ISUZU KB P190 2007 Workshop Repair Manual

PARKING BRAKE SYSTEM 5D-1

Service Precaution
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNECESSARY SRS
SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU/GM will call out those fasteners that require
a replacement after removal. ISUZU/GM will also
call out the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. W hen the parking brake is set, or when the
ignition SW is in the “ON” position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8 −14 notches with 294N (30 kg / 66 lb)
(bench seat) or 6 −9 notches with 294N (30 kg / 66 lb)
(bucket seat). Refer to “Parking Brake Adjustment” in
this section.


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ISUZU KB P190 2007

5D-2 PARKING BRAKE SYSTEM
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bench Seat)


This illustration is based on the RHD model

RTW 75DMF000101

Legend
(1) Front Console Assembly
(2) Glove Box
(3) Instrument Panel Driver Lower Cover Assembly
(4) Driver Knee Bolster Assembly
(5) Driver Air Bag

(6) Steering W heel/Steering Cowl
(7) Meter Cluster Assembly
(8) Dash Side Trim Cover
(9) Front Pillar Trim Cover
(10) Instrument Panel Assembly & Cross Beam


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-3




This illustration is based on the RHD model

RTW 35DLH000101
Legend
(1) Nut
(2) Bolt and W asher
(3) Adjust Nut
(4) Bolt

(5) Front Parking Brake Cable
(6) Clip
(7) Switch
(8) Bolt
(9) Parking Lever Assembly


Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.
Refer to section 10.
2. Bolts (2)(6) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip and take out front parking brake cable from parking lever assembly.
5. Remove bolts (4) and nut (1) and take out parking lever assembly.
6. Remove switch (5).




RTW 65BSH000101

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ISUZU KB P190 2007

5D-4 PARKING BRAKE SYSTEM
Installation
1. Install switch (5).
Torque: 1.5 N ⋅
⋅⋅
⋅
m (0.15 kgf ⋅
⋅⋅
⋅
m/13 lb ⋅
⋅⋅
⋅
in)
2. Set parking lever assembly.
3. Install bolts (4) and nut (1) and tighten them to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
4. Set front parking brake cable in parking leve
r
assembly.
5. Drive clip into the outer cable groove of front parking brake cable at the outside of parking leve
r
assembly.
6. Drive adjust nut (3) on the front end of front parking brake cable so that front ends of rea
r
parking brake fit into the rear end (equalizer) of
front cable.
7. Install instrument panel assembly & cross beam.
Refer to section 10.
8. Install bolts (2)(6) and tighten them to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
9. Install all parts removed.
Refer to section 10.
10. W hen the parking brake cable is replaced, pull the parking brake lever with a force equivalent to
operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
11. Adjust nut (3) so that the lever goes through 8 −14
notches, when pulled with an operation force o
f
294 N (30 kg/66 lb) and check brake for no drag.





RTW 65BSH000101



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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-5
Front Parking Brake Cable
Front Parking Brake Cable and Associated Parts (Bench Seat)



RTW 75DMF000301

Legend
(1) Shift Knob (manual transmission)
(2) Front Floor Console
(3) Bolt

(4) Seat Assembly
(5) Buckle: side seat and Center Seat Belt
(6) Seat Adjuster


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ISUZU KB P190 2007

5D-6 PARKING BRAKE SYSTEM




This illustration is based on the RHD model

RTW 35DMF000101

Legend
(1) Adjust Nut
(2) Clip
(3) Bolt

(4) Bolt
(5) Parking Brake Cable T-end
(6) Front Parking Brake Cable


Removal
1. Remove seat assembly and seat adjuster.
Refer to section 10.
2. Turn over the carpet so that front parking brake cable appears.
3. Remove adjust nut.
4. Pull out clip and take out front parking brake cable.
5. Remove bolt.
6. Disconnect parking brake cable T-ends from front parking brake cable.
7. Take out front parking brake cable through the floor hole.
Installation

