wheel bolt torque ISUZU TF SERIES 2004 Owner's 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.

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)

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.

CLUTCH 7C-25


(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly

4 with the flywheel
knock pin

5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N
m (kgf
m/lb
ft)
18 
3 (1.8 
0.3 / 13.0 
2.2)

201RS017




(8) Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.


4JH1-TC, C24SE
6VE1

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness
Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model)
Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model)
Remove the shift lever from the floor.

14. Transmission member
1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts
fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model)
1) Remove the under cover under the torque converter
housing.
2) Rotate the flywheel by using tire lever or some other
tool, and then remove the torque converter bolts.
16. Transmission coupling bolt
1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer)
Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007 P1010025

6A – 110 ENGINE MECHANICAL









17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.


Rear Plate Torque N·m(kg·m/lbft)
82 (8.4/61)














18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
in the illustration.
Gear stoper: 5-8840-0214-0


Flywheel Bolt Torque N·m(kg·m/lbft)
118 (12/87)











19. Crankshaft Timing Gear
Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0


















20. Idler Gear Shaft
21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.


015LX113 020R100001
020RY00034
020RY00035

ENGINE MECHANICAL 6A – 115



RTW46ASH002201




















4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracke
t
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
6. Tighten the bracket bolts (5) to the specified torque.
7. Tighten the bracket bolts (6) to the specified torque.


Injection pump Bracket Bolt Torque (6) N·m(kg·m/lbft)
19 (1.9/14)

Injection pump Bracket Bolt Torque (5) N·m(kg·m/lbft)
40 (4.1/30)



030RY00007














24. Water Pump
1. Apply the recommended liquid gasket or its equivalent
to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.


Water Pump Bolt Torque N·m(kg·m/lbft)
20 (2.0/14)













25.Timing Gear Case Cover
1.
Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.


Gear Case Cover Bolt Torque N·m(kg·m/lbft)
M8 19 (1.9/14)
M12 76 (7.7/56)

























26. Crankshaft Damper Pulley
Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.


Crankshaft Damper Pulley Bolt Torque N·m(kg·m/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.


014R100014 020R300004

6C – 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section “Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dus
t
entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house at rear left side.
6. Remove fixing bolt of the filler neck from the body.
7.
Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering
and fuel leakage.
NOTE: Refer to“Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9.
Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.
Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, don’t scratch
each hose and tube by around other parts.













Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, don’t scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected agains
t
stopper.
3. Install the tank band and fasten bolt.
Torque N·m (kg·m / lb ft)
68 (6.9 / 50)
NOTE: The anchor of the tank band must be certainly installed
to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this
section when performing any repairs.

6A-44 ENGINE MECHANICAL (6VE1 3.5L)
1. Remove engine assembly.

Refer to removal procedure for Engine
Assembly in this manual.
2. Remove timing belt.

Refer to removal procedure for Timing Belt in
this manual.
3. Remove oil pan and crankcase.

Refer to removal procedure for Oil Pan and
Crankcase in this manual.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6. Remove oil pump assembly.

Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.

Refer to removal procedure for Rear Oil Seal in
this manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.

Install main bearing in the cylinder block and
main bearing cap respectively.

Apply new engine oil to upper and lower main
bearings.
NOTE:

Do not apply engine oil to the bearing back faces.

Make sure that main bearings are in correc
t
position.

Install crankshaft with care.

Apply engine oil to the thrust washer.

Install thrust washer on No.3 journal.

Oil grooves in thrust washer must face the
crankshaft.





015RS012



015RS013
2. Install crankshaft main bearing caps.


Apply engine oil to the thread and seating
surface of each bearing cap fixing bolt.
NOTE:

Do not apply engine oil to the bearing back faces.

Install bearing caps in the order of numbers,
starting with cylinder block front side.

Tighten main bearing fixing bolts to the specified
torque.
Torque: 39 N




m (4.0 kg




m/29 lb ft)


After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.

The cap number must be same as connecting
rod number.


Apply engine oil to the thread and seating
surface of each nut.

ENGINE MECHANICAL (6VE1 3.5L) 6A-45

Tighten nuts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


After tightening the nuts, make sure that the
crankshaft rotates smoothly.
4. Install rear oil seal retainer.

Remove oil on cylinder block and retainer fitting
surface.


Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.

The oil seal retainer must be installed within 5
minutes after sealant application to preven
t
premature hardening of sealant.




015RW002
Legend
(1) Around Bolt Holes
(2) Around Dowel Pin


Apply engine oil to oil seal lip and align a dowel
pin hole in the cylinder block with that in the
retainer.

Tighten retainer fixing bolts to the specified
torque.
Torque: 18 N




m (1.8 kg




m/13 lb ft)




015RW001
5. Install flywheel.

Clean tapped holes in the crankshaft.

Remove oil on crankshaft and flywheel fitting
surface.
NOTE:

Do not reuse the bolts.

Do not apply oil or thread lock to the bolts.

Tighten fixing bolts to the specified torque.
Torque: 54 N




m (5.5 kg




m/40 lb ft)


015RS018