2007 ISUZU KB P190 steering

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

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-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

FRONT ALIGNMENT 3A-9

RTW 53ASH000201
FRT Buffer clearance (Reference Data) mm(in)

4×2 (Except high ride suspension)
25.9(1.02)


RTW 340SH000101-X

RR Buffer clearance (Reference Data)
mm(in)
4×2 (Except high ride suspension)
82 (3.23)



MAXIMUM STEERING ANGLE
4
×2 (Except high ride suspension)
Outside wheel 33.5°
Inside wheel 37.1°


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ISUZU KB P190 2007

3A-12 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 (High ride suspension)
4×4 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 330SH000201

Trim Height
Trim Height : at Curb Weight
Trim height (Z) = A - B
mm (in)
Z
165±5 (6.5 ±0.20) (Philippine only)
140 ±5 (5.5 ±0.20) (Except Philippine)


MAXIMUM STEERING ANGLE
4
×2 (High ride suspension), 4 ×4
Outside wheel 32.8° (Philippine only)
Inside wheel 35.0° (Philippine only)
Outside wheel 32.1° (Except Philippine)
Inside wheel 34.4° (Except Philippine)

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ISUZU KB P190 2007

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

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