ISUZU KB P190 2007 Workshop Repair Manual

CAB 10-3



RUW 5A0SH002901

Important Operations - Removal
3. Room Mirror
Remove the screw and pull the room mirror to the upper side.

8. Windshield
Remove the windshield, carefully following the steps listed
below:
1) Use a knife to cut through part of the adhesive caulking material.
2) Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end o
f
the piano wire through the adhesive caulking material at the
edge of the windshield.
4) Secure the other end of the piano wire to another piece o
f
wood.





5) W ith the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the windshield.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the windshield.



Important Operations - Installation
9. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.
1 : Seal
2 : Clip
3 : Rear (windshield side)
4 : Front


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ISUZU KB P190 2007

10-4 CAB


8. Windshield
1) Clean the windshield bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Mount the body windshield as shown in the illustration. Attach spacers at five locations.
• Always use new spacers.
4) Install the windshield upper molding. • Peel off the tear-away paper from the windshield uppe
r
molding, and start applying it with one end of the
windshield and cut away the surplus at the other end o
f
the windshield for length adjustment.
• Always use new upper molding.
5) Temporarily install the windshield support.


6) Apply primer
1 Sunstar #435-98 or equivalent to the body
side bonding surface. The primer should extend at least 25
mm (0.98 in).
Apply primer Sunstar #435-40 or equivalent to the windshield side bonding surface.
The primer should extend 16.5 mm (0.65 in) and 25 mm (0.98 in) from end of the windshield.


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ISUZU KB P190 2007

CAB 10-5




7) Apply the windshield sealing adhesive
2.
If you are using an air gun, air pressure should be maintained at 147 - 294 kPa.
After drying the primer completely, apply a sealing adhesive (Sunstar #557 or equivalent) along the edge of the
windshield so that the sealing adhesive has a 20 mm (0.79
in) junction at the middle of the base of the windshield.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.


8) Adjust the setting of the windshield with suction discs.
Set the windshield with sealing adhesive applied to the entire circumference on the body panel. Specifically, adjust
the windshield support with the upper molding making
contact with the body panel, press the windshield, and
tighten the windshield support.



9) Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.
Cure the bonding at a temperature of 20 - 30 °C (68 - 86 °F)
for twenty-four hours.
Check that the windshield does not leak water.








2. Wiper Arm Assembly
• Set the wiper arm/blade so that the tips of both blades
are positioned to the specified value of
A and Bfrom
the upper edge of the cowl cover as shown in the figure.

A 40 mm (1.57 in)

B 52 mm (2.05 in)
• Tighten the wiper arm assembly fixing nuts to the
specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
31 (3.2/23)



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ISUZU KB P190 2007

10-6 CAB
REAR WINDOW ASSEMBLY
REMOVAL AND INSTALLATION


Removal Steps
1. Interior trim panels/Headlining
2. Rear defogger connector (W /Rear defogger)
▲ 3. Rear window

Installation Steps
▲
3. Rear window
2. Rear defogger connector (W /Rear defogger)
1. Interior trim panels/Headlining



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ISUZU KB P190 2007

CAB 10-7

Important Operation - Removal
3. Rear Window
Remove the rear window, carefully following the steps listed
below :
1) Use a knife to cut through part of the adhesive caulking material.
2) Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end o
f
the piano wire through the adhesive caulking material at the
edge of the rear window.
4) Secure the other end of the piano wire to another piece o
f
wood.



5) W ith the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the rea
r
window.
6) Lift the rear window from the body.
7) Clean any remaining adhesive caulking material from the area of the body which holds the rear window.
8) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the rear window.


Important Operation - Installation
3. Rear Window
1) Clean the rear window bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Install the fastener tape to the body panel flange.


4) Apply primer 1 Sunster #435-98 or equivalent to the body
side bonding surface.
Apply primer Sunstar #435-40 or equivalent to the rea
r
window side bonding surface.
The primer should extend 23 mm (0.91 in.) from the end o
f
the rear window.

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ISUZU KB P190 2007

10-8 CAB


5) Apply the rear window sealing adhesive 2.
If you are using an air gun, air pressure should be maintained at 147 – 294 kPa.
After drying the primer completely, apply a sealing adhesive (Sunstar #557 or equivalent) along the edge of the rea
r
window so that the sealing adhesive has a 20 mm (0.79 in.)
junction at left corner of the base of the rear window.
Note:
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
6) Insert the rear window supports into the panel and then push the rear window against the panel to fix it in place.
W ipe away any adhesive that oozes out around the edges.
7) Check that the rear window does not leak water.


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ISUZU KB P190 2007

CAB 10-9
FRONT DOOR ASSEMBLY
REMOVAL AND INSTALLATION




This illustration is based on RHD model


Removal Steps
▲ 1 . Door harness
▲ 2. Check arm screw
▲ 3. Lower hinge bolt
4. Upper hinge bolt
5. Door assembly

Installation Steps
5. Door assembly
4. Upper hinge bolt
▲ 3. Lower hinge bolt
▲ 2. Check arm screw
1. Door harness



RUW 5A0SH002 101

Important Operations - Removal
1. Door Harness
Remove the harness bracket and disconnect the doo
r
harness connectors.


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ISUZU KB P190 2007

10-10 CAB


RUW 5A0SH003001

2. Check Arm Screw





3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.





Important Operations – Installation
3. Lower Hinge Bolt; Hinge to Door
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
34 (3.5/25)

2. Check Arm Screw; Check Arm to Body
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
24 (2.4/ 17)

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ISUZU KB P190 2007

CAB 10-11
DISASSEMBLY




This illustration is based on RHD model

RTW 4A0LF000701
Disassembly Steps
▲ 1 . Switch bezel/W indow regulator handle
▲ 2. Power window switch
▲ 3. Bezel
▲ 4. Door mirror cover
▲ 5. Door trim panel
▲ 6. Tweeter (Required Option)
▲ 7. Door mirror assembly
▲ 8. Outer waste seal
▲ 9. Bracket
▲ 10. Speaker assembly
▲ 11 . W aterproof sheet
▲ 12. Inside lever
▲ 13. W indow glass
▲ 14. W indow regulator/Power window
regulator

▲
15. Glass run
▲ 16. Glass run rear channel / Glass ran rear
channel with Door lock control or Anti
theft (European Countries)
▲ 17. Door lock assembly/Door lock assembly
with super lock
▲ 18. Outside handle protector (EUROPE)
▲ 19. Outside handle
▲ 20. Door lock cylinder protector (EUROPE)
▲ 21. Door lock cylinder / Door lock cylinder
with door lock switch (European
Countries)
22. Door harness assembly
23. Anti rattler


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ISUZU KB P190 2007

10-12 CAB

RUW 5A0SH002201

Important Operations
1. Switch Bezel/Window Regulator Handle
• Remove the 2 screws and disconnect the connectors.



•
To remove the regulator handle, remove the clip at the
root of the handle by using wire.



2. Power Window Switch
• Remove the 2 screws.



RUW 5A0SH00230 1

3. Bezel
• Remove the screw.


4. Door Mirror Cover
• Pull out the upper clip, and then take out the cove
r
upward.



5. Door Trim Panel
• Pull out the trim panel at the 8 clip positions (Powe
r
window type).


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ISUZU KB P190 2007