ad blue ISUZU KB P190 2007 Workshop Repair Manual

PROPELLER SHAFT 4A-17
401RS011






Universal Joint Reassembly
1. Set the propeller shafts.
• Be sure to set the propeller shaft yoke by aligning the
setting marks made during disassembly.
2. Spider
• Be sure to install the spider by aligning the setting marks
made during disassembly.
3. Needle Roller Bearing
1) Apply a molybdenum-disulfide grease or a multi-purpose. type grease NLGI No.2 to inside of the bearing cap. Grease Amount g(oz)
Approx. 1.2 (0.042)

401RS012









2) Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that snap ring can
be installed in its groove.

CAUTION: •
••
•
The needle roller bearing cannot be installed smoothly
if it is set at an incorrect angle with the flange.
•
••
•
Excessive hammering will damage the needle rolle
r
bearing.

401R300003








3) Align setting marks and join the yokes.
NOTE:
Assemble the spider and spline yoke so that their grease
fittings are arranged on the same side.(4 ×4)
4. Snap ring
NOTE:
Discard used snap rings and install new ones.

W hen the bearing cap is in position, select and attach a snap
ring of suitable thickness so that the end play of the spider pin
is held within 0.1mm (0.004in).
mm(in)
Snap ring thickness Identification color
1.50 (0.059) Light Blue
1.53 (0.060) W hite
1.56 (0.061) Pink
1.59 (0.063) Yellow
1.62 (0.064) Green
1.65 (0.065) Brown
1.68 (0.066) Not colored
NOTE:
Be sure to use snap rings of the same thickness on both sides.


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ISUZU KB P190 2007

PROPELLER SHAFT 4A-27
401RS012
3. Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that the snap ring
can be installed in its groove.
CAUTION:
The needle roller bearing cannot be installed smoothly if it
is set at an incorrect angle with the flange and excessive
hammering will damage the needle roller bearing.

401RS028
4. Align setting marks (1) and join the yokes.
5. Install snap ring.
NOTE:
Discard used snap rings and install new ones.
W hen the bearing cap is in position, select and attach a snap
ring of suitable thickness so that the end play of the spider pin
is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
1.50 mm (0.059 in); Light Blue
1.53 mm (0.060 in); White
1.56 mm (0.061 in); Pink
1.59 mm (0.063 in); Yellow
1.62 mm (0.064 in); Green
1.65 mm (0.065 in); Brown
1.68 mm (0.066 in); Not colored
NOTE:
Be sure to use snap rings of the same thickness
on both sides.


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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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4B-32 REAR AXLE
16. Tighten the bolt to the specified torque.
Torque :
φ220mm : 108 N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 98 N ⋅m (10 kgf ⋅m/72 lb ⋅ft)


425RS036
• Measure the amount of run-out of the ring gear at
its rear face. It should be 0.05 mm (0.002 in) o
r
less
Gear Tooth Contact Pattern Check and Adjustment
1.
Apply a thin coat of Prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring gea
r
teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.





425RS038
Legend
1. Heel
2. Toe
3. Concave Side(Coast)
4. Convex Side(Drive)



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4C1-6 FRONT WHEEL DRIVE
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). Poor 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 on hour before continuing the installation procedure.


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4C1-36 FRONT WHEEL DRIVE


18. Bolt
Bolt Torque N⋅m (kgf ⋅m/lb ⋅ft)

98 (10.0/72)



Measure the amount of run-out of the ring gear at its rear face.
mm(in)
Standard Limit
0.02 (0.001) 0.05 (0.002)




Gear Tooth Contact Pattern Check and Adjustment
Apply a thin coat of prussian blue or equivalent to the faces of
the 7 - 8 teeth of the ring gear. Check the impression of
contact on the ring gear teeth and make necessary adjustment
as described below if the contact is abnormal.



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ENGINE MECHANICAL 6A – 23

LOCTITE APPLICATION PROCEDURE
LOCTITE Type LOCTITE Color Application Steps
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 270 Green
LOCTITE 271 Red 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.
2. Apply LOCTITE to the bolts.

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

LOCTITE 515 Violet 1. Completely remove lubricant and moisture from the connecting
surfaces.
The surfaces must be perfectly dry.
2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting surfaces.
There must be no gaps in the bead.
3. Tighten the bolts to the specified torque.
4. Let the joined parts set for at least thirty minutes.


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6A – 84 ENGINE MECHANICAL


015RY00017



RTW46ASH002501
REFERENCE

4JA1T(L), 4JA1TC mm (in)
Crankshaft
Bearing Housing Crankshaft Journal
Grade
Mark Diamaeter
Grade
Mark Diamaeter Crankshaft
Bearing
Size Code
1 or - 59.927-59.932
(2.3593-23.595)
2 or - - 59.922-59.927
(2.3591-2.3539) Brown or 41
63.992-
64.000
(2.5194-
2.5197) 3 or
- - - 59.917-59.922
(2.3589-2.3591) Yellow or 5
1 or
- 59.927-59.932
(2.3593-2.3595) Black or 2
2 or
- - 59.922-59.927
(2.3591-2.3593) Blue or 3 2 63.983-
63.992
(2.5190-
2.5194) 3 or
- - - 59.917-59.922
(2.3589-2.3591) Brown or 4
1 or
- 59.927-59.932
(2.3593-2.3595) Green or 1
2 or
- - 59.922-59.927
(2.3591-2.3593)3 63.975-
63.983
(2.5187-
2.5190) 3 or
- - - 59.917-59.922
(2.3598-2.3591) Black or 2

4JH1TC mm (in)
Crankshaft
Bearing Housing Crankshaft Journal
Grade
Mark Diamaeter
Grade
Mark Diamaeter Crankshaft
Bearing
Size Code
1 or - 69.927-69.932
(2.7530-2.7532)
2 or - - 69.922-69.927
(2.7528-2.7530) 4 1
73.992-
74.000
(2.9131-
2.9134) 3 or
- - - 69.917-69.922
(2.7556-2.7528) 5
1 or
- 69.927-69.932
(2.7530-2.7532) 2
2 or
- - 69.922-69.927
(2.7528-2.7530) 3 2 73.983-
73.992
(2.9127-
2.9131) 3 or
- - - 69.917-69.922
(2.7556-2.7528) 4
1 or
- 69.927-69.932
(2.7530-2.7532) 1
2 or
- - 69.922-69.927
(2.7528-2.7530)3 73.975-
73.983
(2.9124-
2.9127) 3 or
- - - 69.917-69.922
(2.7526-2.7528) 2

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Engine Control System (4JH1) 6E-5
Schematic And Routing Diagrams
Vacuum Hose Routing Diagram
Normal Altitude Spec





RTW 66EMF001001
Legend
1. Vacuum Pump
2. Blue Stripe Vacuum Hose
3. EGR Solenoid Valve
4. W hite Stripe Vacuum Hose
5. Intake Duct
6. Yellow Stripe Vacuum Hose
7. EGR Valve




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6E-6 Engine Control System (4JH1)
High Altitude Spec





RTW 66EMF001101

Legend
1. Vacuum Pump
2. W hite Stripe Vacuum Hose
3. EGR Solenoid Valve
4. EGR Valve
5. W hite Stripe Vacuum Hose
6. Vacuum Regulating Valve
7. Port S
8. Port Z
9. Blue Stripe Vacuum Hose
10. Turbocharger Solenoid Valve
11. W hite Stripe Vacuum Hose
12. Yellow Stripe Vacuum Hose
13. Vacuum Pressure Sensor
14. Turbocharger




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