power steering 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 25 of 6020

MAINTENANCE AND LUBRICATION 0B-7
Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)
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
DIESEL ENGINE * Engine oil - - - R - - - R - - - R - - - R - - - R*
Engine oil filter
- - - R - - - R - - - R - - - R - - - R
Oil leakage and contamination I I I I I I I I I I I I I I I I I I I I Idling speed and acceleration I I I I I I I I I I I I I I I I I I I I Fan belt tension and damage I I I I I I I I I I I I I I I I I I I I Exhaust system I I - I - I - I - I - I - I - I - I - I All hoses and pipes in engine
compartment for clog of damage - - - I - - - I - - - I - - - I - - - I
Valve clearance
- - - A - - - A - - - A - - - A - - - A * Air cleaner element I I I I I I I R I I I I I I I R I I I I ** Fuel filter Replace the fuel filter when the fuel filter indicator light is lit. Engine coolant concentration - - - I - - - I - - - I - - - I - - - I Cooling system for water leakage - - - I - - - I - - - I - - - I - - - I CLUTCH Clutch fluid I I - I - I - I - I - I - I - I - I - I Clutch pedal travel and play I I - I - I - I - I - I - I - I - I - I TRANSMISSION OR TRANSMISSION
W ITH TRANSFER CASE
* Manual transmission with fluid - - - R - - - I - - - R - - - I - - - I * Transfer case oil (MT) - - - R - - - I - - - R - - - I - - - I Oil leakage - - - I - - - I - - - I - - - I - - - I Gear control mechanism for
looseness - - - - - - - - - - - I - - - - - - - -
* Automatic transmission fluid - - - I - - - I - - - I - - - I - - - I * Transfer case oil (AT)
- - - R - - - I - - - R - - - I - - - R 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 case for distortion or damage - - - I - - - I - - - I - - - I - - - I Axle shafts 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
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Page 29 of 6020

MAINTENANCE AND LUBRICATION 0B-11
Recommended Fluids and Lubricants (For GENERAL EXPORT)
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly the best lubricants and diesel fuels.
W hen lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
The lubrication intervals in the maintenance schedule and coverage and period of new vehicle warranty are based
on the use of ISUZU genuine lubricants or recommended lubricants listed in the chart, which will serve as a guide
for selecting lubricants of the correct brand name.
GRADE
LUBRICATION MAKE BRAND/TYPE API ACEA JASO
Gasoline engine
crankcase C24SE
ISUZU GENUINE
ISUZU GENUINE
CALTEX
SHELL
ELF
TOTAL
CASTROL
BP BESCO RACING ACE TYPE SJ (5W-30)
BESCO MULTI ACE (7.5W-30)
HAVOLINE FORMULA (15W-40, 10W-30, 20W-50) HELIX PLUS (15W-50)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
GTX-7 (15W-40)
VISCO 3000 (15W-40) SJ
SG SL
SJ/CF SG
SJ/CF
SG/SH
SG/SH
A3/B3
A2/B2
Gasoline engine
crankcase HFV6
CALTEX 10W-30
HAVOLINE FORMULA (10W-30) SL
SL
Diesel engine crankcase
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
CALTEX/CHEVRON
CALTEX/CHEVRON
SHELL
SHELL
ELF
TOTAL
CASTROL
CASTROL
BP BESCO MULTI-Z TYPE CF-4 (10W-30)
BESCO MULTI-Z SUV (5W-30)
BESCO S-3 (10W, 20W, 30, 40)
DELO CXJ (15W-40, 20W-50, 40)
DELO 400 MULTIGRADE (15W-40)
RIMULA X (15W-40)
RIMULA D (15W-40, 30, 40)
PERFO 3F (15W-40)
RUBIA XT (15W-40)
RX SUPER PLUS (15W-40)
TECTION J PLUS (15W-40)
BP VANELLUS C6 (15W-40) CF-4
CD
CD
CD/CF
CD/CE/CF/CI-4 CH-4
CD/CF
CF-4/CE CF-4
CH-4
CH-4
CH-4
E3/E5 E3
B2/E2 E2
E3
E3/B3 E3
DH-1
DH-1
DH-1
DH-1
Manual transmission
C24SE D
Transfer case
ISUZU GENUINE
CALTEX/CHEVRON
SHELL
ELF
TOTAL
CASTROL
BP
BESCO GEAR OIL TRANSAXLE (5W-30)
DELO 400 MULTIGRADE (15W-40)
HELIX PLUS (15W-50)
SUPER SPORTI (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
RX SUPER PLUS (15W-40)
BP VANELLUS C6 (15W-40)
SG CD/CE/CF/CI-4 SJ/CF
SG/CD SJ/CF
CD/CE/CF
CD/CE/CF
E3/E5
A3/B3
A2/B2
DH-1
Manual transmission
HFV6
MOBIL 75W-90
MOBIL XHP (75W-90) GL-3
Differential
Shift on the fly system
(GL-5 only) ISUZU GENUINE
ISUZU GENUINE
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL
BP
BP BESCO GEAR OIL SH (80W-90, 90, 140)
BESCO SHIFT ON THE FLY (75W-90)
THURBAN GL-5 EP (80W-90, 85W-140)
SPIRAX A (140)
TRANSELF TYPE B (80W-90, 85W-140)
TRANSMISSION TM (80W-90, 85W-140)
EPX90 (90)
DYNA DRIVE (80W-90)
ENERGEAR HYPO (90)
ENERGEAR EP (80W-90) GL-5
GL-5 GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
Differential
(Limited Slip Differential) ISUZU GENUINE
CALTEX
SELL
ELF
TOTAL
CASTROL
BP BESCO GEAR OIL LSD (140)
GEAR OIL LSD (90)
SPIRAX A LS 90 (90)
TRANSELF TYPE BLS (90)
TRANSMISSION DA (85W-90)
HYPOY LSX (90)
ENERGEAR LS-M (90) GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
Automatic transmission
4JH1-TC 4JJ1 (Standard Output)
Power steering
ISUZU GENUINE
CALTEX/TEXACO
SHELL
ELF
TOTAL
CASTROL
BP BESCO ATF III
TEXAMATIC 1888 (DEXRON III)
SHELL DONAX TG (DEXRON III)
ELFMATIC G3 (DEXRON III)
TOTAL FLUID AT42 (DEXRON III)
TQ DEXRON III (DEXRON III)
AUTORAN DX3 (DEXRON III)
Automatic transmission
4JJ1 (High Output)
EXXON MOBIL
MOBIL ATF 3309
Automatic transmission
HFV6
DEXRON III
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ISUZU KB P190 2007
Page 31 of 6020

