brake sensor ISUZU KB P190 2007 Workshop Repair Manual

3C-20 FRONT SUSPENSION
Upper Control Arm
Upper Control Arm and Associated Parts



450R300038
Legend
(1) Upper Control Arm Bolt
(2) Bushing
(3) Upper Control Arm Nut
(4) Upper Control Arm Assembly
(5) Upper Ball Joint
(6) Nut and Cotter Pin

(7) Knuckle
(8) Link Nut
(9) Upper Ball Joint Nut
(10) Upper Ball Joint Bolt
(11) Speed Sensor Harness Nut
(12) Brake Fluid Hose Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel
in this section.
3. Remove speed sensor harness nut.
4. Remove brake fluid hose nut.

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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-37
Knuckle
Knuckle and Associated Parts






RUW 63CLF000101
Legend
(1) Torsion Bar
(2) Nut and Cotter Pin, Lower Ball Joint
(3) Back Plate
(4) Nut and Cotter Pin, Upper Ball Joint
(5) Nut and Cotter Pin, Tie-rod End
(6) Knuckle Assembly


(7) Knuckle
(8) Needle Bearing (4 ×4 Model Only)
(9) Thrust W asher (4 ×4 Model Only)
(10) Oil Seal (4 ×4 Model Only)
(11) Speed Sensor harness


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel
in this section.
3. Remove the brake caliper. Refer to Disc Brakes in Brake section.

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ISUZU KB P190 2007

3C-40 FRONT SUSPENSION
Upper Control Arm
Upper Control Arm and Associated Parts



RTW 440LF001301
Legend
(1) Bolt and Plate
(2) Camber Shims
(3) Caster Shims
(4) Nut Assembly
(5) Upper Control Arm Assembly
(6) Fulcrum Pin


(7) Bushing
(8) Plate
(9) Upper Control Arm Nut
(10) Speed Sensor harness
(11) Nut and Cotter Pin
(12) Upper Ball Joint, Bolt and Nut


Removal
1. Raise the vehicle and support the frame with suitable safety stands.
2. Remove wheel and tire assembly. Refer to W heel
in this section.
3. Remove the brake caliper and disconnect brake pipe. Refer to Disc Brakes in Brake section.

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ISUZU KB P190 2007

4B-10 REAR AXLE
Disassembly
• Raise vehicle to the working level.
• Support the axle assembly with the proper jack
and chassis stands.
• Remove wheel and tire.
• Drain differential oil.
• Remove propeller shaft. (Refer to the section
“Rear Propeller Shaft”.)

1. Remove brake drum.
2. Remove ABS sensor. (Refer to the section “ABS”.)
3. Remove brake pipe from wheel cylinder.

420R300003



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ISUZU KB P190 2007

REAR AXLE 4B-19
17. Install brake pipe and ABS sensor and tighten it
to the specified torque.
Torque : ABS Sensor 8 N ⋅m (0.8 kgf ⋅m/69 lb ⋅in)
Brake Pipe 16 N ⋅m (1.6 kgf ⋅m/12 lb ⋅ft)
420R30003

18. Bleed brake pipe at the wheel cylinder. (Refer to
the section “Power-assisted Brake System”)
19. Install brake drum.
• Install propeller shaft. (Refer to Section “Rea
r
Propeller Shaft”.)
• Refill differential oil.
• Install wheel and tire.
• Lower vehicle.




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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-11

Removal
1. Jack up the vehicle and support it using jack stand.
2. Remove the tire and wheel.
3. Remove the stone guard.
4. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front W heel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in this section.
8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.
Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector.
15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.


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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-13


NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly.
8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kgf·m/73 lb·ft)
9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque.
Torque : 93 N·m (9.5kgf·m/69 lb·ft)
10. Install lower nuts of the stabilizer link, tighten it to the specified torque.
Torque : 50 N·m (5.1kgf·m/37 lb·ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake system.
16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque.
Torque : 226 N·m (23.0kgf·m/166 lb·ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Front Alignment section.
20. Tighten the bolts and nuts of the lower control arm to the specified torque.
Refer to Lower Control Arm in Suspension section.


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ISUZU KB P190 2007

4C1-38 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4×2 Except High Ride Suspension Model)
Disassembly
Refer to SECTION 3E “W HEELS AND TIRES” for wheel removal procedure.

RTW 34CLF000801
Disassembly Steps
1. Bolt
▲ 2. Brake caliper
▲ 3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer


8. Outer bearing
▲ 9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor
▲ 13. Bolt
▲ 14. W heel pin



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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-39
Important Operations
Before removal, jack up the front of vehicle and support frame
with jack stands.



2. Brake Caliper
(1) Remove the two bolts from the rear side of the knuckle arm, then remove the brake caliper, with the brake hose
attached.
(2) Use a wire etc., for attaching the brake caliper to the uppe
r
link.
Refer to the section Brake.




3. Hub Cap
W hen removing hub cap, exercise care so as not to scratch or
distort hub fitting face.





9. Hub and Disc Assembly
Using a brass bar to remove the outer bearing outer race (1),
oil seal, inner bearing and inner bearing outer race (2) from the
hug.





If necessary, replace the wheel pin in the following manner.

13. Bolt
14. 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.


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ISUZU KB P190 2007