suspension ISUZU KB P190 2007 Workshop Repair Manual

1

WORKSHOP
REPAIR MANUAL
GE NERAL INFORMATION 0
HEATING AND VENTILATION
BRAKESMAIN INDEX ISUZU

CONTENTS
WHEELS AND TYRES
4
5
BODY 8
SECURITY 11 SUSPENSION

3
STEERING
2
AXLE
FRAME AND CAB
ENGINE
6
TRANSMISSION 7
MY 2007
RESTRAINTS 9
CAB 10
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KB P190

ISUZU KB P190 2007

0B-4 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 × 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
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 absorber mount for looseness - I - I - I - I - I - I - I - I - I - I Rubber bushes of suspension for
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 bearing 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

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

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

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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ISUZU KB P190 2007

2 2
×
××
×
4
×
××
×
×
××
×
F
R O NT ALIG NM EN T 3A -1
SECTIO N 3A
FRONT ALIGNMENT
TABLE OF CONTENTS
Front End A lignment Inspection and A dju st ment ......................................................... 3A-
PA
GE
General Descript ion ..................................................................................................... 3A-
Inspect ion .................................................................................................................... .3A- 3
A lig nm en t f o r 4 2 ( except High Ride Suspension) ........................................................ 3A-
A lignme nt for 4 2 (High Ride Suspension) and 4 4 ...................................................... 3A- 10

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ISUZU KB P190 2007

3A-2 FRONT ALIGNMENT

Front End Alignment Inspection and
Adjustment
General Description
“Front End Alignment” refers to the angular relationship
between the front wheels, the front suspension attaching parts
and the ground.
Proper front end alignment must be maintained in order to
insure efficient steering, good directional stability and to
prevent abnormal tire wear.
The most important factors of front end alignment are wheel
toe-in, wheel camber and axle caster.





Camber:
This illustration shows a view from the front of the vehicle.
Camber is the vertical tilting inward or outward of the front
wheels. W hen the wheels tilt outward at the top, the camber is
positive (+). W hen the wheels tilt inward at the top, the camber
is negative (-). The amount of tilt measured in degrees from
the vertical is called the camber angle (1). If camber is extreme
or unequal between the wheels, improper steering and
excessive tire wear will result. Negative camber causes wear
on the inside of the tire, while positive camber causes wear to
the outside.



Caster:
This illustration shows a view from the side of the vehicle.
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special instrument, but
if you look straight down from the top of the upper control arm
to the ground, the ball joints do not line up (fore and aft) when
a caster angle other than 0 degrees is present. W ith a positive
angle, the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.



Toe-in:
This illustration shows a view from the top of the vehicle.
Toe-in is the measured amount the front wheels are turned in.
The actual amount of toe-in is normally a fraction of a degree.
Toe-in is measured from the center of the tire treads or from
the inside of the tires. The purpose of toe-in is to insure parallel
rolling of the front wheels and to offset any small deflections of
the wheel support system which occurs when the vehicle is
rolling forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.

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ISUZU KB P190 2007

FRONT ALIGNMENT 3A-3

Inspection
Before making any adjustments affecting caster, camber or
toe-in, the following front end inspection should be made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in W heel and Tire System section.
2. Make sure that the vehicle is in an unladen condition (W ith no passengers or loading).
3. Make sure that the spare tire is installed at the normal position.
4. Inspect the front wheel bearings for proper adjustment. Refer to Front Hub and Disc Overhaul in Suspension
section.
5. Inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section.
6. Inspect the wheel and tires for run-out. Refer to W heel Replacement in W heel and Tire System section.
7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable noise. Refer to Shock Absorber in Suspension section.
10. Inspect the control arms or stabilizer bar attachment fo
r
looseness. Refer to Suspension section.
11. Inspect the front end alignment using alignment equipment. Follow the manufacturer’s instructions.
12. Park the vehicle on a level surface.


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ISUZU KB P190 2007

3A-4 FRONT ALIGNMENT
Alignment for 4×
××
×
2 (except High Ride Suspension)
Caster and camber adjustment
The lower links of the 4 X2 vehicle front suspension have an adjusting cam at either end (front and rear). This
permits simultaneous adjustment of camber and caster angle.



Front
Front
RTW 340LF000301

Legend
1. Lower link ASM RH
2. Adjusting cam RR
3. Adjusting cam FRT
4. -direction The lower link ASM moves toward the inside
5. +direction The lower link ASM moves toward the outside
6. Lower link ASM LH
7. Adjusting cam RR
8. Adjusting cam FRT
9. -direction The lower link ASM moves toward the inside
10. +direction The lower link ASM moves toward the outside

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ISUZU KB P190 2007

3A-8 FRONT ALIGNMENT




Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel at front end.
3.
Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks reach the rear end position.
5. Take measurement of distance B between the cente
r
marks at rear end.
The toe-in can be calculated with the following formula.
Toe-in = B - A
Toe-in mm (in)
4×2
(Except high ride suspension) 0
±2 (0 ±0.08)





To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque N⋅m (kgf ⋅m/lb ⋅ft)
98 ±6.0 (10.0 ±0.6 / 72.3 ±4.3)



RTW 53ASH000101

Trim Height
Trim Height : at Curb Weight (Reference Data)
Trim height (Z) = A - B
Front mm (in)
Z
105(4.13)


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ISUZU KB P190 2007