MAINTENANCE AND LUBRICATION 0B-13
RECOMMENDED FLUIDS AND LUBRICANTS (For EUROPE)
In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly the best lubricants and diesel fuels.
W hen lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
LUBRICATION/FLUID GRADE
API ACEA OTHER
Diesel engine crankcase B2/B3
E2/E3
Manual transmission
Transfer case B2/B3
E2/E3
Differential
Shift on the fly system
(GL-5 only)
GL-5
BESCO GEAR OIL SH (80W-90, 90, 140) (ISUZU GENUINE)
BESCO SHIFT ON THE FLY (75W-90) (ISUZU GENUINE)
THURBAN GL-5 EP (80W-90, 85W-140) (CALTEX)
SPIRAX A (140) (SHELL)
TRANSELF TYPE B (80W-90, 85W-140) (ELF)
TRANSMISSION TM (80W-90, 85W-140) (TOTAL)
EPX90 (90)(CASTROL)
DYNA DRIVE (80W-90) (CASTROL)
ENERGEAR HYPO (90) (BP)
ENERGEAR EP (80W-90) (BP)
Differential
(Limited Slip Differential)
(GL-5 only) GL-5
BESCO GEAR OIL LSD (140) (ISUZU GENUINE)
GEAR OIL LSD (90) (CALTEX)
SPIRAX A LS 90 (90) (SHELL)
TRANSELF TYPE BLS (90) (ELF)
TRANSMISSION DA (85W-90) (TOTAL)
HYPOY LSX (90) (CASTROL)
ENERGEAR LS-M (90) (BP)
Automatic transmission MOBIL ATF 3309
Power steering
DEXRON III
Propeller shaft sliding yoke
Universal joint
(General purpose grease in
Molybdenum) NLGI #2 or #3
multi purpose type grease
containing molybdenum disulfide
Engine cooling system Good quality ethylene glycol antifreeze or GM spec.
6033-M or equivalent
NOTE:
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant mixed with 1 bottle (118ml) of Limited
Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or equivalent.
FLUID TYPE
Clutch and brake fluid reservoir Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade
DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
BS (BRITISH STANDARD) Based on K2204 GAS OIL
Based on EN590: 1997L
Based on SAE J-313C
Based on BS EN590: 1997
NOTE:
Use the applicable standard or equivalent for diesel fuels.
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ISUZU KB P190 2007
Page 248 of 6020

STEERING SUSPENSION WHEELS AND TIRES 3-1
SECTI ON 3
STEERING SUSPENSION
TA BLE OF CONTENTS
Section 3A Front A lignment ................................................... ...................................... 249
PA
GE
Section 3B Power Assited Steering System ............................................................... 262
Section 3C Front Suspension ............................................................................... ...... 320
Section 3D Rear Suspension ................................................. ....................................... 3 85
Section 3E Wheels and Tires ................................................. ....................................... 405
WHEELS AND TIRES
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Page 262 of 6020

