open hood ISUZU KB P190 2007 Workshop Repair Manual

1-54 HEATER AND AIR CONDITIONING
OIL RETURN OPERATION
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the
refrigerant in the system.
W hen checking the amount of oil in the system, or replacing
any component of the system, the compressor must be run in
advance for oil return operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is "ON" and Set the fan control knob at its highest position.
3) Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4) Stop the engine.


REPLACEMENT OF COMPONENT PARTS
W hen replacing system component parts, supply the following
amount of oil to the component parts to be installed.
Component parts to be installed Amount of oil
Evaporator 50 cm3 (1.41 lmp fl oz)
Condenser 30 cm3 (0.84 lmp fl oz)
Receiver/drier 30 cm3 (0.84 lmp fl oz)
Refrigerant line (One piece) 10 cm3 (0.28 lmp fl oz)

Refrigeration oil must be replenished if more than two parts
are removed at the same time. After installing these
components, check compressor oil.



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ISUZU KB P190 2007

SHEET METAL 2B-3

RUW 52BSH002501

Important Operations - Removal
1. Washer Nozzle Tube
1) Open the hood.
2) Support the hood.
3) Remove the windshield washer nozzle tube.





RUW 52BSH002601

2. Hood Hinge Bolt
• Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.






RTW 72BSH000501

Important Operations - Installation
3. Engine Hood
• Check the engine hood and fender (1).





• Clearance : 4.0 mm (0.16 in)
• Height (step) : Flushness
• Adjust clearance using the hinges on the engine hood.



RTW 72BSH000701







• Adjust height (step) using the hood rests (1).






Engine Hood Striker
• Apply a light coat of grease to the striker.



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ISUZU KB P190 2007

2B-6 SHEET METAL




RTW 72BSH000301

Important Operations - Removal
2. Intercooler Seal
• Remove the 6 clips.



RUW 52BSH002501
3. Washer Nozzle Tube
1) Open the hood.
2) Support the hood.
3) Remove the windshield washer nozzle tube.




RUW 52BSH002601

4. Hood Hinge Bolt
• Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.









RTW 72BSH000801
8. Engine Hood Bulge
• Remove the 4 nuts.






RTW 72BSH000501

Important Operations - Installation
5. Engine Hood
• Check the engine hood and fender (1).


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ISUZU KB P190 2007

SHEET METAL 2B-9

RUW 52BSH002501

Important Operations - Removal
1. Washer Nozzle Tube
4) Open the hood.
5) Support the hood.
6) Remove the windshield washer nozzle tube.





RUW 52BSH002601
2. Hood Hinge Bolts
• Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.


RTW 72BSH001101

Important Operations - Installation
3. Engine Hood
• Check the engine hood and fender. (1)





• Clearance : 4.0 mm (0.16 in)
• Height (step) : Flushness
• Adjust clearance using the hinges on the engine hood.



RTW 52BSH000301







• Adjust height (step) using the hood rests (1).






Engine Hood Striker
• Apply a light coat of grease to the striker.


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-39
Combination Switch
Combination Switch and Associated Parts









RTW 73BLF000201
Legend
(1) Steering Column Cover
(2) Steering W heel
(3) Inflator Module or Horn Pad
(4) Combination Switch and SRS Coil Assembly
(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)


Removal
1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes (with SRS air bag).
4. Disconnect the yellow 2-way SRS connector located
under the steering column (with SRS air bag).
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to lose its centering which will cause damage to the
coil assembly. (with SRS air bag)
5. Remove the engine hood opening lever, then remove instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).

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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-43
6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood opening lever.
8. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark has
not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701
CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
9. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
ft)
10. Support the inflator module and carefully connect the SRS connector (1) and horn lead (2) (with SRS
air bag).

RTW 73BSH001101
11. Connect the horn leads at center of wheel (without
SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801
12. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag)
Torque: 3 N ⋅
⋅⋅
⋅
m (0.3 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201

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3B-44 POWER-ASSISTED STEERING SYSTEM
13. Align each snap stud of driver air bag to the holes on
steering wheel. (with SRS air bag)

RTW 73BSH001201

RTW 73BSH000401
14. Push the SRS air bag at area-1 (1) and area-2 (2). At
that time confirm the audible noise of each stud.
(with SRS air bag)

RTW 73BSH000301

15. Enable the SRS (Refer to "Enabling the SRS" in this
section). (with SRS air bag)
16. Install driver knee bolster (reinforcement).
17. Install instrument panel lower cover then install the engine hood opening lever.
18. Connect the SRS connector (with SRS air bag).
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)
20. Turn the ignition switch to "ON" while watching warning light and check - the light should flash 7
times and then go off. If lamp does not operate
correctly, refer to Restraints section.




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ISUZU KB P190 2007

3B-46 POWER-ASSISTED STEERING SYSTEM
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to lose its centering which will cause damage to the
coil assembly (with SRS air bag).
5. Remove the engine hood opening lever and steering lower cover.
6. Remove driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
8. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025
9. Check the position of the pins in thier holes. Push the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101

10. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
11. Cancel the lock to release the four pins (with SRS air bag).
12. Loosen the horn pad fixing screw at the rear of the steering wheel (without SRS air bag).
430R300009


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-49
825RS048
4. Install the driver knee bolster assembly.
5. Install the steering lower cover and engine hood opening lever.
6. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark has not been applied in this section.
NOTE: Confirm SRS and horn harness connector is
fixed by the steering wheel.

RTW 73BSH000701

CAUTION: Never apply force to the steering wheel in
the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
7. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
ft)

8. Support inflator module and carefully connect the
SRS connector (1) and horn lead (2), then install
inflator module (with SRS air bag).

RTW 73BSH001101
9. Connect the horn leads at center of wheel (without SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801


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ISUZU KB P190 2007

3B-50 POWER-ASSISTED STEERING SYSTEM
10. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag).
Torque: 3 N ⋅
⋅⋅
⋅
m (0.3 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201
11. Align each snap stud of driver air bag to the holes on
steering wheel (with SRS air bag).

RTW 73BSH001201

RTW 73BSH000401
12. Push the SRS air bag at area-1 (1) and area-2 (2). At that time confirm the audible noise of each stud.
(with SRS air bag)

RTW 73BSH000301
13. Enable the SRS (Refer to "Enabling the SRS" in this section) (with SRS air bag).
14. Install driver knee bolster (reinforcement).
15. Install instrument panel lower cover, then install the engine hood opening lever.
16. Connect the yellow 2-way SRS connector located under the steering column (with SRS air bag).
17. Connect the battery "-" terminal cable (with SRS ai
r
bag).

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

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ISUZU KB P190 2007