ECO mode ISUZU KB P190 2007 Workshop Owner's Guide

REAR AXLE 4B-17
8. Certainly install new snap ring, use snap ring
pliers. W hen transform or damage, replace ne
w
one.




RTW 34BMH000101
Legend
1. Snap ring
2. Crevice
3. Retainer (with ABS)
Retainer (without ABS)


9. Insert a shim of sufficient thickness between
snap ring and end of retainer.

Standard 0 − 0.2 mm (0 − 0.008 in)

Crevice is measured using thickness gauge, and
when crevice exceeds 0.2 mm (0.008 in), it
adjusts so that is may become 0.2 mm (0.008 in)
or less using shim.

Shim Pats No. Thickness

1 9-41519110- ∗ 0.18 mm (0.0071 in)

2 8-97130387- ∗ 0.50 mm (0.0197 in)

Crevice No. of shim Total
mm (in)
1 2 mm (in)
1.0(0.0394)  2 1.00(0.0394)
0.9(0.0354) 2 1 0.86(0.0339)
0.8(0.0315) 1 1 0.68(0.0268)
0.7(0.0276) 1 1 0.68(0.0268)
0.6(0.0236)  1 0.50(0.0197)
0.5(0.0197)  1 0.50(0.0197)
0.4(0.0157) 2  0.36(0.0142)
0.3(0.0118) 1  0.18(0.0071)
0.2(0.0079) 1  0.18(0.0071)

10. Install axle shaft assembly in rear axle case
assembly.
a. Clean the mating surface of axle case and bearing holder.
b. Apply Three Bond 1215 (TB1215) o
r
equivalent on the surface of axle case
assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the specified torque.
Torque : 84 N ⋅m (8.6 kgf ⋅m/62 lb ⋅ft)
12. Install wheel cylinder and tighten the bolt to the specified torque.
Torque : 9 N ⋅m (0.9 kgf ⋅m/78 lb ⋅in)
13. Install parking brake outer cable in back plate and inner cable in parking brake lever.


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ISUZU KB P190 2007

4B-26 REAR AXLE


425RS02

f.
After the ZERO setting is obtained, rotate the
gauging arbor until the dial indicator rod does
not touch the gauging plate. Record the
number the dial indicator needle points.




425RS022
Legend
1. Example=Dial indicator reading on 0.085



g. Record the pinion depth code on the head o
f
the drive pinion. The number indicates a
necessary change in the pinion mounting
distance. A plus number indicates the need
for a greater mounting distance (which can be
achieved by decreasing the shim thickness).
A
minus number indicates the need for a smalle
r
mounting distance (which can be achieved b
y
increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is
“nominal”.

425RS023


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FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................ 4C1- 4
Recommended Liquid Gasket .......................................................................................... 4C1- 6
Recommended Thread Locking Agents .......................................................................... 4C1- 6
Servicing ...................................................................................................................... ...... 4C1- 7
General Description .......................................................................................................... 4C 1- 8
Front Drive Axle Assembly ..............................................................................................4C1- 10 Front Drive Axle Assembly and Associated Parts ....................................................4C1- 10
Removal ........................................................................................................................ 4C1- 11
Installation ................................................................................................................... .4C1- 12
Front Axle Drive Shaft ......................................................................................................4C1 - 14
Front Axle Drive Shaft and Associated Parts ............................................................4C1- 14
Disassembly .................................................................................................................4C1 - 15
Inspection and Repair .................................................................................................4C1- 16
Bushing Replacement ................................................................................................4C1- 17
Reassembly ..................................................................................................................4C1 - 17
Standard Caulk Measure ............................................................................................4C1- 18
Differential................................................................................................................... ......4C1- 20
Disassembly .................................................................................................................4C1 - 20
Major Components ................................................................................................4C1- 20
Minor Components ................................................................................................4C1- 23
Inspection and Repair .................................................................................................4C1- 25
Reassembly .................................................................................................................4C1 - 27
Minor Components..................................................................................................4C1- 27
Major Components ..................................................................................................4C1- 29

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4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET
Type Brand Name Manufacture Remarks

RTV* Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
W ater Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket. Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262
Red 2. Apply LOCTITE to the bolts.


LOCTITE 270
Green

LOCTITE 271
Red
3. Tighten the bolts to the specified torque.
4. W ait at least on hour before continuing the installation procedure.


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4C1-32 FRONT WHEEL DRIVE


(5)
After the ZERO setting is obtained, rotate the gaging arbor
until the dial indicator rod does not touch the gaging plate.
Record the number the dial indicator needle points to.


(6) Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a
greater mounting distance (which can be achieved b
y
decreasing the shim thickness). A minus number indicates
the need for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination
reveals pinion depth code “0”, the pinion is “nominal”.



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-37
















20. Differential Assembly
(1) Clean the faces of the front axle case and differential carrier.

Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2)
Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
26 (2.7/20)
(3) Install the axle shaft assemblies as instructed earlier in this section under “Axle Shaft Replacement”.
(4) Fill the axle case with hypoid gear lubricant, to just belo
w
the filler hole.
Lubricant capacity liter (US/UK gal)
1.4 (0.37/0.31)



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5A-22 BRAKE CONTROL SYSTEM
System Components
Electronic Hydraulic Control Unit (EHCU), four W heel
Speed Sensors, two W arning Lamps, and G sensor.

Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the EHCU according
to the signal from each sensor, cancelling ABS to return
to normal braking when a malfunction has occurred in
the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
left side. It consists of a motor, solenoid valves and a
fail safe relay.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front brake or both rear brakes
according to the signal sent from the EHCU.
Buffer chamber: Temporarily holds the brake fluid that
returns from the front and rear brake so that pressure of
front brake can be reduced smoothly.
Motor: Drives the pump according to the signal from
EHCU.
Fail safe Relay: W hen failure occurs in ABS.
The power supply to solenoid Valve is cut.

