engine ISUZU KB P190 2007 Workshop Manual PDF

3B-52 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to lose its centering which
will cause damage to the SRS coil assembly (with
SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove the driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007

3B-56 POWER-ASSISTED STEERING SYSTEM
9. Turn the SRS coil fully counterclockwise, return
about 3 turns and align the neutral mark (1). (with
SRS air bag)
CAUTION: When turning the SRS coil fully
counterclockwise, stop turning if resistance is felt.
Further forced turning may damage to the cable in
the SRS coil.
826RW 014
10. W hen installing the steering column cover, be sure to
route each wiring harness as illustrated so that the
harnesses do not catch any moving parts.
825RW 017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing. 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.
12. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
ft)
13. Support the module and carefully connect the module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 3 N ⋅
⋅⋅
⋅
m (0.3 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn lead located under the steering column.
19. Connect the battery "-" terminal cable (with SRS ai
r
bag).


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ISUZU KB P190 2007

PROPELLER SHAFT 4A-3
MAIN DATA AND SPECIFICATIONS
REAR PROPELLER SHAFT


4×2 Model 4×4 Model
Engine Model 4JJ1 (Standard Output), 4JK1 (Standard Output) 4JJ1 (Standard Output) 4JK1 (Standard Output)
Transmission Type
5M/T (MUA) A/T 5M/T
(MUA) A/T 5M/T
(MUA)
W heel Base Long ← ← ← ←
Front Suspension High Ride
Suspension Except
High Ride
Suspension High Ride
Suspension Except
High Ride
Suspension 


Rear Axle φ220mm ← ← ← ← ← ←
Type OBS ← ← ← ← ← ←
Outside Diameter mm 68.9 68.9 63.5 63.5 68.9 75 68.9
(in) (2.71) (2.71) (2.50) (2.50) (2.71) (2.95) (2.71)
Inside Diameter mm 64.9 64.9 60.3 60.3 64.9 71.8 64.9
(in) (2.56) (2.56) (2.37) (2.37) (2.56) (2.83) (2.56)
Length 1st(L1) mm 798.5 801.5 720.5 716.5 472.5 1204 472.5
(in) (31.44) (31.56) (28.37) (28.21) (18.60) (47.40) (18.60)
2nd(L2) mm 801 796 801 796 801  801
(in) (31.54) (31.34) (31.54) (31.34) (31.54)  (31.54)
Spline Major mm 29.89 29.89 29.89 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement to T/M)


4×2 Model 4×4 Model
Engine Model 4JJ1 (High Output)
Transmission Type 5M/T (MUX) A/T 5M/T (MUX) A/T
W heel Base Long Long Ext. Long Long Long Long Ext. Long Long
Front Suspension High Ride
Suspension Except High
Ride
Suspension Except High
Ride
Suspension High Ride
Suspension High Ride
Suspension High Ride
25up
Suspension High Ride
Suspension High Ride
Suspension
Rear Axle φ220mm ← ← ← ← ← ← ←
Type OBS ← ← ← ← ← ← ←
Outside Diameter mm 68.9 68.9 68.9 75 68.9 68.9 68.9 75
(in) (2.71) (2.71) (2.71) (2.95) (2.71) (2.71) (2.71) (2.95)
Inside Diameter mm 64.9 64.9 64.9 71.8 64.9 64.9 64.9 71.8
(in) (2.56) (2.56) (2.56) (2.83) (2.56) (2.56) (2.56) (2.83)
Length 1st(L1) mm 777.5 777.5 925.5 706.5 434.5 438.5 584.5 1204
(in) (30.61) (30.61) (36.44) (27.81) (17.11) (17.26) (23.01) (47.40)
2nd(L2) mm 801 796 796 801 801 801 801 
(in) (31.54) (31.34) (31.34) (31.54) (31.54) (31.54) (31.54) 
Spline Major mm 29.89 29.89 29.89 30.48 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.20) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement to T/M)


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ISUZU KB P190 2007

4A-4 PROPELLER SHAFT
4
×2 Model
Engine Model 4JA1-T(L) 4JA1-
TC 4JA1-TC
Transmission Type 5 M/T
(MSG) 5 M/T
(MSG/MUA)5 M/T
(MUA)
5M/T (MUA) 4A/T
W heel Base Long Long Long Long Extra Long Long
Front Suspension  High Ride
Suspension High Ride
Suspension
Except High Ride
Suspension
 
