torque ISUZU KB P190 2007 Workshop Workshop Manual

3B-22 POWER-ASSISTED STEERING SYSTEM
Power Steering Pump (4JJ1-TC, 4JK1-TC)
Power Steering Pump and Associated Parts

RTW 53BMF000201
Legend
(1) Pump Assembly
(2) Flexible Hose
(3) Bolt
(4) Suction Hose
(5) Nut


Removal
1. Remove the cooler compressor drive belt.
2. Place a drain pan below the pump.
3. Disconnect the suction hose.
4. Disconnect the flexible hose.
5. Remove the power steering fixing nut, and remove the pump assembly.

Installation
1. Install the pump assembly. Tighten the fixing nut to
the specified torque.
Torque: 25 N·m (2.5 kgf·m/18 lb·ft)
2. Install the flexible hose.
Tighten the bolts to the specified torque.
Torque: 8 N·m (0.8 kgf·m/69 lb·in)
3. Install the cooler compressor drive belt.
4. Connect the suction hose, then fill the power steering fluid and bleed the power steering system.
Refer to Bleeding the Power Steering System in this section.

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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-25
Reassembly
1. Install two new O-rings on shaft and housing
assembly. Be sure to discard used O-ring.
2. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. A damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
3. Install the vanes on rotor with curved face in contact with the inner wall of cam.
442RS005
4. Install rotor and vanes on cam.
5. Install pump cartridge assembly on shaft and housing assembly.
6. Install a new O-ring on rear housing. Be sure to discard used O-ring. Then install bolt and tighten it to
specified torque.
Torque: 25 N â‹…
â‹…â‹…
â‹…
m (2.5 kgf â‹…
â‹…â‹…
â‹…
m/18 lb â‹…
â‹…â‹…
â‹…
ft)
7. Install a new O-ring on suction pipe. Be sure to
discard used O-ring. Then install bolt and tighten it to
specified torque.
Torque: 10 N â‹…
â‹…â‹…
â‹…
m (1.0 kgf â‹…
â‹…â‹…
â‹…
m/87 lb â‹…
â‹…â‹…
â‹…
in)
8. Install relief valve and spring.
9. Install a new O-ring on connector. Be sure to discard used O-ring. Tighten the connector to specified
torque.
Torque: 59 N â‹…
â‹…â‹…
â‹…
m (6.0 kgf â‹…
â‹…â‹…
â‹…
m/43 lb â‹…
â‹…â‹…
â‹…
ft)
10. Install new O-rings on joint. Be sure to discard used
O-rings. Temporarily tighten the nut with washer.
11. Install bracket. Then install nut and tighten it to specified torque.
Torque: 12 N â‹…
â‹…â‹…
â‹…
m (1.2 kgf â‹…
â‹…â‹…
â‹…
m/104 lb â‹…
â‹…â‹…
â‹…
in)
12. Tighten the nut to the specified torque (This nut was
temporarily tightened in step 10).
Torque: 20 N â‹…
â‹…â‹…
â‹…
m (2.0 kgf â‹…
â‹…â‹…
â‹…
m/14 lb â‹…
â‹…â‹…
â‹…
ft)


Main Data and Specifications
General Specifications
Oil pump Type Vane
Operating fluid
ATF DEXRON®―III


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3B-26 POWER-ASSISTED STEERING SYSTEM
Torque Specifications
Nâ‹…m (kgf â‹…m/Ib â‹…ft)




RTW 73BLF000701





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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-31
Inspection and Repair (with SRS air
bag)
The inflator module consists of a cover, air bag, inflator,
and retainer. Inspect the inflator module mainly for the
following:
・ Check for holes, cracks, severe blemishes and
deformation on the cover.
・ Check that the retainer is not deformed.
・ Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as a result of the inspection,
replace the inflator module with a new one.

Installation
1. Support the inflator module and carefully connect the
SRS connector (1) and horn lead (2) (with SRS ai
r
bag).

RTW 73BSH001101


2. Connect the horn leads at center of wheel (without
SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801
3. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag)
Torque: 3 N â‹…m (0.3 kgf â‹…m/26 lb â‹…in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201


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3B-36 POWER-ASSISTED STEERING SYSTEM


RTW 73BSH001301
14. Remove steering column cover.
15. Disconnect the wiring harness connectors located under the steering column then remove combination
switch and SRS coil assembly.

Installation
1. Align the setting marks made when removing, then
install steering wheel.
Refer to the adjustment method in case a mark has not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701

CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 35 N â‹…
â‹…â‹…
â‹…
m (3.6 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
ft)
3. Support the inflator module and carefully connect the
SRS connector (1) and horn lead (2) (with SRS ai
r
bag).

RTW 73BSH001101
4. Connect the horn leads at center of wheel (without SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801



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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-37

5. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag)
Torque: 3 N â‹…
â‹…â‹…
â‹…
m (0.3 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
in)
NOTE: A horn pad should not be struk during
attachment.

