2007 ISUZU KB P190 air suspension

REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3D- 2 Torque Specifications .................................................................................................. 3D- 3
Rear Suspension ............................................................................................................... 3 D- 5
General Description...................................................................................................... 3D- 5
Leaf Spring and Shock Absorber ..................................................................................... 3D- 6 Leaf Spring and Associated Parts ............................................................................... 3D- 6
Removal ........................................................................................................................ .3D- 7
Inspection and Repair .................................................................................................. 3D- 8
Installation ................................................................................................................... .. 3D- 9
Leaf Spring Assembly ....................................................................................................... 3D- 11
Disassembly .................................................................................................................. 3D - 11
Inspection and Repair .................................................................................................. 3D- 11
Reassembly ................................................................................................................... 3D - 12
Rear Stabilizer Bar ............................................................................................................ 3D- 13
Stabilizer Bar and Associated Parts ........................................................................... 3D- 13
Removal ........................................................................................................................ . 3D- 14
Installation ................................................................................................................... .. 3D- 14
Troubleshooting ................................................................................................................ 3D- 15


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ISUZU KB P190 2007

3D-8 REAR SUSPENSION
INSPECTION AND REPAIR
Make correction or replace parts if wear, damage or abnormal conditions are found through inspection.





Visual Check
Inspect the following parts for wear, damage, nuts or other
abnormal conditions.
• Leaf spring assembly
• Clip
• Center bolt
• U-bolt
• Spring pin
• Shackle pin
• Shock absorber
• Rubber bumper
• Rubber bushing
• Bump rubber seat



Shackle Pin
Shackle Pin diameter mm (in)
17.93 - 18.00 (0.706 - 0.709)



Spring Pin
Spring Pin Diameter mm (in)
13.8 - 14.0 (0.543 - 0.551)



Shock Absorber
Inspection operation of shock absorber
If no resistance is felt while expanding the shock absorber, it
indicates that the absorber is faulty.



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ISUZU KB P190 2007

REAR SUSPENSION 3D-11
LEAF SPRING ASSEMBLY

F03L100004

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.




RTW 430SH000101
2. Apply a setting mark across the springs before
disassembling the leaf spring assembly.

F03L100006
3. Use a bench press and remove the center bolt.
• Discard center bolt and install a new one.

465R300001
4. Disassemble the leaf spring assembly.


Inspection and Repair
Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and repair or
replace if necessary.


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ISUZU KB P190 2007

WHEELS AND TIRES 3E-5
TIRE PRESSURE LABEL (LOCATION: DRIVERS DOOR OR FRAME OF DRIVERS DOOR)

4 ×
××
×
2 Except High Ride Suspension
SEE OW NERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION

Tire Size Wheel Size Tire inflation pressure
KPa (kgf/cm
2/psi)
Front & Rear Front & Rear Front Rear
195R14C 8PR 14X5.5JJ 245 (2.5/36) 441 (4.5/64)
215/70R15C 15X6.5JJ 221 (2.25/32) 368 (3.75/53)

4 ×
××
×
2 High Ride Suspension, 4 ×
××
×
4
SEE OW NERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION

Tire Size Wheel Size Tire inflation pressure
KPa (kgf/cm
2/psi)
Front & Rear Front & Rear Front Rear
225/75R15C 15X6.5JJ 221 (2.25/32) 319 (3.25/46)
245/70R16 16X7JJ 200 (2.0/28) 270 (2.8/40)


Note:
•
••
•
The air pressure of the tire should be maintained as indicated in the label instruction on the driver's
door or frame of driver's door.
Lower pressure can cause burst and adverse vehicle handling.
On the other hand, higher pressure can cause shock-burst and reduce gripping effect.