Rear Axle φ194mm φ220mm ← ← ← ← ←
Type OBS ← ← ← ← ← ←
Outside Diameter mm 63.5 75 75 68.9 68.9 68.9 63.5
(in) (2.50) (2.95) (2.95) (2.71) (2.71) (2.71) (2.50)
Inside Diameter mm 60.3 71.8 71.8 64.9 64.9 64.9 60.3
(in) (2.37) (31.48) (31.48) (2.56) (2.56) (2.56) (2.37)
Length 1st(L1) mm 798.5 799.5 782.5 798.5 801.5 946.5 720.5
(in) (31.44) (31.48) (30.81) (31.44) (31.56) (37.26) (28.37)
2nd(L2) mm 819 801 796 801 796 801 801
(in) (32.24) (31.54) (31.34) (31.54) (31.34) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)


4 ×2 Model
Engine Model C24SE HFV6
Transmission Type 5M/T (MUA) 5M/T (AR-5) 4A/T
W heel Base
Long Extra Long Long Extra Long Long Extra Long
Front Suspension High Ride
Suspension Except High
Ride
Suspension 
High Ride
Suspension ←
← ←
Rear Axle φ220mm ← ←
← ← ← ←
Type OBS ← ←
← ← ← ←
Outside Diameter mm 75 75 75 68.9 68.9 75 75
(in) (2.95) (2.95) (2.95) (2.71) (2.71) (2.95) (2.95)
Inside Diameter mm 71.8 71.8 71.8 64.9 64.9 71.8 71.8
(in) (2.83) (2.83) (2.83) (2.56) (2.56) (2.83) (2.83)
Length 1st(L1) mm 823.5 820.5 970.5 777.5 925.5 784.5 934.5
(in) (32.42) (32.30) (38.21) (30.61) (36.43) (30.89) (36.79)
2nd(L2) mm 801 796 796 801 801 801 801
(in) (31.54) (31.34) (31.34) (31.54) (31.54) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89 29.89 30.48 30.48
Diameter (in) (1.18) (1.18) (1.18) (1.18) (1.18) (1.20) (1.20)
Fix Bolt Size M10 M10 M10 M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)

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PROPELLER SHAFT 4A-5
4 ×4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC
Transmission Type 5M/T (MUA) 5M/T (MUA) 4A/T
W heel Base Long Long Extra Long Long
Front Suspension    
Rear Axle φ220mm ← ← ←
Type OBS ← ← ←
Outside Diameter mm 75 68.9 68.9 63.5
(in) (2.95) (2.71) (2.71) (2.50)
Inside Diameter mm 71.8 64.9 64.9 60.3
(in) (2.83) (2.56) (2.56) (2.37)
Length 1st(L1) mm 469.5 468.5 616.5 402.5
(in) (18.48) (18.44) (24.27) (15.85)
2nd(L2) mm 801 801 801 801
(in) (31.54) (31.54) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)


4 ×4 Model
Engine Model C24SE HFV6
Transmission Type 5M/T
(MUA) 5M/T (AR-5)
4A/T
W heel Base Long Long Extra Long Long
Front Suspension    
Rear Axle φ220mm
← ← ←
Type OBS
← ← ←
Outside Diameter mm 63.5 68.9 68.9 75
(in) (2.50) (2.71) (2.71) (2.95)
Inside Diameter mm 60.3 64.9 64.9 71.8
(in) (2.37) (2.56) (2.56) (2.83)
Length 1st(L1) mm 495.5 476.5 624.5 484.5
(in) (19.51) (18.75) (24.59) (19.07)
2nd(L2) mm 801 801 801 801
(in) (31.54) (31.54) (31.54) (31.54)
Spline Major mm 29.89 29.89 29.89 29.89
Diameter (in) (1.18) (1.18) (1.18) (1.18)
Fix Bolt Size M10 M10 M10 M10
* OBS - Outboard Slip (Spline Engagement To T/M)


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PROPELLER SHAFT 4A-7
Front Propeller Shaft

