air suspension ISUZU KB P190 2007 Workshop Repair Manual

1

WORKSHOP
REPAIR MANUAL
GE NERAL INFORMATION 0
HEATING AND VENTILATION
BRAKESMAIN INDEX ISUZU

CONTENTS
WHEELS AND TYRES
4
5
BODY 8
SECURITY 11 SUSPENSION

3
STEERING
2
AXLE
FRAME AND CAB
ENGINE
6
TRANSMISSION 7
MY 2007
RESTRAINTS 9
CAB 10
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KB P190

ISUZU KB P190 2007

3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
・ If the pressure recorded is within 9800-10300 kPa
(100-105 kg/cm
2/1422-1493psi), the pump is
functioning within its specifications.
・ If the pressure recorded is higher than 10300 kPa
(105 kg/cm
2/1493psi), the valve in the pump is
defective.
・ If the pressure recorded is lower than 9800 kPa
(100 kg/cm
2/1422psi), the valve or the rotating
assembly in the pump is defective.
7. If the pump pressures are within specifications, leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built up at either side of the
power steering unit, the power steering unit is
leaking internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level and make the needed repairs.
10. If the problem still exists, the steering and front suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean, the fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. W hen a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
・ Inspect gear for looseness or damage.
・ Inspect hoses to insure they are not touching an
y
other parts of the vehicle.
・ Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55 °
C (130 °F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. W hen checking the fluid level after the steering system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding the Power Steering System
W hen a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
W hen bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level remains constant after running the engine.
5. Raise and support the front end of the vehicle so that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to settle for a few minutes, then repeat the above
procedure.

Flushing the Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump.
Direct the line toward a large container to catch the
draining fluid.
3. W hile running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.


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ISUZU KB P190 2007

3B-14 POWER-ASSISTED STEERING SYSTEM
Disassembly
NOTE : The valve hosing is made of aluminum and care
should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
For the left side, follow the same steps as right side.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
• Use a pair of pliers to open the clip. Slide the cliptoward the tie-rod end.





RUW 53BSH000401
• Remove band from the bellows by using
screwdriver.





RUW 53BSH000501


CAUTION :
For 4 ×
××
×
2 except High ride suspension models;
The band is not reusable. If removed, it must be
replaced with a new one.
Take care not to damage the bellows during band
removal.
For 4 ×
××
×
4 and 4 ×
××
×
2 High ride suspension models;
The band and bellows are not reusable. If removed,
they must be replaced with a new one.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end, then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.

Inspection and Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are
found during inspection.
Check the following parts.
1. Tie-rod end
2. Lock nut
3. Clip
4. Bellows
5. Band
Tie-Rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.

Tie-Rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Rubber Parts
For 4 ×2 except High ride suspension models;
If wear or damage is found during inspection, replace
with new ones.
For 4 ×4 and 4 ×2 High ride suspension models;
Even if wear or damage is not found after removal,
replace with new ones.

Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line. Torque: 12 N ⋅
⋅⋅
⋅
m (1.2 kgf ⋅
⋅⋅
⋅
m/104 lb ⋅
⋅⋅
⋅
in)


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ISUZU KB P190 2007

SECTION 3C
FRONT SUSPENSION
(4 ×
××
×
2 Except High Ride Suspension)
TABLE OF CONTENTS

Service Precaution ............................................. 3C-8
Shock Absorber .................................................. 3C-9 Shock Absorber and Associated Parts............ 3C-9
Removal .......................................................... 3C-10
Installation ....................................................... 3C-11
Shock Absorber with Coil Spring..................... 3C-13
Stabilizer Bar ...................................................... 3C-16 Stabilizer Bar and Associated Parts ................ 3C-16
Removal .......................................................... 3C-16
Inspection and Repair ..................................... 3C-17
Installation ....................................................... 3C-17
Knuckle............................................................... 3C-18 Knuckle and Associated Parts ........................ 3C-18
Removal .......................................................... 3C-18
Inspection and Repair ..................................... 3C-19
Installation ....................................................... 3C-19
Upper Control Arm ............................................. 3C-20 Upper Control Arm and Associated Parts ....... 3C-20
Removal .......................................................... 3C-20
Inspection and Repair ..................................... 3C-21
Installation ....................................................... 3C-21

Lower Control Arm ............................................. 3C-22
Lower Control Arm and Associated Parts ....... 3C-22
Removal .......................................................... 3C-22
Inspection and Repair ..................................... 3C-23
Installation ....................................................... 3C-23
Upper Ball Joint .................................................. 3C-24 Upper Ball Joint and Associated Parts ............ 3C-24
Removal .......................................................... 3C-24
Inspection and Repair ..................................... 3C-25
Installation ....................................................... 3C-25
Lower Ball Joint .................................................. 3C-26 Lower Ball Joint and Associated Parts ............ 3C-26
Removal .......................................................... 3C-26
Inspection and Repair ..................................... 3C-27
Installation ....................................................... 3C-27
Bump Rubber ..................................................... 3C-28 Bump Rubber Joint and Associated Parts ...... 3C-28
Removal .......................................................... 3C-28
Inspection and Repair ..................................... 3C-28
Installation ....................................................... 3C-28
Special Tools................................................... 3C-29


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ISUZU KB P190 2007

3C-8 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 UNNEEDED 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 indicate those fasteners that require
replacement after removal. ISUZU/GM will also
indicate 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

3C-14 FRONT SUSPENSION
Disassembly

RTW 73CMH000101


1. Install the shock absorber assembly on the strut spring
compressor (5-8840-2842-0).
For the details of the actual operation, follow the steps the
strut spring compressor manufacturer’s instructions.
2. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.



CAUTION:
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.



INSPECTION AND REPAIR
Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.



Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
• Shock absorber
• Rubber bushing
• Coil spring


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ISUZU KB P190 2007

FRONT SUSPENSION 3C-17
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:
• Stabilizer bar
• Rubber bushing
• Link ball joint
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-19
6. Remove the stabilizer link nuts. Right and left.
7. Remove the wheel speed sensor from the knuckle.
8. Remove back plate.
9. Remove lower ball joint by using remover 5-8840- 2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010009
10. Remove upper ball joint by using remover 5-8840-2017-0.
CAUTION: Be careful not to damage the ball joint
boot.

P1010011
11. Remove knuckle.

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:
• Knuckle
• Knuckle arm
Installation
1. Install knuckle assembly.
2. 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)
3. 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)
4. Install back plate.
5. Install wheel speed sensor.
6. Install stabilizer link nut. Right and left.


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ISUZU KB P190 2007

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