2007 ISUZU KB P190 wheel

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

POWER-ASSISTED STEERING SYSTEM 3B-7
Power Steering System Test
Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
(3) Power Steering Unit
(4) Power Steering Pump


The fluid pressure test in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, i
f
necessary, must be made.
・ Inspect pump reservoir for proper fluid level.
・ Inspect pump driver gear condition.
1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses.
2. W ith the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 and
power steering tester adapter 5-8840-2297-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
3. Check the fluid level. Fill the reservoir with powe
r
steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Powe
r
Steering System in this section.
5. Start the engine and check the fluid level. Add power steering fluid if required. W hen the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.


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ISUZU KB P190 2007

3B-8 POWER-ASSISTED STEERING SYSTEM
6. Fully close the shutoff valve. Record the highest
pressures.
・ If the pressure recorded is within 9800-10300 kPa
(100-105 kg/cm
2/1422-1493psi), the pump is
functioning within its specifications.
・ If the pressure recorded is higher than 10300 kPa
(105 kg/cm
2/1493psi), the valve in the pump is
defective.
・ If the pressure recorded is lower than 9800 kPa
(100 kg/cm
2/1422psi), the valve or the rotating
assembly in the pump is defective.
7. If the pump pressures are within specifications, leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built up at either side of the
power steering unit, the power steering unit is
leaking internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level and make the needed repairs.
10. If the problem still exists, the steering and front suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean, the fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. W hen a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
・ Inspect gear for looseness or damage.
・ Inspect hoses to insure they are not touching an
y
other parts of the vehicle.
・ Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55 °
C (130 °F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. W hen checking the fluid level after the steering system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding the Power Steering System
W hen a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
W hen bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level remains constant after running the engine.
5. Raise and support the front end of the vehicle so that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to settle for a few minutes, then repeat the above
procedure.

Flushing the Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet connector and plug the connector port on the pump.
Direct the line toward a large container to catch the
draining fluid.
3. W hile running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-9
4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding the Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. W hile refilling the
reservoir, check the draining fluid for contamination.
If foreign matter is still evident, replace all lines,
disassemble and clean or replace the powe
r
steering system components. Do not re-use any
drained power steering fluid.

Steering Wheel Free Play Inspection
RTW 73BSH000901
1. W ith the tires in the straight-ahead position, check the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running. Free play: 0 - 30 mm (0 - 1.18 in)
2.
Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. W hen test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Front End Alignment Inspection and
Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. 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 .
431R30006
2. Tighten the lock nut to the specified torque. Torque:
98 N ⋅
⋅⋅
⋅
m (10 kgf ⋅
⋅⋅
⋅
m/72 lb ⋅
⋅⋅
⋅
ft)

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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-27
Supplemental Restraint System Steering Wheel & Column
Service Precaution
This steering wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific to
SRS components. W hen servicing a vehicle equipped
with Supplemental Restraint System, pay close attention
to all W ARNINGS and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNECESSARY SRS SYSTEM
REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES THE PROCEDURES DESCRIBED
BELOW TO BE FOLLOWED FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY
CONTAIN A SMALL AMOUNT OF SODIUM
HYDROXIDE, A BY-PRODUCT OF THE
DEPLOYMENT REACTION, THAT IS IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN HANDLING A DEPLO
YED AIR BAG
ASSEMBLY, AND WASH YOUR HANDS WITH MILD
SOAP AND WATER AFTERWARDS.

WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN AIR
BAG ASSEMBLY BY THE WIRES OR CONNECTOR
ON THE UNDERSIDE OF MODULE. IN THE CASE OF
AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
WHEN PLACING A LIVE AIR BAG ASSEMBLY ON
A
BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.
NEVER REST A STEERING COLUMN ASSEMBLY
ON THE STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN VERTICAL.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG ASSEMBLY
TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
A
BATTERY-POWERED OR A/C-POWERED VOLT-
METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED
IN THIS MANUAL. DO NOT USE A NON-POWERED
PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.

SRS Connectors
CAUTION: The special yellow color connectors are
used for the supplemental restraint system-air bag
circuit.
When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
When connecting the SRS connector, insert the
connector completely. Imperfect locking may cause
malfunction of the SRS circuit.


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-29
Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait at least 5 minutes (with SRS air bag).
4. Disconnect the yellow 2-way SRS connector located under the steering column (with SRS air bag).
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to lose its centering which will cause damage to the
coil assembly (with SRS air bag).
5. Disable the SRS (Refer to "Disabling the SRS" in this section) (with SRS air bag).
6. Check the holes on both sides of the steering cove
r
(with SRS air bag).
060R300025


7. Check the position of the pins in their holes. Push
the pin in the direction of the arrow (with SRS ai
r
bag).

RTW 73BSH000101
8. Push the four pins with a φ 5~6 mm (0.20~0.24 in)
bar (with SRS air bag).
060R300031
9. Cancel the lock to release the four pins (with SRS air bag).


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ISUZU KB P190 2007

3B-30 POWER-ASSISTED STEERING SYSTEM
10. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
430R300009
11. Disconnect the SRS air bag connector (1) and horn lead connector (2) located behind the air bag
assembly and remove the air bag assembly (with
SRS air bag).

RTW 73BSH001101


12. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It should be removed first from the bottom
spokes.

RTW 73BSH000601
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE COVER SIDE
UP. THIS IS NECESSARY BECAUSE A FREE SPACE
IS PROVIDED TO ALLOW THE AIR CUSHION TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY MAY RESULT (with SRS ai
r
bag).
430R300007


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ISUZU KB P190 2007

POWER-ASSISTED STEERING SYSTEM 3B-31
Inspection and Repair (with SRS air
bag)
The inflator module consists of a cover, air bag, inflator,
and retainer. Inspect the inflator module mainly for the
following:
・ Check for holes, cracks, severe blemishes and
deformation on the cover.
・ Check that the retainer is not deformed.
・ Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as a result of the inspection,
replace the inflator module with a new one.

Installation
1. Support the inflator module and carefully connect the
SRS connector (1) and horn lead (2) (with SRS ai
r
bag).

RTW 73BSH001101


2. Connect the horn leads at center of wheel (without
SRS air bag).
NOTE: The horn leads (1) are passed along the top o
f
the bracket (2).
(Plastic type steering wheel only)



RTW 73BSH000801
3. Push the horn pad at areas 1-4.
Tighten the horn pad fixing screw to the specifed torque (without SRS air bag)
Torque: 3 N ⋅m (0.3 kgf ⋅m/26 lb ⋅in)
NOTE: A horn pad should not be struck during
attachment.

RTW 73BSH000201


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ISUZU KB P190 2007