air suspension ISUZU KB P190 2007 Workshop Owner's Manual

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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ISUZU KB P190 2007

FRONT SUSPENSION 3C-49
CAUTION: Be careful not to damage the ball joint
boot.



RTW 340SH000401
4. Remove bolt and nut.
5. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.






450RS023

• After moving the ball joint 4 or 5 times, attach nut,
then measure the preload.
Starting torque: 1.3-3.2 N ⋅
⋅⋅
⋅
m (0.13-0.33 kgf ⋅
⋅⋅
⋅
m/0.9-
2.4 lb ⋅
⋅⋅
⋅
ft)








450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install bolt and nut, and then tighten them to the specified torque.
Torque: 57 N ⋅
⋅⋅
⋅
m (5.8 kgf ⋅
⋅⋅
⋅
m/42 lb ⋅
⋅⋅
⋅
ft)
3. Install nut and cotter pin, and then tighten the nut to the specified torque with just enough additional
torque to align cotter pin holes. Install new cotte
r
pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-51
CAUTION: Be careful not to damage the ball joint
boot.





901RW 271
7. Remove lower ball joint nut.
8. Remove lower ball joint bolt.
9. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
through inspection.
• Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with a new one.





450RS026
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N ⋅
⋅⋅
⋅
m (0.25-0.65 kgf ⋅
⋅⋅
⋅
m/1.8-
4.7 lb ⋅
⋅⋅
⋅
ft)







450RS024
• If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install lower ball joint bolt.
3. Install lower ball joint nut and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅
⋅⋅
⋅
ft)
4. Install ball joint nut, then tighten it 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

3C-52 FRONT SUSPENSION
Bump Rubber
Bump Rubber and Associated Parts






RTW 63CMF000101
Legend
(1) Bolt
(2) Bump Rubber




Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
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:
• Bump Rubber

Installation
1. Install bump rubber.
NOTE: Arrow points to the outer side of vehicle afte
r
assembly to vehicle.
2. Install bolt, then tighten it to the specified torque. Torque: 42 N ⋅
⋅⋅
⋅
m (4.3 kgf ⋅
⋅⋅
⋅
m/31 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3D- 2 Torque Specifications .................................................................................................. 3D- 3
Rear Suspension ............................................................................................................... 3 D- 5
General Description...................................................................................................... 3D- 5
Leaf Spring and Shock Absorber ..................................................................................... 3D- 6 Leaf Spring and Associated Parts ............................................................................... 3D- 6
Removal ........................................................................................................................ .3D- 7
Inspection and Repair .................................................................................................. 3D- 8
Installation ................................................................................................................... .. 3D- 9
Leaf Spring Assembly ....................................................................................................... 3D- 11
Disassembly .................................................................................................................. 3D - 11
Inspection and Repair .................................................................................................. 3D- 11
Reassembly ................................................................................................................... 3D - 12
Rear Stabilizer Bar ............................................................................................................ 3D- 13
Stabilizer Bar and Associated Parts ........................................................................... 3D- 13
Removal ........................................................................................................................ . 3D- 14
Installation ................................................................................................................... .. 3D- 14
Troubleshooting ................................................................................................................ 3D- 15


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3D-8 REAR SUSPENSION
INSPECTION AND REPAIR
Make correction or replace parts if wear, damage or abnormal conditions are found through inspection.





Visual Check
Inspect the following parts for wear, damage, nuts or other
abnormal conditions.
• Leaf spring assembly
• Clip
• Center bolt
• U-bolt
• Spring pin
• Shackle pin
• Shock absorber
• Rubber bumper
• Rubber bushing
• Bump rubber seat



Shackle Pin
Shackle Pin diameter mm (in)
17.93 - 18.00 (0.706 - 0.709)



Spring Pin
Spring Pin Diameter mm (in)
13.8 - 14.0 (0.543 - 0.551)



Shock Absorber
Inspection operation of shock absorber
If no resistance is felt while expanding the shock absorber, it
indicates that the absorber is faulty.



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REAR SUSPENSION 3D-11
LEAF SPRING ASSEMBLY

F03L100004

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.




RTW 430SH000101
2. Apply a setting mark across the springs before
disassembling the leaf spring assembly.

F03L100006
3. Use a bench press and remove the center bolt.
• Discard center bolt and install a new one.

465R300001
4. Disassemble the leaf spring assembly.


Inspection and Repair
Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and repair or
replace if necessary.


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ISUZU KB P190 2007

WHEELS AND TIRES 3E-5
TIRE PRESSURE LABEL (LOCATION: DRIVERS DOOR OR FRAME OF DRIVERS DOOR)

4 ×
××
×
2 Except High Ride Suspension
SEE OW NERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION

Tire Size Wheel Size Tire inflation pressure
KPa (kgf/cm
2/psi)
Front & Rear Front & Rear Front Rear
195R14C 8PR 14X5.5JJ 245 (2.5/36) 441 (4.5/64)
215/70R15C 15X6.5JJ 221 (2.25/32) 368 (3.75/53)

4 ×
××
×
2 High Ride Suspension, 4 ×
××
×
4
SEE OW NERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION

Tire Size Wheel Size Tire inflation pressure
KPa (kgf/cm
2/psi)
Front & Rear Front & Rear Front Rear
225/75R15C 15X6.5JJ 221 (2.25/32) 319 (3.25/46)
245/70R16 16X7JJ 200 (2.0/28) 270 (2.8/40)


Note:
•
••
•
The air pressure of the tire should be maintained as indicated in the label instruction on the driver's
door or frame of driver's door.
Lower pressure can cause burst and adverse vehicle handling.
On the other hand, higher pressure can cause shock-burst and reduce gripping effect.



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ISUZU KB P190 2007

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4×2 Except High Ride Suspension Model) ..................................4C1- 38 Disassembly .................................................................................................................4C1 - 38
Inspection and Repair .................................................................................................4C1- 41
Reassembly ..................................................................................................................4C1 - 42
Front Hub and Disc
(4×4, 4×2 High Ride Suspension, 4×4 Rigid Hub, 4×4 Shift On the Fly Model) ..........4C1- 46 Disassembly .................................................................................................................4C1 - 46
Inspection and Repair .................................................................................................4C1- 48
Reassembly ..................................................................................................................4C1 - 49
Front Hub and Disc (4×4 Manual Locking Hub Model)..................................................4C1- 53 Disassembly .................................................................................................................4C1 - 53
Inspection and Repair .................................................................................................4C1- 56
Reassembly ..................................................................................................................4C1 -57
Troubleshooting ...............................................................................................................4 C1-63
Special Service Tool.........................................................................................................4C 1-71


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ISUZU KB P190 2007

ANTI-LOCK BRAKE SYSTEM 5B-9
4×
××
×
2 High Ride Suspension, 4 ×
××
×
4







RTW 55ALF000201
Legend
(1) Connector Portion
(2) Front Speed Sensor Assembly
(3) Bolt: Cable to Knuckle


(4) Bolt: Sensor to Knuckle
(5) Bolt: Cable to Upper Link
Removal
1. Remove speed sensor connector at connector
portion.
2. Remove sensor fixing bolt (4).
3. Remove cable fixing bolts and nut (4 ×2).
4. Disconnect the arrow mark locks of the cable clips.
5. Remove the speed sensor assembly.
Inspection and Repair
1. Check the speed sensor head for presence of
foreign materials; remove any dirt, etc.
2. Check the head for damage; replace speed senso
r
if necessary.
3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the cable while checking for continuity.

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ISUZU KB P190 2007