brake pads ISUZU KB P190 2007 Workshop Repair Manual
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Page 21 of 6020
MAINTENANCE AND LUBRICATION 0B-3
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100(Use odometer reading × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60or months whichever
comes first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
CLUTCH
Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and free play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE
* Automatic transmission fluid (HFV6)
- - I - - I - - I - - I - - I - - I - R (4JH1-TC, 4JJ1 (Standard Output),
4JJ1 (High Output)) - - - I - - - I - - - I - - - I - - - I
* Transfer case oil
- - - I - - - I - - - I - - - I - - - I * Manual transmission fluid - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Gear control mechanism for
looseness - - - I - - - I - - - I - - - I - - - I
PROPELLER SHAFT Loose connections - I - I - I - I - I - I - I - I - I - I * Universal joints and splines for wear
- I - I - I - I - I - I - I - I - I - I Universal joints and sliding sleeve
(4W D) - L - L - L - L - L - L - L - L - L - L
FRONT AND REAR AXLE * Differential gear oil (Front and rear) - R - I - - - R - - - I - - - R - - - I Oil leakage I I I I I I I I I I I I I I I I I I I I Shift on the fly system gear oil I - - I - - - I - - - I - - - I - - - I Front axle shaft boot for damage - - - I - - - I - - - I - - - I - - - I Axle shafts for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle case for distortion or damage - - - I - - - I - - - I - - - I - - - I STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage - I - I - I - I - I - I - I - I - I - I Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and free play I I I I I I I I I I I I I I I I I I I I Pipes and hoses loose connections
or damage I I - I - I - I - I - I - I - I - I - I
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ISUZU KB P190 2007
Page 24 of 6020
0B-6 MAINTENANCE AND LUBRICATION
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
STEERING Power steering fluid I I I I I I I R I I I I I I I R I I I I Oil leakage I I I I I I I I I I I I I I I I I I I I * Steering system for looseness or
damage - I - I - I - I - I - I - I - I - I - I
Power steering hose
- I - I - I - I - I - I - I - R - I - I Steering wheel play I I I I I I I I I I I I I I I I I I I I Steering function I I I I I I I I I I I I I I I I I I I I Right and left turning radius - - - I - - - I - - - I - - - I - - - I W heel alignment - - - I - - - I - - - I - - - I - - - I Joint ball for oil leakage or damage
- I - I - I - I - I - I - I - I - I - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I
SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and play I I I I I I I I I I I I I I I I I I I I Pipes and hoses for loose
connections or damage I I - I - I - I - I - I - I - I - I - I
PARKING BRAKE Parking brake function I I I I I I I I I I I I I I I I I I I I Parking brake lever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage
- I - I - I - I - I - I - I - I - I - I SUSPENSION Leaf/Coil/Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for looseness or damage
I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - I - I
Spring action for loss of balance due
to weakening - - - I - - - I - - - I - - - I - - - I
Joint ball rubber boot for damage
- I - I - I - I - I - I - I - I - I - I WHEELS W heel nuts T T - T - T - T - T - T - T - T - T - T W heel disc for damage I I - I - I - I - I - I - I - I - I - I Front hub bearing grease
- - - - - R - - - - - R - - - - - R - - Front and rear hub bearings for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation
Rotate as required OTHERS Bolts and nuts on chassis and body I I - I - I - I - I - I - I - I - I - I Lube front free - wheeling hubs - - - - - L - - - - - L - - - - - L - -
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ISUZU KB P190 2007
Page 26 of 6020
0B-8 MAINTENANCE AND LUBRICATION
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL: × 1,000 km 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
