shock absorber
• Rubber bushing
• Coil spring


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ISUZU KB P190 2007

3C-22 FRONT SUSPENSION
Lower Control Arm
Lower Control Arm and Associated Parts
RTW 340LF002301
Legend
(1) Cam bolt
(2) Bush
(3) Cam plate
(4) Lower Control Arm Nut
(5) Shock Absorber Nut

(6) Lower Ball Joint Bolt
(7) Lower Ball Joint
(8) Nut and cotter pin
(9) Lower Ball Joint Nut
(10) Link Nut
(11) Shock Absorber Bolt


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel
in this section.
3. Remove the tie-rod end from the knuckle. Refer to Power Steering Unit in Steering section.

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-23
4. Support lower control arm with a jack.
5. Remove the link nut.
6. Remove the nut and cotter pin.
7. Remove the shock absorber lower end from the lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove lower control arm nut and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.
Inspection and Repair
Make the necessary adjustments or parts replacement
if wear, damage, corrosion or any other abnormal
condition is found during inspection.
Check the following parts:
• Lower control arm
• Bushing
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.


P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅ft)
5. Install shock absorber and tighten it to the specified torque.
NOTE: Apply oil to the thread.
NOTE: Tighten the lower control arm nut with the parts
in the position shown in the illustration below.

Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅ft)






RTW 53ASH000201
6. Install stabilizer link and tighten it to the specified
torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
7. Install lower control arm nut and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the lower control arm nut with the parts
in the position shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N ⋅
⋅⋅
⋅
m (19.0 kgf ⋅
⋅⋅
⋅
m/137 lb ⋅
⋅⋅
⋅
ft)






















RTW 53ASH000201
8. 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: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅ft)

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ISUZU KB P190 2007

SECTION 3C
FRONT SUSPENSION
(4 ×
××
×
2 High Ride Suspension, 4 ×
××
×
4)
TABLE OF CONTENTS

Shock Absorber .................................................. 3C - 31 Shock Absorber and Associated Parts............ 3C - 31
Removal .......................................................... 3C - 31
Inspection and Repair ..................................... 3C - 31
Installation ....................................................... 3C - 31
Stabilizer Bar ...................................................... 3C - 32 Stabilizer Bar and Associated Parts ................ 3C - 32
Removal .......................................................... 3C - 32
Inspection and Repair ..................................... 3C - 32
Installation ....................................................... 3C - 33
Torsion Bar ......................................................... 3C - 34 Torsion Bar and Associated Parts................... 3C - 34
Removal .......................................................... 3C - 34
Inspection and Repair ..................................... 3C - 35
Installation ....................................................... 3C - 35
Knuckle............................................................... 3C - 37 Knuckle and Associated Parts ........................ 3C - 37
Removal .......................................................... 3C - 37
Inspection and Repair ..................................... 3C - 39
Installation ....................................................... 3C - 39
Upper Control Arm ............................................. 3C - 40 Upper Control Arm and Associated Parts ....... 3C - 40
Removal .......................................................... 3C - 40

Installation ....................................................... 3C - 42
Lower Control Arm ............................................. 3C - 44 Lower Control Arm and Associated Parts ....... 3C - 44
Removal .......................................................... 3C - 45
Inspection and Repair ..................................... 3C - 46
Installation ....................................................... 3C - 46
Upper Ball Joint .................................................. 3C - 48 Upper Ball Joint and Associated Parts ............ 3C - 48
Removal .......................................................... 3C - 48
Inspection and Repair ..................................... 3C - 49
Installation ....................................................... 3C - 49
Lower Ball Joint .................................................. 3C - 50 Lower Ball Joint and Associated Parts ............ 3C - 50
Removal .......................................................... 3C - 50
Inspection and Repair ..................................... 3C - 51
Installation ....................................................... 3C - 51
Bump Rubber ..................................................... 3C - 52 Bump Rubber and Associated Parts ............... 3C - 52
Removal .......................................................... 3C - 52
Inspection and Repair ..................................... 3C - 52
Installation ....................................................... 3C - 52
Special Tools ..................................................... 3C - 53


Ins
pec tion and Repair ..................................... 3C - 41
Service Precaution ................................ ............ 3C - 30

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-31
Shock Absorber
Shock Absorber and Associated Parts
RTW 340MF000901
Legend
(1) Shock Absorber Nut
(2) Rubber Bushing and W asher

(3) Shock Absorber Bolt and Nut
(4) Shock Absorber
(5) Rubber Bushing and W asher


Removal
1. Raise the vehicle and support it with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel Replacement in this section.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.
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:
• Shock absorber
• Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install shock absorber nut, then tighten it to the specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
5. Install shock absorber bolt and nut, and then tighten to the specified torque.
Torque: 93 N ⋅
⋅⋅
⋅
m (9.5 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

3C-44 FRONT SUSPENSION
Lower Control Arm
Lower Control Arm and Associated Parts
RTW 33CLF000201
Legend
(1) Cam Bolt
(2) Bush, Front
(3) Cam Plate and Nut
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint


(8) Bolt, Torsion Bar Arm
(9) Torsion Bar Arm Bracket and Nut
(10) Torsion Bar
(11) Lower Control Arm
(12) Lower Ball Joint and Nut
(13) Shock Absorber, Bolt and Nut
(14) Stabilizer Link and Nut



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ISUZU KB P190 2007

FRONT SUSPENSION 3C-45
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel in this section.
3. Remove the tie-rod end from the knuckle. Refer to Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar; refer to Torsion Bar in this section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control arm.
11. Remove the shock absorber lower end from the lower control arm.
12. Remove the lower ball joint from the lower control arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-8840- 2123-0.





Front
901RW 154





Front
901RW 155
19. Remove rear bushing by using remover 5-8840-
2124-0.




Front
901RW 051




Front
901RW 052

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ISUZU KB P190 2007

3C-46 FRONT SUSPENSION
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:
• Lower control arm
• Bushing
Installation
1. Install rear bushing by using installer 5-8840-2124-
0.





Front
901RW 053
2. Install front bushing by using installer 5-8840-
2123-0.





Front
901RW 156



3. Install lower ball joint bolt.
4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install cam bolt so the hole and projection are upward.
8. Install lower ball joint and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅
⋅⋅
⋅
ft)
9. Install shock absorber and tighten it to the specified torque.
Torque: 93 N ⋅
⋅⋅
⋅
m (9.5 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
ft)
10. Install stabilizer link and tighten it to the specified torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
11. Install torsion bar arm bracket and tighten it to the specified torque.
Torque: 116 N ⋅
⋅⋅
⋅
m (11.8 kgf ⋅
⋅⋅
⋅
m/85 lb ⋅
⋅⋅
⋅
ft)
12. Install Torsion bar; refer to Torsion Bar in this section.
13. Install rear nut and tighten nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut or bolt with the parts in the
position shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 235 N ⋅
⋅⋅
⋅
m (24.0 kgf ⋅
⋅⋅
⋅
m/174 lb ⋅
⋅⋅
⋅
ft)









RTW 53ASH000301


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