1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake cable T-end
and front parking brake equalizer (arrow mark).
2. Let rear end (equalizer) of front parking brake cable enter the floor hole and connect it with
parking brake rear cable T-end.
3. Set front parking brake cable in the parking leve
r
assembly.
4. Drive clip into the outer cable groove of front parking brake cable at the outside of the parking
lever assembly.
5. Install bolt on the floor and tighten to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-7
6. Drive adjust nut on the front end of front parking
brake cable so that parking brake cable T-end fits
into the rear end (equalizer) of front cable.
7. Fit the carpet on the floor.
8. Install seat adjuster and seat assembly.
Refer to section 10.
9. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
10. Adjust nut so that parking brake lever goes through 8 −14 notches, when pulled with an
operation force of 294 N (30 kg/66 lb).
11. Check brake for no drag.


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ISUZU KB P190 2007

5D-8 PARKING BRAKE SYSTEM
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bucket Seat)



RTW 35DSF000101

Legend
(1) Rear Floor Console
(2) Parking Brake Cable T-end
(3) Adjust Nut

(4) Switch
(5) Parking Brake Lever Assembly
(6) Bolt
(7) Equalizer


Removal
1. Remove rear floor console.
Refer to section 10.
2. Loosen adjust nut.
3. Remove bolt.
4. Remove switch.
5. Disconnect parking brake cable T-end from parking brake lever assembly.
6. Take out parking brake lever assembly.

Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake rear cable
T-end and parking brake lever equalizer. (arrow
mark).
2. Connect parking brake rear cable T-end to equalizer.
3. Install switch.

4. Tighten the parking brake lever fixing bolt to the
specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
5. Drive adjust nut on parking brake assembly so that parking brake cable T-end fits into equalizer.
6. Install rear floor console.
Refer to section 10.
7. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
8. Adjust nut so that parking brake lever goes through 6 −9 notches, when pulled with an
operation force of 294 N (30 kg/66 lb).
9. Check brake for no drag.


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-9
Parking Brake Rear Cable
Parking Brake Rear Cable and Associated Parts

RTW 55DLF000101

Legend
(1) Tension Pin
(2) Shoe Clamp Spring
(3) Return Spring
(4) Shoe Assembly with Parking Brake Lever
(5) Shoe Assembly with Adjuster Lever
(6) Spring
(7) Parking Brake Rear Cable

(8) Nut
(9) Parking Brake Cable Bolt
(10) Parking Brake Cable Nut
(11) T-end
(12) Outer Cable Retainer
(13) Equalizer
(14) Adjuster Lever Clip



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ISUZU KB P190 2007

5D-10 PARKING BRAKE SYSTEM
Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin and shoe clamp spring.
4. Remove return spring.
5. Remove shoe assembly with parking brake lever.
6. Remove shoe assembly with adjuster lever and spring.
7. Remove parking brake inner cable from parking brake lever.
8. Use offset box wrench (12 mm hex.) to compress locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.




RTW 55CSH000301

Legend
(1) Offset Box W rench (12 mm hex)
9. Remove nut to fix the cable on the leaf spring.
10. Take out parking brake rear cable from the back plate.
11. Remove parking brake cable bolt and nut.
12. Disconnect T-end from the equalizer of front cable.

Installation

NOTE: Be sure to use a new shoe clamp spring and a
new adjuster lever clip.
1. Apply grease (multipurpose type grease) to the connecting portion of the rear cable and equalizer.
(arrow mark).
2. Install parking brake outer cable in back plate and inner cable in parking brake lever.
3. Install return spring.
4. Install shoe clamp spring and tension pin.
5. Install shoe assembly with adjuster lever, shoe assembly with parking brake lever and spring. ----
snap action
6. Install nut and tighten it to the specified torque. Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
7. Connect T-end with equalizer through outer cable retainer.
8. Install parking brake cable nut and tighten it to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
9. Install parking brake cable bolt and tighten it to the specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13.
Adjust parking brake lever adjusting nut so that
parking brake lever goes through 6-9 notches
(Bucket Seat) or 8 −14 notches (Bench Seat), when
pulled with an operation force of 294 N (30 kg/
66 lb).
14. Check brake for no drag.


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ISUZU KB P190 2007