RTW 73BSH000201
6. Align each snap stud of driver air bag to the holes on
steering wheel. (with SRS air bag)

RTW 73BSH001201


RTW 73BSH000401
7. Push the SRS air at bag at area-1 (1) and area-2 (2).
At that time confirm the audible noise of each stud.
(with SRS air bag)

RTW 73BSH000301
8. Enable the SRS (Refer to "Enabling the SRS" in this section) (with SRS air bag).
9. Connect the SRS connector (with SRS air bag).
10. Connect the battery "-" terminal cable (with SRS ai
r
bag).
11. Turn the ignition switch to "ON" while watching warning light and check - the light should flash 7
times and then go off. If lamp does not operate
correctly, refer to Restraints section.



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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-43
6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood opening lever.
8. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark has
not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701
CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
9. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N â‹…
â‹…â‹…
â‹…
m (3.6 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
ft)
10. Support the inflator module and carefully connect the SRS connector (1) and horn lead (2) (with SRS
air bag).

RTW 73BSH001101
11. Connect the horn leads at center of wheel (without
SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801
12. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag)
Torque: 3 N â‹…
â‹…â‹…
â‹…
m (0.3 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201

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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-49
825RS048
4. Install the driver knee bolster assembly.
5. Install the steering lower cover and engine hood opening lever.
6. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark has not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701

CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
7. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N â‹…
â‹…â‹…
â‹…
m (3.6 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
ft)

8. Support inflator module and carefully connect the
SRS connector (1) and horn lead (2), then install
inflator module (with SRS air bag).

RTW 73BSH001101
9. Connect the horn leads at center of wheel (without SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801


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ISUZU KB P190 2007

3B-50 POWER-ASSISTED STEERING SYSTEM
10. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag).
Torque: 3 N â‹…
â‹…â‹…
â‹…
m (0.3 kgf â‹…
â‹…â‹…
â‹…
m/26 lb â‹…
â‹…â‹…
â‹…
in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201
11. Align each snap stud of driver air bag to the holes on
steering wheel (with SRS air bag).

RTW 73BSH001201

RTW 73BSH000401
12. Push the SRS air bag at area-1 (1) and area-2 (2). At that time confirm the audible noise of each stud.
(with SRS air bag)

RTW 73BSH000301
13. Enable the SRS (Refer to "Enabling the SRS" in this section) (with SRS air bag).
14. Install driver knee bolster (reinforcement).
15. Install instrument panel lower cover, then install the engine hood opening lever.
16. Connect the yellow 2-way SRS connector located under the steering column (with SRS air bag).
17. Connect the battery "-" terminal cable (with SRS ai
r
bag).

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

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POWER-ASSISTED STEERING SYSTEM 3B-55
Check clearance between capsule and bracket. It must
be less than 1 mm (0.039 in).
431RW 031

Column Universal Joint (between the
power steering unit and the steering shaft)
If resistance is felt when checked by rotating the joint,
replace the lower second steering shaft.

Shaft Universal Joint (between the lower
second steering shaft and the second
steering shaft)
If resistance is felt when checked by rotating the joint,
replace the second steering shaft assembly.

Tilt Mechanism
The tilt mechanism should move smoothly.
W hile locking the tilt mechanism, be sure the steering
column is latched securely by pushing the steering
wheel upward and downward.

Installation
1. Align the setting mark (1) on the second steering
shaft and the steering column assembly (applied at
disassembly).
2. Connect the steering column assembly to the second steering shaft. Tighten the bolts to the specified
torque.
Torque: 31 N â‹…
â‹…â‹…
â‹…
m (3.2 kgf â‹…
â‹…â‹…
â‹…
m/23 lb â‹…
â‹…â‹…
â‹…
ft)





RTW 53BSH00301
3. Thread the steering column assembly through the
hole in the dashpanel. Temporarily tighten the
steering column and the second steering shaft fixing
bolts.
4.
Align the setting marks (applied at disassembly) and
connect the lower second steering shaft and the
second steering shaft. Tighten the universal joint
bolts to the specified torque.
Torque: 31 N â‹…
â‹…â‹…
â‹…
m (3.2 kgf â‹…
â‹…â‹…
â‹…
m/23 lb â‹…
â‹…â‹…
â‹…
ft)
5. Tighten the steering column fixing bolt (pedal bracket side) to the specified torque (This bolt was
temporarily tightened in Step 3).
Torque: 20 N â‹…
â‹…â‹…
â‹…
m (2.0 kgf â‹…
â‹…â‹…
â‹…
m/14 lb â‹…
â‹…â‹…
â‹…
ft)
6. Tighten the second steering shaft fixing bolt to the specified torque (This bolt was temporarily tightened
in Step 3)
Torque: 20 N â‹…
â‹…â‹…
â‹…
m (2.0 kgf â‹…
â‹…â‹…
â‹…
m/14 lb â‹…
â‹…â‹…
â‹…
ft)
7. Tighten the steering column fixing bolt (dashpanel side) to the specified torque (This bolt was
temporarily tightened in Step 3).
Torque: 20 N â‹…
â‹…â‹…
â‹…
m (2.0 kgf â‹…
â‹…â‹…
â‹…
m/14 lb â‹…
â‹…â‹…
â‹…
ft)
8. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.

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