lock ISUZU TF SERIES 2004 Workshop Manual

CAB 10-25
REASSEMBLY

RTW3A0LF000701

Reassembly Steps
1. Anti rattler
2. Door harness assembly

3. Outside handle
4. Window glass
5. Glass run
6. Door lock assembly
7. Glass run rear channel
8. Window regulator/Power window regulator


9. Outer waste seal
10. Inside lever
11. Waterproof sheet
12. Speaker assembly
13. Bracket
14. Door trim panel
15. Bezel
16. Power window switch

17. Switch bezel/Window regulator handle

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

CAB 10-31



13.Ashtray Case

Pull out the ashtray case.
14. Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15. Control Lever Assembly


Remove the 2 fixing screws.
17.Ashtray Bracket


Remove the 3 fixing screws and illumination connector.


Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21. Passenger Air Bag



Remove 2 fixing bolts, 2 fixing nuts and connector.
22. Side Ventilation Grille.

Pull out the grilles and disconnect switch connecto
r
(Driver’s side).
23. Vent Duct Assembly/Defroster Nozzle Assembly


Refer to section 1 “HVAC” for defroster nozzle and
ventilation duct removal steps.




25. Instrument Panel


Remove the clip and 6 fixing bolts.
26. Cross Beam

CAB 10-59


Important Operations - Removal
1. Front Sill Plate



Pull out the 4 clip positions.


2. Fuel Filler Lid Opener Cover


Pull out the 3 clip positions.



3. Fuel Filler Lid Opener Lever


Remove the 2 opener fixing bolts and disconnect the
cable.



5. Fuel Filler Lid Cable Assembly


Remove some fixing clips, turn the cable holder on the
side of recess in 90counterclockwise and remove i
t
from the recess. Pull out the grommet to frontward o
f
vehicle and remove the cable assembly.

10-62 CAB



Important Operations - Removal
1. Front Sill Plate



Pull out 4 clip positions.
2. Rear Sill Plate


Pull out 2 clip positions.

4. Fuel Filler Lid Opener Cover


Pull out the 3 clip positions.



5. Fuel Filler Lid Opener Lever


Remove the 2 opener fixing bolts and disconnect the
cable.



7. Fuel Filler Lid Cable Assembly


Remove some fixing clips, turn the cable holder on the
side of recess in 90counterclockwise and remove i
t
from the recess. Pull out the grommet to frontward o
f
vehicle and remove the cable assembly.

10-74 CAB
REAR SEAT (CREW CAB)
REMOVAL AND INSTALLATION

RTW3A0SF000101

Removal Steps

1. Nut
2. Rear seat assembly

Installation Steps
2. Rear seat assembly

1. Nut





Important Operation - Removal
1. Nut
Pull the strap to release the seat back lock and fold
down the seat back.



Important Operation - Installation
1. Nut

Torque N 
m (kgf 
m/lb 
ft)
40 (4.1 / 30)

CAB 10-89
TAIL GATE ASSEMBLY
REMOVAL AND INSTALLATION




CENTER PULL HANDLE MODEL
Removal Steps
1. Hole cover plate

2. Outside handle assembly
3. Tail gate lock assembly
4. Tail gate link

5. Tail gate
6. Tail gate hinge
7. Tail gate lock striker


Installation Steps


7. Tail gate lock striker

6. Tail gate hinge

5. Tail gate
4. Tail gate link

3. Tail gate lock assembly

2. Outside handle assembly
1. Hole cover plate

10-90 CAB



Important Operations - Removal
2. Outside Handle Assembly


Disconnect the lock link and remove the 2 fixing bolts.
5. Tail Gate
1) Removing the tailgate assembly may require two people.
2) Remove the tailgate hinge fixing bolts.



Important Operations - Installation
7. Tail Gate Lock Striker


Tighten the lock striker fixing bolts to the specified
torque.
Torque Nm(kgfm/lbft)
15 (1.5 / 11)
















6. Tail Gate Hinge


Tighten the hinge fixing bolts to the specified torque.
C: Bolt
Torque Nm(kgfm/lbft)
40 (4.1 / 30)
5. Tail Gate
1) A: Bolts
Torque N
m(kgf
m/lb
in)
13 (1.3 / 113)
2) B: Bolt
Torque N
m(kgf
m/lb
in)
25 (2.5 / 18)
3) Check the tailgate and rear body.
a. Clearance: 5.0 mm (0.20 in.)
b. Height (Step): Flush
c. Height (Step): Flush
3. Tail Gate Lock Assembly


Tighten the lock assembly fixing bolts to the specified
torque.
Torque N
m(kgf
m/lb
ft)
15 (1.5 / 11)
2. Outside Handle Assembly


Tighten the outside handle assembly fixing bolts to the
specified torque and if remove the key cylinder (i
f
equipped) tighten it to the specified torque.
Torque N
m(kgf
m/lb
in)
9 (0.9 / 78)

CLUTCH 7C-19
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.




CLUTCH PEDAL PLAY
Inspection
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is within the standard value.
Pedal Free Play mm(in)
H 5.0-15.0 (0.2-0.6)



Adjustment of the clutch switch (or stopper bolt)
Turn the clutch switch or stopper bolt
1 until the switch bolt
or
stopper bolt
just touches the clutch pedal arm.
Adjust clutch switch
or stopper bolt
by backing it out half a turn,
and measure the clearance (L) between the clutch pedal arm
and the clutch switch bolt end
or stopper bolt.
Lock the lock nut

2.
Connect clutch switch connector.
Clutch switch and clutch pedal
Clearance mm(in)
(L) 0.5-1.5 (0.020-0.059)

CLUTCH 7C-23
015RW053
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Remove flywheel assembly and crankshaft bearing. Do no
t
remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding
hammer 5-8840-0019-0 (J-23907) to remove the crankshaf
t
bearing



Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

015RW054
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Install flywheel assembly and crankshaft bearing. Use the
installer 5-8840-0125-0 (J-26516-A) and driver handle 5-
8840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RS047
(2) Install new flywheel fixing bolts in the order illustrated and
tighten them to the specified torque.
N
m (kg
m/lb ft)

6VE1 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.