ISUZU KB P190 2007 Workshop Repair Manual

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 ⋅m (kgf ⋅m/lb ⋅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 ⋅m (kgf ⋅m/lb ⋅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 ⋅m (kgf ⋅m/lb ⋅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 N⋅m (kgf ⋅m/lb ⋅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 ⋅m (kgf ⋅m/lb ⋅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 ⋅m (kgf ⋅m/lb ⋅ft)
39 (4.0/29)

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3D-10 REAR SUSPENSION
9. Install the parking brake cable on the leaf spring and
tighten the nut at its bracket.
Torque N ⋅m (kgf ⋅m/lb ⋅in)
7 (0.7/61)


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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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3D-12 REAR SUSPENSION
Reassembly
1. Apply grease to both faces of each leaf spring at
reassembly.
2. Set the leaf springs, aligning them to the setting mark made
before disassembly.

F03L100006
3. Assemble the leaf springs using a bench press.
4. Apply grease to the outside of the bushing.
Install a new center bolt and tighten it to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
29 (3.0/22)
5. Install the bushing using a bench press and a suitable metal fitting.



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REAR SUSPENSION 3D-13
REAR STABILIZER BAR
STABILIZER BAR AND ASSOCIATED PARTS





RTW 73DLF000101

Legend
1. Bolt
2. Bush
3. Stabilizer Bar
4. Cap
5. Nut


6. Link
7. Stabilizer Bar Assembly
8. Nut




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3D-14 REAR SUSPENSION

Removal
1. Remove the bolt and nut.
2. Take out the stabilizer bar assembly.
3. Remove the nut and take out the link from the stabilizer
bar.
4. Take out the cap and bush from the stabilizer bar.




Installation
1. Set the bush and cap on the stabilizer bar.
2. Install the link on the stabilizer bar and tighten the nut to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
50 (5.1/37)

3. Install the stabilizer bar assembly on the rear axle and
tighten the bolt to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
25 (2.5/18)

4. Set the stabilizer bar assembly to the frame bracket and
tighten the nut to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
50 (5.1/37)



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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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3D-16 REAR SUSPENSION
2. REDUCTION IN GROUND CLEARANCE
Checkpoint Problem Countermeasure

Bushings
Leaf springs
Regrease
Replace
Retighten
Replace
Poorly lubricated
Deteriorated or disintegrated
Loosened
Broken
Springs clip bandsReplaceW orn or broken
Continued on the next page OK
NG
NG
NG
NG
NG
OK
OK
Condition of load
W ipe off excess greaseOver lubricated
NG



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ISUZU KB P190 2007