engine remove ISUZU TF SERIES 2004 Workshop Manual

HEATER AND AIR CONDITIONING 1-49

OIL RETURN OPERATION
There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the
refrigerant in the system.
When checking the amount of oil in the system, or replacing
any component of the system, the compressor must be run in
advance for oil return operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is "ON" and Set the fan
control knob at its highest position.
3) Run the compressor for more than 20 minutes between
800 and 1,000 rpm in order to operate the system.
4) Stop the engine.


REPLACEMENT OF COMPONENT PARTS
When replacing system component parts, supply the following
amount of oil to the component parts to be installed.

Component parts to be installed Amount of oil
Evaporator 50 cm3 (1.7 fl.oz.)
Condenser 30 cm3 (1.0 fl.oz.)
Receiver/drier 30 cm3 (1.0 fl.oz.)
Refrigerant line (One piece) 10 cm3 (0.3 fl.oz.)

Refrigeration oil must be replenished if more than two parts
are removed at the same time. After installing these
components, check compressor oil.

1-50 HEATER AND AIR CONDITIONING
DISASSEMBLY


This illustration is based on the 4J engine model
871R300002

Disassembly Steps

1. Drive plate bolt
2. Plain washer

3. Drive plate
4. Snap ring

5. Pulley assembly

6. Snap ring
7. Thermo sensor and lead wire connector
8. Field coil
9. Compressor

Important Operations - Dissassembly


1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from rotating, then remove the bolt.
Drive Plate Holder: 5-8840-4056-0 (J-37872)

MSG MODEL 7B-7
REMOVAL AND INSTALLATION

Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before
you begin.





Important Operations - Removal
Battery Cable
Disconnect the negative (-) cable from the battery terminal.

Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.



Gear Shift Lever
1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.



Lifting the Vehicle
1. Jack up the vehicle.
2. Place chassis stands at the front and the rear of the
vehicle.




Transmission Oil Draining
1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.

MSG MODEL 7B-9

Engine Lifting Hanger
1. Attach the engine lifting hanger to the front portion of the
engine.
2.
Attach the lifting wire to both ends of the engine lifting
hanger.





Starter Motor
Remove the starter motor motor from the engine rear plate.




Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts
1
from the transmission 2.
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber
3 from the transmission
4.
6. Remove the gear control box from the transmission.



7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative
efforts of two mechanics.
1) Remove the transmission nuts and bolts
1 from the
engine rear plate.
2) Place a transmission jack
2 beneath the transmission .
Do not raise the transmission jack.

7B-14 MSG MODEL



Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the
2nd exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.

Gear Shift Lever
1. Replenish the transmission case with the specified engine
oil.
Transmission Case Oil lit(US gal.)
1.55 (0.41)

2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified
torque.
Shift Lever Cover Bolt Torque N

m(kgf

m/lb

ft)
19.6 (2.0 / 14.5)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.



Lowering the Vehicle
1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.



Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.



Battery Cable
Connect the negative (-) cable to the battery terminal.

MANUAL TRANSMISSION 7B1-9

6. Remove gear control lever (5).
7. Raise and support vehicle with suitable stands.
8. Remove rear propeller shaft (6).
NOTE: Apply alignment marks on the flange at the
differential side.

401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the
engine side but not remove them. (Diesel engine
only)
150R300003

10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the
transmission.

Neutral Switch


Back up Switch

Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly

7B1-10 MANUAL TRANSMISSION




6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it.
Diesel engine
220LV019
6VE1
206RW002
14. Support transmission with a transmission jack.
220RS001
15. Remove engine rear mount nuts (11) fixing on cross
member from transmission crossmember (12).
16. Remove engine rear mount nuts (13) fixing on
transmission.
220R300029

Legend
(1) Transmission
(2) Nut : rear mount to transmission
(3) Rear Mount Rubber
(4) Nut : rear mount to crossmember
(5) Transmission Crossmember

MANUAL TRANSMISSION 7B1-11

17. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.
501R300008
18. Take out the rear mount rubber (14).
19. Remove starter (15) (Diesel engine only).
060L100070
20. Use the clutch release bearing remover 5-8840-
2291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection
1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.

7B1-12 MANUAL TRANSMISSION

NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RW063
220RW064

220RW019

Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
21. Remove transmission retaining nuts and bolts(16).
Remove transmission assembly (17) from the
vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.

7B1-16 MANUAL TRANSMISSION

6. Install starter(15). (Diesel engine only)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
the specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).
Torque: 52 N




m (5.3 kg




m/38 lb




ft)
Remove the transmission jack from transmission
side.
10. Apply grease to top hole portion of the shift fork.
Install slave cylinder (10) and tighten the bolts to the
specified torque.
Torque: 76 N




m (7.7 kg




m/56 lb




ft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut 76 N




m (7.7 kg




m/56 lb




ft)
Nut 37 N





m (3.8 kg





m/28 lb





ft)
Diesel engine
220R300012

Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly




6VE1, C24NE
Scan-1
12. Connect transmission harness connectors and clip.
Connector: neutral switch, car speed sensor, and
backup switch.
13. Tighten exhaust pipe fixing nuts (7) to the specified
torque. (Diesel engine only)
Torque: 67 N




m (6.8 kg




m/49 lb




ft)
150R300003