section 8 ISUZU TF SERIES 2004 Owners Manual

CAB 10-83
RTW3A0SH000601

Important Operations - Removal
3. Cover


Pry the lower portion of the cover and remove it.


4. Rear End Trim Cover


Refer to Interior Trim Panels in this section.
RTW3A0SH001601
Important Operations - Installation
6. Rear center seat belt

Install the seat belt webbing through the through ring on
the back panel as shown in the illustration.















5. Bolt: Rear Center Seat Belt to Floor Panel
Torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)

1. Nut: Rear Seat Assembly/Rear Seat Belt Buckle to Floo
r
Panel
Torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)

CAB 10-85
Important Operations - Removal
1.
Body side rear lower trim cover



Refer to Interior Trim Panels in this section..
RTW3A0SH000301

3. Upper anchor bolt


Open the through ring anchor cover and remove the
seat belt upper anchor bolt








Important Operations - Installation
4. Retractor fixing bolt
Bolt torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)
3. Upper anchor bolt
Bolt torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)
2. Lower anchor bolt
Bolt torque N
m (kgf
m/lb
ft)
40 (4.1 / 30)

10-86 CAB
REMOVAL AND INSTALLATION
(REAR SEAT BELT BACKLE)

RTW3A0SF000201

Removal Steps

1. Cover
2. Bolt
3. Rear seat belt buckle

Installation Steps
3. Rear seat belt buckle

2. Bolt
1. Cover



Important Operation - Removal
1. Cover


Refer to Jump Seat (Extend Cab) in this section.





Important Operation - Installation
2. Bolt: Jump Seat Assembly/Rear Seat Belt Buckle to
Floor Panel
Torque N 
m (kgf 
m/lb 
ft)
40 (4.1 / 30)

WORKSHOP MANUAL

TF SERIES




CLUTCH






SECTION 7C

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description......................................................................................................... 7C- 3
Torque Specification ....................................................................................................... 7C-15
Servicing........................................................................................................................... 7C-19
Clutch................................................................................................................................ 7C-21
Removal and Installation ............................................................................................ 7C-21
Inspection and Repair................................................................................................. 7C-26
Clutch Control .................................................................................................................. 7C-32
Removal and Installation ............................................................................................ 7C-32
Master Cylinder ................................................................................................................ 7C-33
Disassembly ................................................................................................................ 7C-33
Reassembly ................................................................................................................. 7C-34
Slave Cylinder (4J, C24SE) ............................................................................................. 7C-35
Disassembly ................................................................................................................ 7C-35
Inspection and Repair................................................................................................. 7C-36
Reassembly ................................................................................................................. 7C-37
Slave Cylinder (6VE1) ...................................................................................................... 7C-38
Disassembly ................................................................................................................ 7C-38
Inspection and Repair................................................................................................. 7C-39
Reassembly ................................................................................................................. 7C-40
Hydraulic Damper Cylinder ............................................................................................. 7C-41
Inspection and Repair................................................................................................. 7C-41
Troubleshooting .............................................................................................................. 7C-42
Special Service Tool ........................................................................................................ 7C-51

7C-22 CLUTCH


Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.


2. Clutch Pressure Plate Assembly
3. Driven Plate Assembly
(1) Use the clutch pilot aligner

1 to prevent the driven plate
assembly

2 from falling free.
Clutch Pilot Aligner : 5-85253-001-0





(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly

3 from the flywheel.
(4) Remove the driven plate from the flywheel.

201RS017


220RW088-X

4. Release Bearing (6VE1)
5. Shift Fork (6VE1)

(1) Remove the release bearing (1) from the transmission
case.
(2) Remove the shift fork snap pin (2).
(3) Remove the shift fork pin and shift fork (3) from the fulcrum
bridge.
6VE1 4JH1-TC, C24SE

7C-42 CLUTCH

TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage

WORKSHOP MANUAL

TF SERIES




ELECTRICAL-BODY AND CHASSIS






SECTION 8

ELECTRICAL-BODY AND CHASSIS 8A-1
SECTION 8A
ELECTRICAL-BODY AND CHASSIS
TABLE OF CONTENTS
PAGE
General Information ........................................................................................................ 8A- 4
Notes for Working on Electrical Items .......................................................................... 8A- 5
Symbols and Abbreviations ........................................................................................... 8A- 11
Symbols ...................................................................................................................... 8A- 11
Abbreviations ............................................................................................................. 8A- 12
Parts for Electrical Circuit .............................................................................................. 8A- 13
Wiring .......................................................................................................................... 8A- 13
Fuse ............................................................................................................................. 8A- 15
Fusible Link ................................................................................................................ 8A- 15
Relay ............................................................................................................................ 8A- 16
Diode ........................................................................................................................... 8A- 17
Connector ................................................................................................................... 8A- 18
Battery ......................................................................................................................... 8A- 19
Reading the Circuit Diagram .......................................................................................... 8A- 22
Parts Location ............................................................................................................ 8A- 22
Circuit Diagram ........................................................................................................... 8A- 23
Connector List ............................................................................................................. 8A- 23
Main Data and Specifications ........................................................................................ 8A- 24
Bulb Specifications .................................................................................................... 8A- 24
Relay and Fuse ................................................................................................................ 8A- 26
Relay and Fuse Box Location ................................................................................... 8A- 26
Relay Location ............................................................................................................ 8A- 28

ELECTRICAL-BODY AND CHASSIS 8A-9

SPLICING WIRE
Open the Harness
If the harness is taped, remove the tape.
To avoid wire insulation damage, use a sewing "seam ripper"
(available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the
desired wire.
Cut the wire
Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to cut
more wire off to change the location of a splice.
You may have to adjust splice locations to make certain that
each splice is at least 1-1/2" (40 mm) away from other splices,
harness branches, or connectors.
Strip the insulation
When replacing a wire, use a wire of the same size as the
original wire.
Check the stripped wire for nicks or cut strands.
If the wire is damaged, repeat the procedure on a new section
of wire.
The two stripped wire ends should be equal in length.



Crimp the Wires
Select the proper clip to secure the splice.
To determine the proper clip size for the wire being spliced,
follow the directions included with your clips.
Select the correct anvil on the crimper.
(On most crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them between
your thumb and forefinger.
Then, enter the splice clip under the stripped wires and hold it
in place.




Open the crimping tool to its full width and rest one handle
on a firm flat surface.

Center the back of the splice clip on the proper anvil and
close the crimping tool to the point where the back of the
splice clip touches the wings of the clip.

Make sure that the clip and wires are still in the correc
t
position. Then, apply pressure until the crimping tool closes.



Before crimping the ends of the clip, be sure that:

The wires extend beyond the clip in each direction.

No strands of wire are cut loose.

No insulation is caught under the clip.
Crimp the splice again, once on each end.
Do not let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.