torque ISUZU TF SERIES 2004 Workshop Manual

ENGINE EXHAUST 6F-15
Main Data and Specifications
Torque Specification

N
m (kgf
m)
43N ⋅m (4.4 kgf ⋅m)
43N ⋅m (4.4 kgf ⋅m)

ENGINE LUBRICATION 6G-3

Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.

ENGINE LUBRICATION 6G-5

Inspection and Repair
CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found through inspection.
Body and Gears
The pump assembly must be replaced if one or more of the
conditions below is discovered during inspection:
Indentation of gear pair - Use feeler strip and straight edge.
Dimension: 0.03 mm to 0.10 mm
(0.0012 to 0.0039 in)



Oil Strainer
Check the oil strainer for cracking and scoring. If cracking and
scoring are found, the oil strainer must be replaced.




Reassembly
1. Install oil pressure switch to the oil pump.
Torque: 40 N




m (4.1 kgf




m)
2. Install the oil pump with the sleeve and the gasket.
Torque: 6 N




m (0.6 kgf




m)
3. Install oil strainer.
Torque: 8 N




m (0.8 kgf




m)
4. Install the oil pan.
Tighten the bolts:
15 N




m (1.5 kgf




m)
5. Install crankshaft timing pulley.
Tighten the bolts:
20 N




m (2.0 kgf




m)

ENGINE LUBRICATION 6G-7










Inspection and Repair
CAUTION: Make necessary correction or parts replacement if wear, damage or any other
abnormal conditions are found through
inspection.

Reassembly
To install, follows the disassembly steps in the reverse order.

Important
Sealer - Apply silicon into groove in oil pan lugs prior to fitment of oil pan to block, remove excess sealer after oil pan
is bolted to block.

(2.4L 4 ×4 Model)
4
3
1
2

(2.4L 4 ×2 Model)
4
3
1
2

Torque
Bolts - Tighten bolts to the specified torque.
Torque : 20 N
m (2.0 kgf
m)
Engine oil - Refill engine oil to the oil pan. (Lit)
Replacement Oil Fill Volume 2.4L
Without filter change 4.00
With filter change 4.25

ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (C24SE)
CONTENTS

Service Precaution............................................... 6H-1
Accelerator Pedal Control Cable...................... 6H-2
Removal.............................................................. 6H-2
Inspection........................................................... 6H-3
Installation.......................................................... 6H-3




Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.


CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

6J-2 INDUCTION

Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.


RTW46JSH000101










Air Cleaner Filter
NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.

Removal
1. Remove positive ventilation hose connector.
2. Remove intake air temperature sensor.
3. Remove mass air flow sensor.
4. Remove air cleaner duct assembly.
5. Remove air cleaner element.

Inspection
Check the air cleaner filter for damage or dust clogging.
Replace if it is damaged, or clean if it is clogged.



Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.

FRAME AND BUMPER 2A-3



Important Operations - Removal
1. Radiator Grille

Refer to the Radiator Grille in this section.



2. Front Bumper Fascia



Remove the nine clips and four screws.


Disconnect the fog light harness connectors.


Important Operations - Installation






8. Front Bumper Inpact Bar Assembly (For Europe
equipment)
7. Front Bumper Inpact Bar Assembly (Except Europe
equipment)
Tighten the fixing bolts to the specified torque.

Torque N
m(kgf
m/lb
ft)
62 (6.3
/ 46)
This illustration is except Europe equipment model.




5. Front Bumper Flare Assembly
Tighten the fixing nuts to the specified torque.

Torque N
m(kgf
m/lb
in)
7 (0.7
/ 61)






4. Fog Light
Tighten the fixing nuts to the specified torque.

Torque N
m(kgf
m/lb
in)
7 (0.7
/ 61)

FRAME AND BUMPER 2A-5

RTW32ASH000101

2. Side Step Pad

Push out the 4 fixing portions of side step pad from the
back face of the rear step bumper.
RTW32ASH000201

4. Rear Bumper Center Pad


Remove the 2 clips from both end of the center pad.

Push out the 7 fixing portions of center pad from the
back face of the rear step bumper.
RTW32AM H000101






















Important Operations - Installation
7. Rear bumper


Tighten the fixing bolts to the specified torque.
A: Bolt
Torque Nm(kgfm/lbft)
40 (4.1
/ 30)
6. Back Bar / Conner Brace
1) B: Bolt
Torque N
m(kgf
m/lb
ft)
40 (4.1
/ 30)

2) C: Bolt
Torque Nm(kgfm/lbin)
9 (0.9
/ 78)

3) D: Bolt
Torque N
m(kgf
m/lb
ft)
85 (8.7
/ 63)

2A-6 FRAME AND BUMPER
RTW32AMH000201







1. Rear Step Bumper Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 3 fixing bolts on the each side of back bar.

Torque N
m(kgf
m/lb
ft)
150 (15.3
/ 111)

2A-8 FRAME AND BUMPER






Important Operations - Installation
3. Nut


Tighten the fixing bolts to the specified torque.
Torque N
m (kgf
m/lb
ft)
116 (11.8
/ 85)















RTW42AMH000101







2. Rear Bumper Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 2 fixing bolts on the each side of back bar.

Torque N
m (kgf
m/lb
ft)
150 (15.3
/ 111)

1. Rear Guard Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 2 fixing bolts on the each side of back bar.

Torque N
m (kgf
m/lb
ft)
150 (15.3
/ 111)