torque ISUZU KB P190 2007 Workshop Manual PDF

FRONT SUSPENSION 3C-21
5. Remove link nut.
6. Remove upper ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010005
7. Remove upper control arm nut.
8. Remove upper control arm bolt.
9. Remove upper ball joint bolt and nut.
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
during inspection.
Check the following parts:
• Upper control arm
• Bushing
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.


P1010062
2. Install upper ball joint and tighten it to the specified
torque.
Torque: 31 N ⋅
⋅⋅
⋅
m (3.2 kgf ⋅
⋅⋅
⋅
m/23 lb ⋅ft)
3. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅ft)
4. Install upper control arm assembly.
5. Install upper control arm bolt and nut.
NOTE: Apply oil to the thread.
NOTE: Tighten the bolt with the parts in the position
shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅ft)




















RTW 53ASH000201
6. Install brake fluid hose nut.
7. Install speed sensor harness nut.

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-23
4. Support lower control arm with a jack.
5. Remove the link nut.
6. Remove the nut and cotter pin.
7. Remove the shock absorber lower end from the lower control arm.
8. Remove the lower ball joint from the lower control arm.
9. Remove lower control arm nut and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.
Inspection and Repair
Make the necessary adjustments or parts replacement
if wear, damage, corrosion or any other abnormal
condition is found during inspection.
Check the following parts:
• Lower control arm
• Bushing
Installation
1. Install rear bushing by using installer 5-8840-
0257-0 and 5-8840-2327-0.


P1010063
2. Install lower control arm.
3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅ft)
5. Install shock absorber and tighten it to the specified torque.
NOTE: Apply oil to the thread.
NOTE: Tighten the lower control arm nut with the parts
in the position shown in the illustration below.

Torque: 137 N ⋅
⋅⋅
⋅
m (14.0 kgf ⋅
⋅⋅
⋅
m/101 lb ⋅ft)






RTW 53ASH000201
6. Install stabilizer link and tighten it to the specified
torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)
7. Install lower control arm nut and cam plate and tighten lower link nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the lower control arm nut with the parts
in the position shown in the illustration below.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186 N ⋅
⋅⋅
⋅
m (19.0 kgf ⋅
⋅⋅
⋅
m/137 lb ⋅
⋅⋅
⋅
ft)






















RTW 53ASH000201
8. Install nut and cotter pin then tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-25

P1010005
5. Remove upper ball joint bolt and nut.
6. Remove upper ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
during inspection.
• Inspect the lower end of the boot for damage o
r
grease leaks. Move the ball joint as shown in the
figure to confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.





450R300030
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 1.3-3.2 N ⋅
⋅⋅
⋅
m (0.13-0.33 kgf ⋅
⋅⋅
⋅
m/0.9-
2.4 lb ⋅ft)








450RS024
If the above limits specified are exceeded, replace the
ball joint assembly.
Installation
1. Install upper ball joint.
2. Install upper ball joint bolt and nut, and then tighten them to the specified torque.
Torque: 31 N ⋅
⋅⋅
⋅
m (3.2 kgf ⋅
⋅⋅
⋅
m/23 lb ⋅ft)
3. Install nut and cotter pin then tighten the nut to the specified torque with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅ft)
4. Install link nut, then tighten to the specified torque. Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-27
CAUTION: Be careful not to damage the ball joint
boot.


P1010003
6. Remove lower ball joint nut.
7. Remove lower ball joint bolt.
8. Remove lower ball joint.
Inspection and Repair
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition is found
during inspection.
• Inspect the lower end of the boot for damage o
r
grease leaks. Move the ball joint as shown in the
figure to confirm its normal movement.
• Inspect screw/taper area of ball for damage.
• If any defects are found by the above inspections,
replace the ball joint assembly with new one.






450RS026
• After moving the ball joint 4 or 5 times, attach nut
then measure the preload.
Starting torque: 2.5-6.4 N ⋅
⋅⋅
⋅
m (0.26-0.65 kgf ⋅
⋅⋅
⋅
m/1.9-
4.7 lb ⋅ft)







450RS024
• If the above limits specified are exceeded, replace
the ball joint assembly.
Installation
1. Install lower ball joint.
2. Install lower ball joint bolt.
3. Install lower ball joint nut and tighten it to the specified torque.
Torque: 127 N ⋅
⋅⋅
⋅
m (13.0 kgf ⋅
⋅⋅
⋅
m/94 lb ⋅ft)
4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅ft)
5. Install link nut, then tighten to the specified torque. Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅ft)

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ISUZU KB P190 2007

3C-28 FRONT SUSPENSION
Bump Rubber
Bump Rubber and Associated Parts
RTW 340LF002601
Legend
(1) Bolt


(2) Bump Rubber


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove bolt.
3. Remove bump rubber.
Inspection and Repair
Make the necessary adjustments or parts replacement
if wear, damage, corrosion or any other abnormal
condition is found during inspection.
Check the following parts:
• Bump Rubber
Installation
1. Install bump rubber.
2. Install bolt, then tighten it to the specified torque. Torque: 42 N ⋅
⋅⋅
⋅
m (4.3 kgf ⋅
⋅⋅
⋅
m/31 lb ⋅ft)

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ISUZU KB P190 2007

3C-30 FRONT SUSPENSION

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.