POWER-ASSISTED STEERING SYSTEM 3B-1
SECTION 3B
POWER-ASSISTED STEERING SYSTEM
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 3B – 4
Power Steering System Test .......................................................................................... 3B – 7
Maintenance .................................................................................................................... . 3B – 8
Fluid Level .................................................................................................................... .... 3B – 8
Bleeding The Power Steering System ........................................................................... 3B – 8
Bleeding Procedure ......................................................................................................... 3B – 8
Flushing The Power Steering System............................................................................ 3B – 8
Steering Wheel Free Play Inspection ............................................................................. 3B – 9
Front End Alignment Inspection and Adjustment......................................................... 3B – 9
Special Tools .................................................................................................................. . 3B – 10
Power Steering Unit......................................................................................................... 3B – 11
Power Steering Unit and Associated Parts............................................................... 3B – 11
Removal ....................................................................................................................... 3B – 11
Installation ................................................................................................................... 3B – 12
Power Steering Unit Disassembled View.................................................................. 3B – 13
Disassembly ................................................................................................................ 3B – 14
Inspection and Repair................................................................................................. 3B – 14
Reassembly ................................................................................................................. 3B – 14
Main Data and Specifications .................................................................................... 3B – 15
Special Tools ............................................................................................................... 3B – 16
Power Steering Pump...................................................................................................... 3B – 17
Power Steering Pump and Associated Parts (4JH1-TC, 4JA1-T) ............................ 3B – 17
Removal ....................................................................................................................... 3B – 17
Installation ................................................................................................................... 3B – 17
Power Steering Pump Disassembled View .............................................................. 3B – 18
Disassembly ................................................................................................................ 3B – 19
Inspection and Repair................................................................................................. 3B – 19
Reassembly ................................................................................................................. 3B – 20
Main Data and Specifications .................................................................................... 3B – 20
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ISUZU KB P190 2007
Page 263 of 6020

3B-2 POWER-ASSISTED STEERING SYSTEM
PAGE
Power Steering Pump (4JJ1-TC, 4JK1-TC) .................................................................... 3B – 22 Power Steering Pump and Associated Parts............................................................ 3B – 22
Removal ....................................................................................................................... 3B – 22
Installation ................................................................................................................... 3B – 22
Power Steering Pump Disassembled View .............................................................. 3B – 23
Disassembly ................................................................................................................ 3B – 24
Inspection and Repair................................................................................................. 3B – 24
Reassembly ................................................................................................................. 3B – 25
Main Data and Specifications .................................................................................... 3B – 25
Supplemental Restraint System Steering Wheel & Column ........................................ 3B – 27 Service Precaution ...................................................................................................... 3B – 2 7
SRS Connectors .......................................................................................................... 3B – 2 7
Inflator Module ................................................................................................................ . 3B – 28
Inflator Module and Associated Parts ....................................................................... 3B – 28
Removal ....................................................................................................................... 3B – 29
Inspection and Repair (with SRS air bag) ................................................................. 3B – 31
Installation ................................................................................................................... 3B – 31
Steering Wheel................................................................................................................. 3B – 33
Steering Wheel and Associated Parts ....................................................................... 3B – 33
Removal ....................................................................................................................... 3B – 33
Installation ................................................................................................................... 3B – 36
The adjustment method in case a mark has not been applied .................................... 3B – 38
Combination Switch ........................................................................................................ 3B – 39
Combination Switch and Associated Parts .............................................................. 3B – 39
Removal ....................................................................................................................... 3B – 39
Installation ................................................................................................................... 3B – 42
Lock Cylinder .................................................................................................................. . 3B – 45
Lock Cylinder and Associated Parts ......................................................................... 3B – 45
Removal ....................................................................................................................... 3B – 45
Installation ................................................................................................................... 3B – 48
System Inspection (with SRS air bag) ....................................................................... 3B – 50
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ISUZU KB P190 2007
Page 264 of 6020

POWER-ASSISTED STEERING SYSTEM 3B-3
PAGE
Steering Column .............................................................................................................. 3 B – 51
Steering Column and Associated Parts .................................................................... 3B – 51
Removal ....................................................................................................................... 3B – 51
Inspection .................................................................................................................... 3B – 54
Installation ................................................................................................................... 3B – 55
System Inspection (with SRS air bag) ....................................................................... 3B – 57
Supplemental Restraint System Steering Wheel & Column and Associated Parts ... 3B – 58 Main Data and Specifications .................................................................................... 3B – 58
Special Tools ............................................................................................................... 3B – 58
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ISUZU KB P190 2007
Page 265 of 6020

3B-4 POWER-ASSISTED STEERING SYSTEM
General Description
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering unit, a pressure hose
and a return hose.
Power Steering Unit
440R300001
The power steering unit is a rack and pinion type.
The toe-in angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
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ISUZU KB P190 2007