section 8 ISUZU TF SERIES 2004 Workshop Manual

3B-56 POWER-ASSISTED STEERING SYSTEM

CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to become uncentered which
will cause damage to the SRS coil assembly. (with
SRS air bag)
5. Remove the engine hood opening lever and
steering lower cover.
6. Remove the driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)
8. Check the both side hole of the steering cover. (with
SRS air bag)
060R300025
9. Check the position of the pins in a hole. Push the
pin in the direction of an arrow. (with SRS air bag)
060R300032

10. Push the four pins at 
5
6 mm bar. (with SRS ai
r
bag)
060R300031
11. Cancel the lock four pins. (with SRS air bag)
12. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
430R300009

3B-60 POWER-ASSISTED STEERING SYSTEM

9. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
CAUTION: When turning the SRS coil counte
r
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
826RW014
10. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
12. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N




m (3.2 – 4.0 kg




m/23 - 29 lb ft)
13. Support the module and carefully connect the
module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

POWER-ASSISTED STEERING SYSTEM 3B-61

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

FRONT SUSPENSION 3C-1
SECTION 3C
FRONT SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3C- 2
Torque Specifications ....................................................................................................... 3C- 3
Special Parts Fixing Nuts and Bolts ............................................................................ 3C- 3
Front Suspension .............................................................................................................. 3C- 6
General Description ...................................................................................................... 3C- 6
Front Suspension (4




2 Except High Ride Suspension)............................................. 3C- 8
Front Suspension (4





2 High Ride Suspension, 4





4) ................................................. 3C- 30
Troubleshooting ............................................................................................................ 3C- 54

FRONT SUSPENSION 3C-9

Shock Absorber
Shock Absorber and Associated Parts


RTW440LF001201

Legend

(1)
Shock Absorber ASM with coil

(2)
Nut

(3)
Nut

(4)
Nut


(5)
Lower ball joint Nut and cot ter pin

(6)
Nut

(7)
Bolt

(8)
Cam bolt


Removal
1. Raise the vehicle and support it with suitable
safety stands.

2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.
3. Remove nut (6).
CAUTION: Be careful not o break the ball joint boot.

FRONT SUSPENSION 3C-11

NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55N





m (5.6kg





m/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137N




m (14.0kg




m/101 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.




RTW340SH001301-X
4. Install nut (6), then tighten it to the specified
torque.
Torque: 50N




m (5.1kg




m/37 lb ft)
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (5).
Torque: 147N




m (15.0kg




m/108 lb ft)


NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.

7. Nut (3) tighten it to the specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 186N




m (19.0kg




m/137 lb ft)


NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.





RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in
this section.

FRONT SUSPENSION 3C-15

Stabilizer Bar
Stabilizer Bar and Associated Parts



RTW340LF000901
Legend

(1)
Stabilizer Bar

(2)
Link

(3)
Nut


(4)
Nut

(5)
Bracket and Bolt

(6)
Rubber Bushing


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section.

3. Remove nut (3) and (4).
CAUTION: Be careful not to break the ball joint
boot.

4. Remove link.
5. Remove bracket and bolt.
6. Remove stabilizer bar.
7. Remove rubber bushing.

FRONT SUSPENSION 3C-17

Knuckle
Knuckle and Associated Parts


450R300037
Legend

(1)
Nut and Cotter Pin

(2)
Back Plate

(3)
Nut and Cotter Pin


(4)
Nut and Cotter Pin

(5)
Knuckle

(6)
Bolt


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.

3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.
4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.

FRONT SUSPENSION 3C-19

Upper Control Arm
Upper Control Arm and Associated Parts


450R300038
Legend

(1)
Bolt

(2)
Bushing

(3)
Nut

(4)
Upper Control Arm Assembly

(5)
Upper Ball Joint

(6)
Nut and Cotter Pin


(7)
Knuckle

(8)
Nut

(9)
Nut

(10)
Bolt

(11)
Nut

(12)
Nut

Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove nut (11).
4. Remove nut (12).

FRONT SUSPENSION 3C-21

Lower Control Arm
Lower Control Arm and Associated Parts
RTW340LF002301
Legend

(1)
Cam bolt

(2)
Bush

(3)
Cam plate

(4)
Nut

(5)
Nut


(6)
Bolt

(7)
Lower Ball Joint

(8)
Nut and cotter pin

(9)
Nut

(10) Nut

(11) Bolt


Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
in this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.