set clock ISUZU KB P190 2007 Workshop Repair Manual

HEATER AND AIR CONDITIONING 1-37
refrigerant container.


1) Make sure the evacuation process is correctly completed.
2) Connect the center-hose of the manifold gauge to the refrigerant container. •
••
•
Turn the charge valve handle counterclockwise to purge
to the charging line and purge any air exiting in the
center-hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the refrigerant about 200 g (0.44 lbs.). •
••
•
Make sure the high-pressure hand valve is closed.
•
••
•
Avoid charging the refrigerant by turning the refrigerant
container upside down.
4) Close the low-pressure hand valve of the manifold gauge. •
••
•
Check to ensure that the degree of pressure does not
change.
5) Check the refrigerant leaks by using a HFC-134a leak detector. •
••
•
If a leak occurs, repair the leak connection, and start all
over again from the first step of evacuation.
6) If no leaks are found, open the low-pressure hand valve of the manifold gauge. Then continue charging refrigerant to
the system. •
••
•
W hen charging the system becomes difficult:
(1) Run the engine at Idling and close the all vehicle doors.
(2) A/C switch is "ON".
(3) Set the fan control knob (fan switch) to its highest position.
(4) Set air source selector lever to “RECIRC”



WARNING
BE ABSOLUTELY SURE NOT TO OPEN THE HIGH-
PRESSURE HAND VALVE. SHOULD THE HIGH-
PRESSURE HAND VALVE BE OPENED, THE HIGH-
PRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT
CONTAINER TO BURST.
7) W hen the refrigerant container is emptied, use the following procedure to replace it with a new refrigerant container.
(1) Close the low-pressure hand valve.
(2) Raise the needle upward and remove the charge valve.
(3) Reinstall the charge valve to the new refrigerant container.
(4) Purge any air existing in the center hose of the manifold gauge.






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ISUZU KB P190 2007

3B-56 POWER-ASSISTED STEERING SYSTEM
9. Turn the SRS coil fully counterclockwise, return
about 3 turns and align the neutral mark (1). (with
SRS air bag)
CAUTION: When turning the SRS coil fully
counterclockwise, stop turning if resistance is felt.
Further forced turning may damage to the cable in
the SRS coil.
826RW 014
10. W hen installing the steering column cover, be sure to
route each wiring harness as illustrated so that the
harnesses do not catch any moving parts.
825RW 017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing. 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.
12. Tighten the steering wheel fixing nut to the specified torque.
Torque: 35 N ⋅
⋅⋅
⋅
m (3.6 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
ft)
13. Support the module and carefully connect the module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 3 N ⋅
⋅⋅
⋅
m (0.3 kgf ⋅
⋅⋅
⋅
m/26 lb ⋅
⋅⋅
⋅
in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn lead located under the steering column.
19. Connect the battery "-" terminal cable (with SRS ai
r
bag).


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ISUZU KB P190 2007

REAR AXLE 4B-25
b. Tighten the nut to the specified torque.
Torque:
φ220mm : 2.7 N ⋅m (0.28 kgf ⋅m/24 lb ⋅in)
φ194mm : 2.3 N ⋅m (0.23 kgf ⋅m/20 lb ⋅in)



425RW 030

c. Clean the side bearing bores. Place discs and
dial indicator on to arbor, and place tool into
position in side bearing bores. Install and
tighten the bearing caps to the specified
torque.
Torque : φ220mm : 108N ⋅m (11 kgf ⋅m/80 lb ⋅ft)
φ194mm : 94N ⋅m (10 kgf ⋅m/72 lb ⋅ft)

425RW 031
Legend
φ
φφ
φ
220mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2166-0
3. Disc (2 pcs.) : 5-8840-2167-0
4. Arbor : 5-8840-0128-0
φ
φφ
φ
194mm
1. Dial Indicator : 5-8840-0126-0
2. Gauge Plate : 5-8840-2087-0
3. Disc (2 pcs.) : 5-8840-2088-0
4. Arbor : 5-8840-0128-0



Note :
The scale on the dial indicator (5-8840-0126-0) is
inch unit.
d. Set the dial indicator 5-8840-0126-0 to “0”.
Place it on the mounting post of the gauging
arbor with the contact button touching the
indicator pad. Force the dial indicato
r
downward until the needle has made a hal
f
turn clockwise. Tighten down the dial indicato
r
in this position.




425RS020
Legend
1. Dial Indicator
2. Gauging Arbor
3. Plunger
4. Gauge Plate


e. Position the plunger on the gauge plate. Move
the gauging arbor slowly back and forth and
locate the position at which the dial indicato
r
shows the greatest deflection. At this point,
once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.