ABS Warning Lamp


RTW 75ASH000101
Vehicles equipped with the Anti-lock Brake System
have an amber “ABS” warning lamp on the instrument
panel. The “ABS” warning lamp will illuminate if a
malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In the
case of an electronic malfunction, the EHCU will turn
“ON” the “ABS” warning lamp and disable the anti-lock
braking function.

The “ABS” warning lamp will turn “ON” for
approximately three seconds after the ignition switch is
in the “ON” position.
If the “ABS” warning lamp stays “ON” after the ignition
switch is in the “ON” position, or comes “ON” and stays
“ON” while driving, the Anti-lock Brake System should
be inspected for a malfunction according to the
diagnostic procedure.

Wheel Speed Sensor (WSS)
It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear wheels.
The rotor is press-fit in the axle shaft.

G Sensor
The G sensor detects the vehicle deceleration speed
and sends a signal to the EHCU. In 4W D operation, all
four wheels may be decelerated in almost the same
phase, since all wheels are connected mechanically.
This tendency is noticeable, particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G sensor judges whether the friction coefficient of
the road surface is low or high, and changes the
EHCU's operating system to ensure ABS and EBD
control.

Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal “bump” will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or popping
noise may be heard during brake applications when the
anti-lock feature is being used.
W hen the anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on the
pedal will provide the shortest stopping distance.




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BRAKE CONTROL SYSTEM 5A-23
Electronic Brake-force Distribution (EBD) System
ABS has the EBD function. EBD is a function which
controls braking force distribution of a front wheel and a
rear wheel, and makes brake fluid pressure of a rear
wheel the optimal. If the rate of slip of a rear wheel
becomes greater compared to a front wheel, the brake
fluid pressure of a rear wheel will be controlled in order
to perform braking force distribution between the front
and rear wheels. EBD enables the braking power of a
rear wheel to always be utilized for the maximum
according to the load change concerning the back axis
according to the vehicle’s loading state (No luggage,
loading, etc.), deceleration, etc. Brake fluid pressure
control to a rear wheel is performed by the EBD function
which uses the ABS function without the mechanical
proportioning valve.
C05L300016
Brake Pedal Travel
Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.

Acronyms and Abbreviations
Several acronyms and abbreviations are commonly
used throughout this section:
ABS
Anti-lock Brake System
CKT
Circuit
DLC
Data Link Connector
EBD
Electronic Brake-force Distribution
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolutions per Second
VDC
DC Volts
VAC
AC Volts
W/L
W arning Lamp
WSS
W heel Speed Sensor

General Diagnosis
General Information
ABS problems can be classified into two types, those
which can be detected by the ABS warning lamp and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
“BASIC DIAGNOSTIC FLOW CHART” and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.

ABS Service Precautions
Required Tools and Items:
• Box W rench
• Brake Fluid
• Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.

5-8840-0366-0 High Impedance Multimeter
W hen circuit measurements are requested, use a circuit
tester with high impedance.

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BRAKE CONTROL SYSTEM 5A-25
“ABS” Warning Lamp
W hen ABS and problems occur that actuate the “ABS”
warning lamp, the code corresponding to the problem is
stored in the EHCU. Only ordinary braking is available
when the ABS is deactivated. Even when the “ABS”
warning lamp is actuated, if the starter switch is set ON
after setting it OFF once, the EHCU checks up on the
entire system. If there is no abnormality, the EHCU
judges ABS to work correctly and the warning lamp is lit
normally, even though the problem code is stored.
NOTE: Illumination of the “ABS” warning lamp indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still
available.

Normal Operation
“ABS ” Warning Lamp
W hen the ignition is first moved from “OFF” to “RUN”,
the amber “ABS” warning lamp will turn “ON”. The
“ABS” warning lamp will turn “ON” during engine
starting and will usually stay “ON” for approximately
three seconds after the ignition switch is returned to the
“ON” position. The warning lamp should remain “OFF”
at all other times.

Brake (EBD) Warning Lamp


RTW 75ASH000101
Vehicles equipped with the EBD (Electronic Brake-force
Distribution) System have a “Brake” warning lamp on
the instrument panel.
If the ABS warning lamp and Brake warning lamp are
turned "ON", then EBD has failed. ( Parking brake
switch is "OFF")
In the following conditions, the EBD warning lamp is
"ON".
• Starter switch is "ON", engine "OFF". ( Parking brake switch is "OFF")
If engine is started, then EBD warning lamp is "OFF".
( Parking brake switch is "OFF")



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5A-34 BRAKE CONTROL SYSTEM
Warning Lamp System Control Main Items DTC
(Flash Code) Description
ABS Brake
(EBD) ABS EBD


× × Battery, W iring or EHCU
(less than 8V) C0277 (77) System Voltage Low

× × Battery or W iring
(less than 10V)
C0278 (78) System Voltage High
× × Battery or W iring EHCU
C0282
(82) 4 W heel Drive State Input Signal
Failure × × W iring
C0285
(85) Control Module Vehicle Options
Incorrect × × Vehicle (Sensor or EHCU)

*A : W hen three or more failures are detected, the EBD warning lamp is "ON" and control is canceled.
*B : The ABS lamp is “OFF” when the ABS lamp is “ON” after a repair, until the vehicle’s speed becomes
more than 10km/h (6mph) in the following ignition
cycle and failure is not detected.


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