2007 ISUZU KB P190 parking brake

5D-8 PARKING BRAKE SYSTEM
Parking Brake Lever
Parking Brake Lever Assembly and Associated Parts (Bucket Seat)



RTW 35DSF000101

Legend
(1) Rear Floor Console
(2) Parking Brake Cable T-end
(3) Adjust Nut

(4) Switch
(5) Parking Brake Lever Assembly
(6) Bolt
(7) Equalizer


Removal
1. Remove rear floor console.
Refer to section 10.
2. Loosen adjust nut.
3. Remove bolt.
4. Remove switch.
5. Disconnect parking brake cable T-end from parking brake lever assembly.
6. Take out parking brake lever assembly.

Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake rear cable
T-end and parking brake lever equalizer. (arrow
mark).
2. Connect parking brake rear cable T-end to equalizer.
3. Install switch.

4. Tighten the parking brake lever fixing bolt to the
specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
5. Drive adjust nut on parking brake assembly so that parking brake cable T-end fits into equalizer.
6. Install rear floor console.
Refer to section 10.
7. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
8. Adjust nut so that parking brake lever goes through 6 −9 notches, when pulled with an
operation force of 294 N (30 kg/66 lb).
9. Check brake for no drag.


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-9
Parking Brake Rear Cable
Parking Brake Rear Cable and Associated Parts

RTW 55DLF000101

Legend
(1) Tension Pin
(2) Shoe Clamp Spring
(3) Return Spring
(4) Shoe Assembly with Parking Brake Lever
(5) Shoe Assembly with Adjuster Lever
(6) Spring
(7) Parking Brake Rear Cable

(8) Nut
(9) Parking Brake Cable Bolt
(10) Parking Brake Cable Nut
(11) T-end
(12) Outer Cable Retainer
(13) Equalizer
(14) Adjuster Lever Clip



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ISUZU KB P190 2007

5D-10 PARKING BRAKE SYSTEM
Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin and shoe clamp spring.
4. Remove return spring.
5. Remove shoe assembly with parking brake lever.
6. Remove shoe assembly with adjuster lever and spring.
7. Remove parking brake inner cable from parking brake lever.
8. Use offset box wrench (12 mm hex.) to compress locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.




RTW 55CSH000301

Legend
(1) Offset Box W rench (12 mm hex)
9. Remove nut to fix the cable on the leaf spring.
10. Take out parking brake rear cable from the back plate.
11. Remove parking brake cable bolt and nut.
12. Disconnect T-end from the equalizer of front cable.

Installation

NOTE: Be sure to use a new shoe clamp spring and a
new adjuster lever clip.
1. Apply grease (multipurpose type grease) to the connecting portion of the rear cable and equalizer.
(arrow mark).
2. Install parking brake outer cable in back plate and inner cable in parking brake lever.
3. Install return spring.
4. Install shoe clamp spring and tension pin.
5. Install shoe assembly with adjuster lever, shoe assembly with parking brake lever and spring. ----
snap action
6. Install nut and tighten it to the specified torque. Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
7. Connect T-end with equalizer through outer cable retainer.
8. Install parking brake cable nut and tighten it to the specified torque.
Torque: 15 N ⋅
⋅⋅
⋅
m (1.5 kgf ⋅
⋅⋅
⋅
m/11 lb ⋅
⋅⋅
⋅
ft)
9. Install parking brake cable bolt and tighten it to the specified torque.
Torque: 7 N ⋅
⋅⋅
⋅
m (0.7 kgf ⋅
⋅⋅
⋅
m/61 lb ⋅
⋅⋅
⋅
in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to operating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13.
Adjust parking brake lever adjusting nut so that
parking brake lever goes through 6-9 notches
(Bucket Seat) or 8 −14 notches (Bench Seat), when
pulled with an operation force of 294 N (30 kg/
66 lb).
14. Check brake for no drag.