(Use odometer reading or × 1,000 miles 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
months whichever comes
first)
or months 6 12 18 24 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120
SERVICE BRAKES Brake fluid - - - I - - - I - - - I - - - I - - - I Brake system for fluid leakage I I I I I I I I I I I I I I I I I I I I Brake function I I I I I I I I I I I I I I I I I I I I * Front disc brake pads and discs wear - I - I - I - I - I - I - I - I - I - I * Rear brake lining and drum wear - I - I - I - I - I - I - I - I - I - I Brake pedal travel and play I I I I I I I I I I I I I I I I I I I I Pipes and hoses for loose
connections or damage I I - I - I - I - I - I - I - I - I - I
PARKING BRAKE Parking brake function I I I I I I I I I I I I I I I I I I I I Parking brake lever travel I I I I I I I I I I I I I I I I I I I I Cables for looseness or damage and
guide for damage I I I I I I I I I I I I I I I I I I I I
Ratchet for wear or damage - I - I - I - I - I - I - I - I - I - I
SUSPENSION Leaf/Coil/Torsion bar springs for
damage I I - I - I - I - I - I - I - I - I - I
Mount for looseness or damage I I - I - I - I - I - I - I - I - I - I Shock absorbers for oil leakage - I - I - I - I - I - I - I - I - I - I Shock absorbers mount for
looseness - I - I - I - I - I - I - I - I - I - I
Rubber bushes of suspension wear
or damage - I - I - I - I - I - I - I - I - - - I
Spring action for loss of balance due
to weakening - - - I - - - I - - - I - - - I - I - I
Joint ball rubber boot for damage - I - I - I - I - I - I - I - I - I - I
WHEELS W heel nuts T T - T - T - T - T - T - T - T - T - T W heel disc for damage I I - I - I - I - I - I - I - I - I - I Front hub bearing grease - - - - - R - - - - - R - - - - - R - - Front and rear hub bearings for
looseness - I - I - I - I - I - I - I - I - I - I
Tire pressure and damage I I - I - I - I - I - I - I - I - I - I Tire rotation
(Rotate as required) OTHERS Bolts and nuts on chassis and body - - - I - - - I - - - I - - - I - - - I Lube front free - wheeling hubs - - - - - - - L - - - - - - - L - - - -
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ISUZU KB P190 2007
Page 27 of 6020
MAINTENANCE AND LUBRICATION 0B-9
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)
Severe driving conditions
A : Repeated short trips
C24SE : C24SE Gasoline engine
B : Driving on rough roads
HFV6 : HFV6 Gasoline engine
C : Driving on dusty roads
G : Gasoline engine
D : Driving in extremely cold weather and/or on salted roads
4JA1-T : 4JA1-T Diesel engine
E : Towing trailer or climbing mountain frequently
4JH1-TC : 4JH1-TC Diesel engine
F : Operation in high ambient temperature conditions
4JJ1 (Standard Output):
4JJ1 Standard Output Diesel engine
4JJ1 (High Output): 4JJ1 High Output Diesel engine
D : Diesel engine
MT : Manual transmission
AT : Automatic transmission
4W D : Four wheel drive
Condition
A B C D E F A+D
Engine oil G : Change every 5,000 km (3,000 miles) or 3 month
4JA1-T : Change every 2,500 km (1,500 miles) 4JH1-TC 4JJ1 (Standard Output) 4JJ1 (High Output):
Change every 5,000 km (3,000 miles)
Engine oil filter G : Replace every 5,000 km (3,000 miles) or 3 monthD : Replace every 5,000 km (3,000 miles)
Exhaust pipes and mounting Inspect every 5,000 km (3,000 miles)
Air cleaner element
Replace every 20,000 km (12,000 miles) D : Inspect every 2,500 km (1,500 miles)
Steering system for looseness
or damage Inspect every 5,000 km (3,000 miles)
Universal joints and sleeves Inspect for wear and lubricate every 5,000 km (3,000 miles)
Transmission or transmission
with transfer case oil MTC24SE D Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles) MT HFV6 Change every 40,000 km (24,000 miles)
AT Transmission:
Change every 20,000 km (12,000 miles)
4W D Transfer:
Change every 20,000 km (12,000 miles)
Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)
Front brake pads and di
scs
wear Inspect every 5,000 km (3,000 miles)
Rear brake lining and drum
