wheel bolts ISUZU KB P190 2007 Workshop Manual PDF

CLUTCH 7C-23


Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.


2. Pressure Plate Assembly
3. Driven Plate Assembly
(1) Use the clutch pilot aligner
1 to prevent the driven plate
assembly
2 from falling free.
Clutch Pilot Aligner : 5-8525-3001-0(J-24547)



4J series, C24SE (MSG, MUA)


(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly
3 from the flywheel.
(4) Remove the driven plate from the flywheel.


4JJ1 (High Output) (MUX)
RTW 77CSH000601

RTW 77CSH000801
4. Shift Fork (MUX)
5. Release Bearing (MUX)
(1) Remove the shift fork snap pin (2).
(2) Remove the shift fork pin and shift fork (3) from the fulcrum bridge.
(3) Remove the release bearing (1) from the transmission case.

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ISUZU KB P190 2007

7C-24 CLUTCH
015RW 053
6. Flywheel Assembly and Crank Bearing (MUX)
(1) Remove flywheel assembly and crankshaft bearing. Do not remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding hammer 5-8840-0019-0 (J-23907) to remove the crankshaft
bearing



Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

015RW 054
6. Flywheel Assembly and Crank Bearing (MUX)
(1) Install flywheel assembly and crankshaft bearing. Use the installer 5-8840-0125-0 (J-26516-A) and driver handle 5-
8840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RS047
(2) Install new flywheel fixing bolts in the order illustrated and tighten them to the specified torque. N⋅m (kg ⋅m/lb ⋅ft)
MUX 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.

RTW 77CSH000701
5. Release Bearing (MUX)
4. Shift Fork (MUX)
(1)
Apply molybdenum disulfide type grease to the pin hole
inner circumferences and thrust surfaces.


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ISUZU KB P190 2007

CLUTCH 7C-25
201RW 012
(2) Apply molybdenum disulfide type grease to the areas shown in illustration.
(3) Install the release bearing to the transmission front cover.
(4) Install the shift fork to the fulcrum bridge and insert the pin from bottom of the fulcrum bridge.
(5) Install the washer and snap pin.





3. Driven plate Assembly
2. Pressure Plate Assembly
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner
1 to install the driven plate
assembly
2 to the flywheel 3.
Clutch Pilot Aligner : 5-8525-3001-0(J-24547)


4 4J series, C24SE (MSG, MUA)

(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly
4 with the flywheel
knock pin
5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the numerical order shown in the illustration.
Clutch Cover Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)
18 ± 3 (1.8 ± 0.3 / 13.0 ± 2.2)


4JJ1 (High Output) (MUX)
RTW 77CSH000601


(8) Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.


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CLUTCH 7C-27



RTW 67CSH000101


Clutch Set Force
1. Invert the pressure plate assembly.
2. Place a metal sheet “A” on the pressure plate.
3. Compress the pressure plate assembly until the distance “B” becomes specified.
Thickness and Distance mm(in
)

A B
4JJ1 (High Output)
(MUX) 8.3 (0.327) 12 (0.472)
4JA1-T (MSG) 7.8 (0.307) 20 (0.787)
4J series (MUA) 7.8 (0.307) 18 (0.709)
C24SE (MUA) 8.0 (0.315) 7.9 (0.311)
4. Note the pressure plate gauge reading.
Driven Plate Clamping Load N (kg/Ib)
Standard
4JJ1 (High Output) (MUX) 6860 (700/1544)
4JA1-T (MSG) 5070 (517/1140)
4J series (MUA) 6300 (642/1415)
C24SE (MUA) 5500 (561/1237)

RTW 37CSH000101
Diaphragm Spring Finger Height
1. Place a new driven plate or the appropriate spacer beneath
the pressure plate.
2. Fully compress the pressure plate and diaphragm spring. There are two ways to do this.
• Use a bench press to press down on the assembly from the
top.
• Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 - 98 N
(11 - 22 lb) in direction of release, when clutch cover assembly
is bolted to the flywheel.


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SUPPLEMENTAL RESTRAINT SYSTEM 9A-41
Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN
A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWDER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AN AIR BAG ASSEMBLY BY THE WIRES
OR CONNECTOR ON THE UNDERSIDE OF THE
MODULE. IN THE CASE OF AN ACCIDENTAL
DEPLOYMENT, THE BAG WILL THEN DEPLOY
WITH MINIMAL CHANCE OF INJURY. WHEN
PLACING ALIVE AIR BAG ASSEMBLY ON
A
BENCH OR OTHER SURFACE, ALWAYS FACE
THE BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE. NEVER REST A STEERING COLUMN
ASSEMBLY ON THE STEERING WHEEL WITH THE
AIR BAG ASSEMBLY FACE DOWN AND COLUMN
VERTICAL. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
WARNING: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT THE COIL ASSEMBLY
WIRE FOR ANY SIGNS OF SCORCHING, MELTING
OR ANY OTHER DAMAGE DUE TO EXCESSIVE
HEAT. IF THE COIL HAS BEEN DAMAGED,
REPLACE IT.

Removal
1. Disable the SRS. (Refer to “Disabling the SRS” in this section)
2. Remove the glove box.
3. Remove the glove box cover.

4. Remove the passenger air bag assembly fixing
bolts and nuts. Universal joint is used when
removing a nut.





RTW 79ASH001301
060R300044
5. Remove the passenger air bag assembly.
6. Disconnect the passenger air bag assembl
y
harness connector.


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9A-44 SUPPLEMENTAL RESTRAINT SYSTEM
Main Data and Specifications
Fastener Tightening Specification
Application N·m kgf ·m lb ·ft/lb ·in
SRS control unit 7 0.7 61 lb ·in
Steering wheel fixing bolt 35 3.6 26 lb ·ft
Steering column (dash panel side fixing bolts) 20 2.0 14 lb ·ft
Steering column (Pedal bracket fixing bolt) 20 2.0 14 lb ·ft
Steering column (Universal joint fixing bolt) 31 3.2 23 lb ·ft
Passenger Air Bag fixing bolt & nut 8 0.8 69 lb ·in

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CAB 10-29


Important Operations
1. Front Console Assembly • Refer to Floor Consol in this section.



RTW 6A0SH000101

2. Glove Box
• Remove 2 fixing screws and pull on the handle.




RTW 6A0SH000201

3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.


4. Driver Knee Bolster Assembly
• Remove 4 fixing bolts.
Caution:
For precautions on installation or removal of the SRS-air
bag system, refer to section 9 “Supplemental Restraint
System (SRS) - AIR BAG”
5. Driver Air Bag
6. Steering Wheel/Steering Cowl • Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.



7. Meter Cluster Assembly
• Pull out the 4 clip positions.


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ISUZU KB P190 2007

10-34 CAB
Important Operations
17. Instrument Panel Assembly & Cross Beam 1) Tighten the 4 bolts fixing the cross beam and body panel to the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
19 (1.9/14)

RUW 5A0SH002801
2) A Bolt: Steering Column to Cross Beam
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
15 (1.5/11)

3) C Bolt: Parking Brake Bracket to Cross Beam
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
15 (1.5/11)

23. Steering Wheel/Steering Cowl • Tighten the steering wheel fixing nut to the specified
torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
34 (3.5/25)




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ISUZU KB P190 2007