4×4 Model
Engine Model 4JK1 (Standard Output),
4JJ1 (Standard Output) 4JJ1 (High Output)
4JJ1 (Standard Output),
4JJ1 (High Output)
Transmission Type 5M/T (MUA) 5M/T (MUX) 4A/T
W heel Base Long Long Long
Outside Diameter mm 40 40 40
(in) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32
(in) (1.26) (1.26) (1.26)
Length (L) mm 579 618 649
(in) (22.80) (24.33) (25.55)
Spline Outside
Diameter mm
33
33
33
(in) (1.30) (1.30) (1.30)

Fix Bolt Size T/F M10 M10 M10
Axle M10 M10 M10

4 ×4 Model
Engine Model 4JA1-T(L) 4JA1-TC 4JH1-TC C24SE HFV6
Transmission Type 5M/T (MUA) 5M/T (MUA) 4A/T 5M/T
(MUA) 5M/T (AR-5),
4A/T
W heel Base Long Long Long Long Long
Outside Diameter mm 40 40 40 40 40
(in) (1.57) (1.57) (1.57) (1.57) (1.57)
Inside Diameter mm 32 32 32 32 32
(in) (1.26) (1.26) (1.26) (1.26) (1.26)
Length (L) mm 607 607 676 586 596
(in) (23.90) (23.90) (26.61) (23.07) (23.46)
Fix Bolt Size T/F M10 M10 M10 M10 M10
Axle M10 M10 M10 M10 M10










RUW 54ASF000401

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4A-10 PROPELLER SHAFT
4×
××
×
2 M/T AR-5, 4 ×
××
×
2 A/T 4L60-E Model







RTW 64ASF000101
Torque is transmitted from the transmission to the
axle through propeller shaft and universal joint
assembles. All propeller shafts are the balanced
tubular type. A splined slip joint is provided in some
drivelines.
• Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted.
•
Alignment marks should be applied to each
propeller shaft before removal.
• Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.
• Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.


Phasing
The propeller shaft is designer and built with the yoke lugs
(ears) in line with each other. This design produces the
smoothest running shaft possible, called phasing. Vibration can
be caused by an out-of-phase propeller shaft. The propeller
shaft down each time the universal joint goes around. This
vibration would be the same as a person snapping rope and
watching the “wave” reaction flow to the end. A propeller shaft
working in phase would be similar to two persons snapping a
rope at the same time, and watching the “waves” meet and
cancel each other out. In comparison, this would be the same
as the universal joints on a propeller shaft. A total cancellation
of vibration produces a smooth flow of power in the driveline. It
is very important to apply a reference mark to the propeller
shaft before removal, to assure installation alignment.

401RW 015
Universal Joint
A universal joint consists of two Y-shaped yokes (2) connected
by a crossmember called a spider (1).
The spider is shaped like a cross. Universal joints are designed
to handle the effects of various loadings and front or rear axle
windup during acceleration. W ithin the designed angle
variations, the universal joint will operate efficiently and safely.
W hen the design angle is changed or exceeded the
operational life of the joint may decrease.
The bearings used in universal joints are of the needle roller
type. The needle rollers are held in place on the trunnions by
round bearing cups. The bearing cups are held inside the
yokes by snap rings.

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4B-6 REAR AXLE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV* Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
W ater Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poo
r
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262
Red 2. Apply LOCTITE to the bolts.


LOCTITE 270
Green

LOCTITE 271
Red
3. Tighten the bolts to the specified torque.
4. W ait at least one hour before continuing the installation procedure.



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REAR AXLE 4B-7
REAR AXLE ASSEMBLY
General Description
A03R300001

The rear axle assembly is of the semi–floating type in
which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the cente
r
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The φ220 mm (8.6 in) or φ194mm (7.6 in) ring gea
r
rear axle uses a conventional ring and pinion gear set
to transmit the driving force of the engine to the rea
r
wheels. This gear set transfers this driving force at a
90 degree angle from the propeller shaft to the drive
shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered rolle
r
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with
12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings, which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing.

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REAR AXLE 4B-45
TROUBLESHOOTING


Refer to this Section to quickly diagnose and repai
r
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise 1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage 1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the W heels (Propeller Shaft Operation is Normal)







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