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ISUZU KB P190 2007

4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4×2 Except High Ride Suspension Model) ..................................4C1- 38 Disassembly .................................................................................................................4C1 - 38
Inspection and Repair .................................................................................................4C1- 41
Reassembly ..................................................................................................................4C1 - 42
Front Hub and Disc
(4×4, 4×2 High Ride Suspension, 4×4 Rigid Hub, 4×4 Shift On the Fly Model) ..........4C1- 46 Disassembly .................................................................................................................4C1 - 46
Inspection and Repair .................................................................................................4C1- 48
Reassembly ..................................................................................................................4C1 - 49
Front Hub and Disc (4×4 Manual Locking Hub Model)..................................................4C1- 53 Disassembly .................................................................................................................4C1 - 53
Inspection and Repair .................................................................................................4C1- 56
Reassembly ..................................................................................................................4C1 -57
Troubleshooting ...............................................................................................................4 C1-63
Special Service Tool.........................................................................................................4C 1-71


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ANTI-LOCK BRAKE SYSTEM 5B-9
4×
××
×
2 High Ride Suspension, 4 ×
××
×
4







RTW 55ALF000201
Legend
(1) Connector Portion
(2) Front Speed Sensor Assembly
(3) Bolt: Cable to Knuckle


(4) Bolt: Sensor to Knuckle
(5) Bolt: Cable to Upper Link
Removal
1. Remove speed sensor connector at connector
portion.
2. Remove sensor fixing bolt (4).
3. Remove cable fixing bolts and nut (4 ×2).
4. Disconnect the arrow mark locks of the cable clips.
5. Remove the speed sensor assembly.
Inspection and Repair
1. Check the speed sensor head for presence of
foreign materials; remove any dirt, etc.
2. Check the head for damage; replace speed senso
r
if necessary.
3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the cable while checking for continuity.

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ISUZU KB P190 2007

5C-28 BRAKES

27. After the bleeding operation is completed on each individual
wheel, check the level of the brake fluid in the reservoir and
replenish up to the “MAX" level as necessary.
28. Attach the reservoir cap.
29. Stop the engine.




05007-1

BRAKE LINE (HOSES AND PIPES)
• Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or replace parts if these abnormal conditions are found through inspection.
• All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and bent when working with them, and pay special attention to
all the brake lines not to damage them when repairing o
r
replacing other parts (axle, suspension, etc).
• Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints, retighten or replace these parts.
This procedure must be performed whenever brake lines are installed.
• After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.



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ISUZU KB P190 2007

6E–64 ENGINE DRIVEABILITY AND EMISSIONS
– Are there areas subjected to vibration ormovement (engine, transmission or
suspension)?
– Are there areas exposed to moisture, road salt or other corrosives (battery acid, oil or other
fluids)?
– Are there common mounting areas with other systems/components?
– Have previous repairs been performed to wiring, connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
– Does the vehicle have aftermarket or dealer- installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem
At this point, you should have a good idea of what could
cause the present condition, as well as could not cause
the condition. Actions to take include the following:
• Divide (and separate, where possible) the system or circuit into smaller sections
• Confine the problem to a smaller area of the vehicle (start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
• For two or more circuits that do not share a common power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
• Loose connections: – Open/high resistance in terminals, splices,connectors or grounds
• Incorrect connector/harness routing (usually in new vehicles or after a repair has been made):
– Open/high resistance in terminals, splices, connectors of grounds
• Corrosion and wire damage:
– Open/high resistance in terminals, splices,connectors of grounds
• Component failure: – Opens/short and high resistance in relays,modules, switches or loads
• Aftermarket equipment affecting normal operation of other systems
You may isolate circuits by:
• Unplugging connectors or removing a fuse to separate one part of the circuit from another part
• Operating shared circuits and eliminating those that function normally from the suspect circuit
• If only one component fails to operate, begin testing at the component
• If a number of components do no operate, begin tests at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
• Service manual
• Technical equipment (for data analysis)
• Experience
• Technical Assistance
• Circuit testing tools
5d. Intermittent Diagnosis
By definition, an intermittent problem is one that does
not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
• Faulty electrical connections and wiring
• Malfunctioning components (such as sticking relays, solenoids, etc.)
• EMI/RFI (Electromagnetic/radio frequency interference)
• Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
external and internal system conditions to duplicate the
problem.
What you should do
Step 1: Acquire information
A thorough and comprehensive customer check sheet
is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
Step 2: Analyze the intermittent problem
Analyze the customer check sheet and service history
file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.

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ISUZU KB P190 2007