torque ISUZU TF SERIES 2004 Owners Manual

5D-10 PARKING BRAKE SYSTEM

Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin (1) and shoe clamp spring (2).
4. Remove return spring (3).
5. Remove shoe assemblly with parking brake leve
r
(4).
6. Remove shoe assembly with adjuster lever (5) and
spring (6).
7. Remove parking brake inner cable from parking
brake lever (4).
8. Use offset box wrench (12mm 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.





311RS012

Legend
(1) Offset Box Wrench (12mm hex)
9. Remove nut (8) to fix the cable (7) on the leaf
spring.
10. Take out parking brake rear cable (7) from the
back plate.
11. Remove bolt (9) and nut (10).
12. Disconnect T-end (11) from the equalizer of front
cable.

Installation
NOTE: Be sure to use the new shoe clamp spring (2)
and the new adjuster lever clip (14).
1. Apply grease (multipurpose type grease) to the
connecting portion of the rear cable (11) and
equalizer (13). (aroow mark).
2. Install parking brake outer cable in back plate and
inner cable in parking brake lever (4).
3. Install return spring (3).
4. Install shoe clamp spring (2) and tension pin (1)
5. Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever (4) and spring
(6). ---- snap action
6. Install nut (8) and tighten it to the specified torque.
Torque: 7N




m (0.7 kg




m/61 lb in)
7. Connect T-end (11) with equalizer (13) through
outer cable retainer (12).
8. Install nut (10) and tighten it to the specifed
torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
9. Install bolt (9) and tighten it to the specified
torque.
Torque: 7 N




m (0.7 kg




m/61 lb in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to
poerating 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 8

14 (bench
seat) or 6

8 (bucket seat) notches, when pulled
with a operation force of 294N (30 kg/66 lb).
14. Check brake for no drag.

PARKING BRAKE SYSTEM 5D-13

Torque Specifications
N




m (kg




m/lb ft)



This illustration is based on RHD model.
RTW35DSF000201

N




m (kg




m/lb ft)





E05R300006

10-6 CAB




7) Apply the window glass sealing adhesive
2.
If you are using an air gun, air pressure should be
maintained at 147 - 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in) junction a
t
middle of the vase of the glass.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.




8) Adjust the setting of the windshield glass with suction discs.
Set the windshield with sealing adhesive applied to entire
circumference in the body panel. Specifically, adjus
t
windshield support with the upper molding making contact
with the body panel, press the glass, and tighten the
windshield support.



9) Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.
Cure the bonding at a temperature of 68
- 86
F (20
-
30
C) for twenty-four hours.
Check that the windshield does not leak water.









8. Wiper Arm Assembly


Set the wiper arm/blade so that the tips of both blades
are positioned the specified value of
A and Bfrom the
upper edge of the cowl cover as shown in the figure.

A 40 mm (1.57 in)

B 52 mm (2.05 in)


Tighten the wiper arm assembly fixing nuts to the
specified torque.
Torque Nm (kgfm/lbft)
31 (3.1/23)

CAB 10-11


2. Check Arm Screw




3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.





Important Operations – Installation
3. Lower Hinge Bolt; Hinge to Door
Torque N

m (kgf

m/lb

ft)
34 (3.5/25)

2. Check Arm Screw; Check Arm to Body
Torque N
m (kgf
m/lb
ft)
24 (2.4/17)

CAB 10-17


Important Operations
3. Door Lock Cylinder


Tighten the door lock cylinder fixing bolts to the specified
torque.
Torque N
m (kgf
m/lb
in)
9 (0.9/78)


4. Door Lock Cylinder Protector (EUROPE)


Tighten the door lock cylinder protector fixing bolt to the
specified torque.
Torque Nm (kgfm/lbin)
9 (0.9/78)


5. Outside Handle


Tighten the outside handle fixing bolts to the specified
torque.
Torque N
m (kgf
m/lb
in)
9 (0.9/78)


6. Outside Handle Protector (EUROPE)

Tighten the outside handle protector fixing bolt to the
specified torque.
Torque N
m (kgf
m/lb
in)
9 (0.9/78)




11. Window Glass


Insert the window glass into position by tilting it as
necessary, then set it against the channel of the windo
w
regulator.






Attach the window glass to the window regulator with the
2 bolts.

CAB 10-21


3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.





Important Operations – Installation
3. Lower Hinge Bolt; Hinge to Door
Torque N
m (kgf
m/lb
ft)
34 (3.5/25)

2. Check Arm Screw; Check Arm to Body
Torque N
m (kgf
m/lb
ft)
24 (2.4/17)

10-26 CAB

Important Operations
3. Outside Handle


Tighten the outside handle fixing bolts to the specified
torque.
Torque N
m (kgf
m/lb
in)
9 (0.9/78)



17. Window Regulator Handle


Install the regulator handle as illustrated when closing
the window glass.

CAB 10-33
Important Operations
15. Instrument Panel & Crass Beam Assembly
1) Tighten the 4 bolts fixing the cross beam and body panel
to the specified torque.
Torque N
m (kgf
m/lb
ft)
19 (1.9/14)

2) A Bolt: Steering Column to Cross Beam
Torque N
m (kgf
m/lb
ft)
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
Torque N
m (kgf
m/lb
ft)
15 (1.5/11)


3) C Bolt: Parking Brake Bracket to Cross Beam
Torque Nm (kgfm/lbft)
15 (1.5/11)

21. Steering Wheel/Steering Cowl

Tighten the steering wheel fixing nut to the specified
truque.
Torque N
m (kgf
m/lb
ft)
35 (3.6/26)

10-44 CAB
INTERIOR TRIM PANELS
REMOVAL AND INSTALLATION

RTW3A0MF001301

EXTEND CAB Model
Removal Steps
1. Sill plate
2. Dash side trim cover

3. Front pillar trim cover

4. Rear upper cushion
5. Jack cover

6. Rear end trim cover

7. Rear speaker grille/Rear speaker

8. Body side rear lower trim cover
9. Door finisher

10. Tongue side seat belt

11. Body side rear upper trim cover


Installation Steps
11. Body side rear upper trim cover

10. Torque side seat belt
9. Door finisher
8. Body side rear lower trim cover
7. Rear speaker grille/Rear speaker

6. Rear end trim cover
5. Jack cover
4. Rear upper cushion
3. Front pillar trim assembly
2. Dash side trim cover
1. Sill plate

CAB 10-47
Important Operations - Installation
10. Tongue Side Seat Belt


Tighten the seat belt upper anchor bolt to the specified
torque.
Torque N
m (kgf
m/lb
ft)
40 (4.1/30)




6. Rear End Trim Cover


Insert the hooks on the back upper portion of trim cove
r
to the body panel.