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-31
Shock Absorber
Shock Absorber and Associated Parts
RTW 340MF000901
Legend
(1) Shock Absorber Nut
(2) Rubber Bushing and W asher

(3) Shock Absorber Bolt and Nut
(4) Shock Absorber
(5) Rubber Bushing and W asher


Removal
1. Raise the vehicle and support it with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel Replacement in this section.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.
Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Shock absorber
• Rubber bushing
Installation
1. Install rubber bushing and washer.
2. Install shock absorber.
3. Install rubber bushing and washer.
4. Install shock absorber nut, then tighten it to the specified torque.
Torque: 20 N ⋅
⋅⋅
⋅
m (2.0 kgf ⋅
⋅⋅
⋅
m/14 lb ⋅
⋅⋅
⋅
ft)
5. Install shock absorber bolt and nut, and then tighten to the specified torque.
Torque: 93 N ⋅
⋅⋅
⋅
m (9.5 kgf ⋅
⋅⋅
⋅
m/69 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

FRONT SUSPENSION 3C-33
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt then tighten it to the specified torque.
Torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kgf ⋅
⋅⋅
⋅
m/18 lb ⋅
⋅⋅
⋅
ft)
4. Install link.
5. Install link nut, then tighten it to the specified torque.
Torque: 50 N ⋅
⋅⋅
⋅
m (5.1 kgf ⋅
⋅⋅
⋅
m/37 lb ⋅
⋅⋅
⋅
ft)


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ISUZU KB P190 2007

FRONT SUSPENSION 3C-39
Inspection and Repair
Make necessary correction or replace parts if wear,
damage, corrosion or any other abnormal condition is
found through inspection.
Check the following parts:
• Knuckle
• Thrust washer (4 ×4 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g (0.18 oz))
and install needle bearing by using installer 5-
8840-2128-0 and grip 5-8840-0007-0. (4 ×4 Model
Only)






(4 ×4 Model Only)
901RW 275
2. Apply multipurpose type grease to the thrust
washer, and install washer with chamfered side
facing knuckle. (4 ×4 Model Only)

3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2
g (0.07 oz)). Then use installer 5-8840-2851-0 (2)
and grip 5-8840-0007-0 (1) to install oil seal. Afte
r
fitting the oil seal to the installer, drive it to the
knuckle using a hammer or bench press until the
tool front face contacts with the thrust washer.
(4 ×4 Model Only)





RTW 73CSH000101
4. Install knuckle assembly.
5. Install upper ball joint and tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
6. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 147 N ⋅
⋅⋅
⋅
m (15.0 kgf ⋅
⋅⋅
⋅
m/108 lb ⋅
⋅⋅
⋅
ft)
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar; refer to Torsion Bar in this
section.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering.

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ISUZU KB P190 2007

3C-42 FRONT SUSPENSION
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0 and 5-8840-2307-0.



RTW 340SH000701




RTW 340SH000801
3. Install upper ball joint and tighten it to the specified
torque.
Torque: 57 N ⋅
⋅⋅
⋅
m (5.8 kgf ⋅
⋅⋅
⋅
m/42 lb ⋅
⋅⋅
⋅
ft)
4. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin.
Torque: 98 N ⋅
⋅⋅
⋅
m (10.0 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)
5. Install plate.

6. Install upper control arm nut and tighten fulcrum
pin nut finger-tight.
NOTE: Apply oil to the thread.
NOTE: Tighten the nut with the parts in the position
shown in the illustration below.
Buffer clearance: 29.7 mm (1.17 in)
Torque: 108 N ⋅
⋅⋅
⋅
m (11.0 kgf ⋅
⋅⋅
⋅
m/80 lb ⋅
⋅⋅
⋅
ft)






RTW 53ASH000301
7. Install upper control arm assembly with the fulcrum
pin projections turned inward.










RTW 53CSH000101-X

8. Install the caster shims (b) between the chassis
frame and fulcrum pin.



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ISUZU KB P190 2007