wear Inspect every 5,000 km (3,000 miles)
Interval
Item
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Page 28 of 6020
0B-10 MAINTENANCE AND LUBRICATION
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)
Severe driving conditions
MT : Manual transmission
A: Repeated short trips
AT : Automatic transmission
B: Driving on rough roads
4W D : Four wheel drive
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountein frequently
Condition
Item Interval A B C D E A+D
Engine oil Change every 5,000 km (3,000 miles)
Engine oil filter Replace every 5,000 km (3,000 miles)
Exhaust pipes and mounting Inspect every 10,000 km (6,000 miles)
Air cleaner element
Replace every 20,000 km (12,000 miles)
Steering system for looseness or
damage Inspect every 5,000 km (3,000 miles)
Universal joints and sleeves Inspect for wear and lubricate every 10,000 km (6,000 miles)
Transmission or transmission
with transfer case oil MT Change every 30,000 km (18,000 miles)
after changing at initial 10,000 km (6,000 miles)
AT
Transmission:
Inspection every 20,000 km (12,000 miles)
4W D Transfer:
Change every 30,000 km (18,000 miles)
After changing at initial 10,000 km (6,000 miles)
Differential oil
Change every 20,000 km (12,000 miles)
after changing at initial 10,000 km (6,000 miles)
Front brake pads and di
scs wear Inspect every 5, 000 km (3,000 miles)
Rear brake lining and drum wear Inspect every 5,000 km (3,000 miles)
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ISUZU KB P190 2007
Page 551 of 6020
FRONT WHEEL DRIVE 4C1-47
Important Operations
6. Hub nut
W rench : 5-8840-2117-0
7. Hub and disc assembly
Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
Refer to Section “Brake” for disc brake caliper removal
procedure.
12. Bolt
13. Wheel Pin ; Front Hub
(1) Scribe mark on hub to disc before disassembly to insure proper assembly.
(2) Drive out the ABS sensor rotor using a metal bar and hammer through the two bolt holes.
• Discard the used ABS sensor rotor
Refer to the section Brake.
(3) Clamp hub and disc assembly in vise using protective pads
and remove six (6) disc to hub retaining bolts.
(4) Place hub on a suitable work surface and remove wheel
studs, as required, using a hammer.
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ISUZU KB P190 2007
Page 559 of 6020
FRONT WHEEL DRIVE 4C1-55
12. Bolt
13. Wheel Pin ; Front Hub
( 1 ) Scribe mark on hub to disc before disassembly to insure
proper assembly.
(2) Drive out the ABS sensor rotor using a metal bar and hammer through the two bolt holes.
• Discard the used ABS sensor rotor
Refer to the section Brake.
(3) Clamp hub and disc assembly in vise using protective pads
and remove six (6) disc to hub retaining bolts.
(4) Place hub on a suitable work surface and remove wheel
studs, as required, using a hammer.
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ISUZU KB P190 2007
Page 736 of 6020
BRAKES 5C-37
REMOVAL AND INSTALLATION OF DISC PAD
RUW 55CSH001501
Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don’t remove the brake hose from the caliper when
replacing pads.
2. Rotate the Caliper Upward
Remove the caliper from the support bracket and move the
caliper to the upper link or the frame.
Note:
While caliper is removed from the support bracket, neve
r
step on the brake pedal or the piston will protrude rapidly.
RUW 55CSH001601
3. Pad Assembly with Shim
Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.
4. Clip; Pad
Discard the used clip and install a new one.
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ISUZU KB P190 2007
Page 740 of 6020
BRAKES 5C-41
Thickness of Disc Pad
Thickness (t) mm (in)
Standard Limit
10.0 (0.394) 1.8 (0.071)
Replace the front disc pad whenever the pad wear indicato
r
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.
All four brake pads should be replaced together.
302R300019
Seal and Boot
The dust seal, dust boot and ring seal should be replaced each
time the caliper is overhauled.
Discard these used rubber parts.
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