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-11
Inspection and Repair
Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is
less than 1.0 mm (0.039 in).
Minimum limit: 1.0 mm (0.039 in)








308RS004
Parking Brake Adjustment
NOTE: All brakes are self-adjusting. Brakes are
adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rea
r
brake auto-adjuster produces a clicking sound. The
same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rea
r
brake assembly.
1. Move the parking brake lever to its fully released position.
2. Parking brake cable must be loosened sufficiently.
(Loosen the adjust nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it until the clicking sound can no longe
r
be heard.
If the difference between the brake drum inside
diameter and the brake shoes external diameter is
adjusted to be 0.4 mm (0.0157 in), the number o
f
times for depressing the brake pedal can be
reduced.

4. Remove the drum. Measure the brake drum inside
diameter and the brake shoes external diameter.
Total shoe clearance: 0.4 mm (0.0157 in)
If incorrect, readjust the brake shoe clearance.
5. Rotate the adjust nut of hand brake lever until all slack disappears from the cable. Set the adjust
nut.
6. After the rear brake shoe/drum gap has been adjusted, perform parking brake cable adjustment.
7. Turn the adjusting nut so that the parking brake lever travels 6 −9 notches (Bucket Seat) or 8 −14
notches (Bench Seat) when pulled up with a force
of 294 N (30 kg/66 lb).
8. Make sure there is no brake dragging.



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ISUZU KB P190 2007

5D-12 PARKING BRAKE SYSTEM
Main Data and Specifications
General Specifications

Type Leading-Trailing
Drum inside diameter 254 mm (10 in) or 295 mm (11.6 in)
Parking brake lever stroke
6−9 notches; Bucket Seat
8 −14 notches; Bench Seat
W hen pulled with a force of 294 N (30 kg/66 lb)


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ISUZU KB P190 2007

PARKING BRAKE SYSTEM 5D-13
Torque Specifications
N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)

This illustration is based on the RHD model
RTW 35DSF000201

N⋅
⋅⋅
⋅
m (kgf ⋅
⋅⋅
⋅
m/lb ⋅
⋅⋅
⋅
ft)



E05R300006



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ISUZU KB P190 2007

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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ISUZU KB P190 2007

FUEL SYSTEM (4JK1/4JJ1) 6C-7
g. Check that the warning lamp in the meter is off.
2. Draining with drain plug in engine room. a. W ith the engine off, open the engine hood and loosen the drain plug (1) located on the left
hand side of the engine room. (3-4 turns)
b. Turn the starter switch to the “ON” position fo
r
10 seconds, and then turn the starter switch to
the “OFF” position for 10 seconds. Then, once
again turn the starter switch to the “ON”
position for 10 seconds.
c. Tighten the drain plug firmly.
d.
After starting the engine, check that there is no
fuel leakage from the drain plug. Also check
that the water separator indicator has turned
off.










RTW 76CSH001301
NOTE:
• If the water separator requires frequent draining,
have the fuel tank drained at your ISUZU/GM
Dealer.
• Be sure to stop the engine when draining the fuel
tank.
• Confirm that there are no combustible materials
under the drain hose, and use a receptacle to
catch the drained water.


Engine starting cautions
• Before starting the engine, turn the ignition switch
to the “ON” position. W ait 15 seconds. Return the
switch to the “LOCK” position. Repeat this
procedure 5 times.
• After starting the engine, allow it to idle for 10
minutes.

Fuel Pump Functional Check
1. Turn the starter switch to “ON” position.
2. Touch the under portion of the Fuel Tank by the hand as shown in the following figure within 12
seconds.





RTW 56CSH003501
Legend
1. Touch this area by the hand

3. Make sure a vibration by the Fuel Pump is
detected.
Fuel Pump stops within 12 seconds of turning the starter switch to the “ON” position.
W hen the check is repeated, return the starte
r
switch to the “LOCK” position for 10 – 15 seconds
and perform procedures 1 – 3.
WARNING: FUEL PUMP FUNCTIONAL CHECK
MUST BE CONDUCTED UNDER THE FOLLOWING
CONDITIONS TO AVOID INJURY.
•
••
•
APPLY THE PARKING BRAKE.
•
••
•
STOP THE ENGINE.


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ISUZU KB P190 2007