ABS ISUZU KB P190 2007 Workshop Owner's Guide

3C-54 FRONT SUSPENSION
TROUBLESHOOTING
1. VIBRATION, SHOCK, AND SHIMMY OF STEERING WHEEL
Checkpoint Problem Countermeasure



Check front axle


Check wheel alignment


Check suspension ball joint


Check shock absorber or
attaching nut and bolt


Replace


Adjust


Replace


Replace or retighten


Check steering unit and
linkage


Faulty


Worn


Malfunction or loose


Check upper and lower link
bushings
Replace


Adjust


Worn


Incorrect

OK
OK
OK
NG
NG
NG
NG
NG
NG
OK
OK
Check vehicle trim height



• Improperly adjusted or worn front
wheel bearing.
• W orn or incorrectly adjusted wheel
bearing.
Replace; refer to Section 4C "Front
Wheel Drive"

• Insufficiently tightened steering
gear housing.
• W ear of steering linkage.
• Excessive backlash due to
improper adjustment of the steering
gear box.
• W orn column bearing, weakened
column bearing spring, or loose
clamp.
Replace; refer to Section 3B
"Steering"
• Improper tire pressure.
• Imbalance and deformation of frond
wheel.
• Unevenly worn tire or insufficient
tightening of wheel nuts.
Replace; refer to Section 3E "Wheel
and Tires"



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ISUZU KB P190 2007

FRONT SUSPENSION 3C-59
5. NOISES
Checkpoint Problem Countermeasure



Lubricating oil and grease for
upper and lower ball joint


Shock absorber


Stabilizer fixing nuts and bolts


Upper and lower links
bushings


Replace


Replace


Retighten


Replace


Insufficient


Faulty


Loose


Worn


Shock absorber fixing nut and
bolt

Retighten

Loose

Continued on the next page OK
OK
OK
OK
NG
NG
NG
NG
NG
OK

Upper and lower ball joint

Replace

Damaged

NG



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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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ISUZU KB P190 2007

3D-2 REAR SUSPENSION
MAIN DATA AND SPECIFICATIONS
General Specifications Models Standard Suspension, Soft ride Suspension Heavy-duty
Suspension
Items 4
× 2
(Except High Ride Suspension)
4 × 2 (High Ride Suspension)
4 × 4 4
× 2
Type
Leaf rigid

Leaf spring

No. of leaves
5
7
Spring eye type Berlin eye type
Up turned eye type
Bushing outside dia mm(in) Front; 40 (1.57), Rear; 30 (1.18)
Length mm(in) 1,200 (47.24)
Width mm(in) 60 (2.36)

Rear shock absorbers

Type
Gas-sealed, Twin tube
Mean stroke
mm(in)
198 (7.80) 199 (7.83) 198 (7.80)
Compressed length mm(in)
323 (12.7) 349 (13.7) 323 (12.7)
Extended length mm(in) 521 (20.5) 549 (21.6) 521 (20.5)

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REAR SUSPENSION 3D-5
REAR SUSPENSION
GENERAL DESCRIPTION

Rear suspension absorbs vibration from the road surface thus preventing vehicle damage, as well as providing a
comfortable ride.

Components parts
• Spring between the body and the axle case
• Spring shackle connecting the spring to the body
• Clamp and U-bolt fixing the axle case to the spring
• Shock absorber as a countermeasure for vibration


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3D-6 REAR SUSPENSION
LEAF SPRING AND SHOCK ABSORBER
LEAF SPRING AND ASSOCIATED PARTS

460R300001

Legend
1. Parking Brake Cable Bracket
2. Nut and W asher
3. Nut and W asher
4. Shock Absorber
5. Nut
6. U Bolt and Seat
7. Lower Clamp
8. Nut
9. Shackle Plate


10. Shackle Pin
11. Rubber Bushing
12. Nut and Plain W asher
13. Spring Pin
14. Leaf Spring
15. Bump Rubber




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ISUZU KB P190 2007

REAR SUSPENSION 3D-7
F03L100003

Removal
• Jack up the rear axle and place chassis stands under the
frame near the front end of the rear spring brackets.
Note:
• Be careful not to stretch the flexible brake hose o
r
parking brake cable.
• Support the vehicle on the specified jack point.
1. Remove the parking brake cable from the leaf spring.
2. Loosen the shock absorber fixing nut and remove the nut and special washer from the lower clamp.


3. Remove the shock absorber fixing nut and washer at frame
side.
4. Lifting the rear axle using a jack, remove the shock
absorber and lower the jack.
5. Remove the U bolt fixing nut.
6. Take out the U bolt, seat and lower clamp.
7. Support the leaf spring using a jack and remove the shackle pin fixing nuts.
8. Drive out the shackle pin, using a brass bar and hammer.
9. Remove the shackle plate and rubber bushings.
10. Remove the nut and drive out the shackle using a brass bar and hammer.
11. Remove the leaf spring.
12. Remove the bump rubber.



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ISUZU KB P190 2007

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-9
Installation
1. Install the bump rubber and bolt and tighten it to thespecified torque.
Torque N â‹…m (kgf â‹…m/lb â‹…ft)
42 (4.3/31)
2. Install the leaf spring. • The leaf spring assembly should be installed so that the
built-in rubber bush is toward the front.
• Align the holes of the spring eye and frame bracket.
• Insert the spring pin toward vehicle inner side, through
the frame bracket holes and the spring bush hole.
• Tighten the nut a little and, after the vehicle is lowered,
tighten it to the specified torque.
Torque N â‹…m (kgf â‹…m/lb â‹…ft)
152 (15.5/112)





RTW 340LF000101





RTW 63DSH000101
• Apply rubber grease to inside and outside of the rubber
bushing.
• Install the rubber bushings into the hole in the frame
side bracket and the spring rear eye.
• Install the shackle pin and shackle plate.
• Tighten the nuts a little and, after vehicle is lowered,
tighten it to the specified torque.
Torque N â‹…m (kgf â‹…m/lb â‹…ft)
98 (10.0/72)
3. Support the lower clamp under the leaf spring.
4. Apply oil to the thread portion of U bolt.
Install the U bolt (1) and seat (2) on the rear axle and insert
the U bolt in the lower clamp holes.
Tolerance of assembling the seat
A
90° ±2°
5. Tighten the nut to the specified torque.
NOTE: Apply oil to the thread.
Torque Nâ‹…m (kgf â‹…m/lb â‹…ft)
78 (8.0/58)
6. Install the shock absorber and inner washer on the lower clamp pin and frame side pin.
7. Install the washer and nut on the frame side pin and tighten the nut to the specified torque.
Torque N â‹…m (kgf â‹…m/lb â‹…ft)
39 (4.0/29)
8. Install the washer and nut on the lower clamp pin and tighten the nut to the specified torque.
Torque N â‹…m (kgf â‹…m/lb â‹…ft)
39 (4.0/29)

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REAR SUSPENSION 3D-15
TROUBLESHOOTING
1. BODY INCLINATION
Checkpoint Problem Countermeasure

ReplaceBushings worn or
disintegrated
NG
Mounting brackets
Shock absorbers
ReplaceDefective
Spring brackets and U-bolts
Shackle pins and bushings
Replace
Retighten
Replace
Cracked
Bolt loosened
W orn or disintegrated
Regrease
Replace
Poorly lubricated
W eak or broken
OK
OK
OK NG
NG
NG
NG
NG
NG
OKSpring



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