ISUZU KB P190 2007 Workshop Repair Manual

3C-40 FRONT SUSPENSION
Upper Control Arm
Upper Control Arm and Associated Parts



RTW 440LF001301
Legend
(1) Bolt and Plate
(2) Camber Shims
(3) Caster Shims
(4) Nut Assembly
(5) Upper Control Arm Assembly
(6) Fulcrum Pin


(7) Bushing
(8) Plate
(9) Upper Control Arm Nut
(10) Speed Sensor harness
(11) Nut and Cotter Pin
(12) Upper Ball Joint, Bolt and Nut


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 brake caliper and disconnect brake pipe. Refer to Disc Brakes in Brake section.

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-41
4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle using remover 5-8840-2121-0.
CAUTION: Be careful not to damage the ball joint
boot.


RTW 340SH000401
7. Remove upper ball joint.
8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and number of shims.
11. Remove caster shims and note the positions and number of shims.
12. Remove upper control arm assembly.
13. Remove upper control arm nut.
14. Remove plate.

15. Remove bushing by using remover 5-8840-0256-0.


RTW 340SH000501




RTW 340SH000601
16. Remove fulcrum pin.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts:
• Upper control arm
• Bushing
• Fulcrum pin


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ISUZU KB P190 2007

3C-42 FRONT SUSPENSION
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0 and 5-8840-2307-0.



RTW 340SH000701




RTW 340SH000801
3. Install upper ball joint and tighten it to the specified
torque.
Torque: 57 N ⋅
⋅⋅
⋅
m (5.8 kgf ⋅
⋅⋅
⋅
m/42 lb ⋅
⋅⋅
⋅
ft)
4. 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: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
5. Install plate.

6. Install upper control arm nut and tighten fulcrum
pin nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N ⋅
⋅⋅
⋅
m (11.0 kgf ⋅
⋅⋅
⋅
m/80 lb ⋅
⋅⋅
⋅
ft)






RTW 53ASH000301
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.










RTW 53CSH000101-X

8. Install the caster shims (b) between the chassis
frame and fulcrum pin.



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ISUZU KB P190 2007

FRONT SUSPENSION 3C-43
9. Install the camber shims (a) between the chassis
frame and fulcrum pin.



RTW 53CSH000201
10. Install nut assembly.
11. Install bolt and plate (a), and then tighten the bolt to the specified torque.
Torque: 152 N ⋅
⋅⋅
⋅
m (15.5 kgf ⋅
⋅⋅
⋅
m/112 lb ⋅
⋅⋅
⋅
ft)
NOTE: Apply oil to the thread.
12. Install speed sensor harness.


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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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ISUZU KB P190 2007

FRONT SUSPENSION 3C-47
14. Install cam plate and nut then tighten lower link 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: 186 N ⋅
⋅⋅
⋅
m (19.0 kgf ⋅
⋅⋅
⋅
m/137 lb ⋅
⋅⋅
⋅
ft)
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.







RTW 53ASH000301



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ISUZU KB P190 2007

3C-48 FRONT SUSPENSION
Upper Ball Joint
Upper Ball Joint and Associated Parts



RTW 440LF001401
Legend
(1) Bolt and Nut
(2) Upper Ball Joint


(3) Nut and Cotter Pin


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then use remover 5-8840-2121-0 to remove the uppe
r
ball joint from the knuckle.


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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