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ISUZU KB P190 2007

FRONT WHEEL DRIVE 4C1-31








Tighten the nut to the specified torque.
N⋅m (kgf ⋅m/lb ⋅in)
New bearing 2.3 (0.23/20)
Used bearing 0.98 - 1.18
(0.10 – 0.12/9 – 10)
(2) Clean the side bearing bores. Install the dial indicator with the discs and Arbor. Install and tighten the bearing caps to
the specified torque.
Torque N ⋅m (kgf ⋅m/lb ⋅ft)
98 (10.0/72)

1 Dial indicator : 5-8840-0126-0
2 Disc (2 pcs.) : 5-8840-2088-0
3 Arbor : 5-8840-0128-0
4 Gage plate : 5-8840-2087-0




(3) Set the dial indicator to “0”. Place it on the mounting post of
the gaging arbor with the contact button touching the
indicator pad. Force the dial indicator downward until the
needle has made a half turn clockwise. Tighten down the
dial indicator in this position.




(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.


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ISUZU KB P190 2007

4C1-54 FRONT WHEEL DRIVE



Important Operations
1. Bolt
Before removal, shift transfer lever into “2H” position and set
free wheeling hub knob into “FREE” position.



6. Hub nut
W rench : 5-8840-2 117-0




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.



14. Clutch Assembly
W hile pushing follower knob, turn clutch assembly clockwise
and then remove clutch assembly from knob.





19. Retaining Spring
Remove retaining spring from clutch assembly by turning it
counterclockwise.


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ISUZU KB P190 2007

BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW 35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal. mm (in)
Pedal free play (L1) 6 - 10 (0.24 - 0.39)
M/T 174 - 186 (6.85 - 7.32) Height (L2)
A/T 176 - 188 (6.93 - 7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque
N⋅m (kgf ⋅m/lb ⋅
⋅⋅
⋅
ft)
15 - 25 (1.5 – 2.5 / 11 - 18)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 57 mm (2.24 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005

How to connect the CLEVICE of the BOOSTER ROD with the
PEDAL ARM and how to adjust the PEDAL SW .
After connecting the CLEVIS of the BOOSTER ROD to the
PEDAL ARM, adjust the PEDAL SW mounted (PDA) to the
PEDAL BRACKET using the procedure explained below.
1. Set the hole of the CLEVIS of the BOOSTER & M/CYL
ROD with the hole in the PEDAL ARM.
2. Enter the PIN; PUSH ROD to the PEDAL to the holes from the left side of the PEDAL.
3. Enter and fix the PIN; SNAP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SW ITCH counter- clock-wise.

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6A – 34 ENGINE MECHANICAL



RTW 46ASH000701
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8 °)
is aligned with the pointer.

Injection Timing : BTDC 8 ° ± 2 °

Standard Reading mm (in)
0.5 (0.02)

If the injection timing is outside the specified range,
continue with the following steps.


10. Loosen the injection pump fixing nuts and bracket bolts.
11. Adjust the injection pump setting angle.
W hen large than standard value W hen smaller than standard
value
R A


A: Move the injection pump toward the engine.
R: Move the injection pump away from the engine.
12. Install the distributor head bolt.
Distributor head bolt torque N·m (kg·m /lb·ft)
29 (3.0/22)



ENGINE CONTROL (4JA1T(L) only)
Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant temperature reaches 70 - 80 °C (158 - 176 °F).


4. Disconnect the engine control cable from the control lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed. If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 ± 25 rpm



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6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.

Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown in the illustration.
Gear stoper: 5-8840-0214-0

Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the No.1 piston.
2. Apply engine oil to the idler gear and the idler gear shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are facing the front of the engine.


015LX113
020R100001
020RY00034
020RY00035

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6D – 28 ENGINE ELECTRICAL
BRUSH AND BRUSH HOLDER
1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length mm (in)
Standard Limit
15 (0.59) 12 (0.47)


RTW46DSH004001













RTW46DSH004101
2. Use a circuit tester to check the brush holder
insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.





3. Inspect the brushes for excessive wear. If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.

OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise. It should turn smoothly.
3. Try to rotate the pinion in the opposite direction. The pinion should lock.
065RY00035


RTW46DSH004401
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.


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ENGINE MECHANICAL (4JK1/4JJ1) 6A-147
Reassembly
1. Install the gasket on the element.
2. Install the element.
3. Tighten the element fixing nut using the specified torque.
Tightening torque: 25 N ⋅
⋅⋅
⋅
m (2.5 kg ⋅
⋅⋅
⋅
m / 18 lb ft)

Installation
1. Install the oil filter and cooler.
• Install the O-ring on the oil filter and cooler,
apply grease.
•
Apply the liquid gasket and mount within 5
minutes. Apply liquid gasket (ThreeBond TB-
1207C or equivalent) to the flange surface
groove (cylinder block). Bead diameter must
be between 2 and 3 mm (0.079 and 0.118 in).
Refer to the illustration for the offset position
(no more than 1 mm (0.004 in)).






RTW 56ASH013101
Legend
1. Liquid Gasket
2. O-ring

• Align the oil filter and cooler holes with the
cylinder block studs. Install the oil cooler to the
cylinder clock.


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