oil ISUZU TF SERIES 2004 Workshop Manual

3B-50 POWER-ASSISTED STEERING SYSTEM

CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Remove the engine hood opening lever and
steering lower cover.
6. Remove 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-52 POWER-ASSISTED STEERING SYSTEM

430R300007
17. Remove steering column cover.
18. Disconnect the wiring harness connectors located
under the steering column.
19. Remove the combination switch assembly with SRS
coil.
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly. (with SRS air bag)
430R300014
20. Turn the ignition switch to the ACC position.

21. Insert a pin (1) into the hole and push on it. Pull the
key cylinder free.
P1010003

Installation
1. Install lock cylinder assembly.
2. Install the combination switch assembly with SRS
coil. (with SRS air bag)
3. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
CAUTION:
When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage the cable
in the SRS coil.
(with SRS air bag)
826RW014
Legend
(1) Neutral mark

POWER-ASSISTED STEERING SYSTEM 3B-55

Steering Column
Steering Column and Associated Parts



This illustration is based on the RHD model.
RTW43BLF000201
Legend
(1) Inflator Module or Horn Pad
(2) Steering Wheel
(3) Steering Column Cover
(4) Combination Switch and SRS Coil Assembly
(5) Steering Column Assembly
(6) Second Steering Shaft
(7) Lower Second Steering Shaft
(8) Instrument Panel Lower Cover
(9) Driver Knee Bolster (reinforcement)



Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".

3. Disconnect the battery "-" terminal cable, and wait at
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)

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-58 POWER-ASSISTED STEERING SYSTEM

16. Remove steering column cover.
17. Disconnect the wiring harness connectors located
under the steering column.
18. Remove the combination switch assembly with SRS
coil.
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly.
430R300014
19. Remove snap ring.
20. Remove cushion rubber.
21. Remove shift lock cable (For A/T).
22. Disconnect the starter switch harness connecto
r
located under the steering column, then remove
lock cylinder assembly.

23.
Apply a setting mark (1) across the universal joint
and transfer gear to reassemble the parts in thei
r
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.



RTW33BSH000501

Inspection
If the abnormal conditions are found through inspection,
replace the steering column assembly.

Column Capsule
Check capsules on steering column bracket assembly;
all must be securely seated in bracket slots and
checked for any loose conditions when pushed or pulled
by hand.
431RW030

POWER-ASSISTED STEERING SYSTEM 3B-59

Check clearance between capsule and bracket. If must
be within 1mm (0.039 in).
431RW031

Column Universal Joint (between the
power steering unit and the steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the lower second steering shaft.

Shaft Universal Joint (between the lower
second steering shaft and the second
steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the second steering shaft assembly.

Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.

Installation
1. Align the setting marks on the second steering shaft
and the steering column assembly (applied at
disassembly).
2. Connect the steering column assembly to the second
steering shaft. Tighten the bolts to the specified
torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
3. Thread the steering column assembly through the
hole in the dashpanel. Temporarily tighten the
steering column and the second steering shaft fixing
bolt.
4. Connect the lower second steering shaft and the
second steering shaft. Tighten the universal joint
bolts to the specified torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
5. Tighten the steering column fixing bolt (pedal brkt
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)

6. Tighten the second steering shaft fixing bolt to the
specified torque (This bolt was temporarily tightened
in Step 3)
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
7. Tighten the steering column fixing bolt (dashpanel
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
8. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.

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)

3C-2 FRONT SUSPENSION
MAIN DATA AND SPECIFICATIONS
4




2 (EXCEPT HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, coil spring
with stabilizer bar.
Coil spring Spring Rate 4JH1-TC / 4JA1-TC / 4JA1-L (ENGINE); 9.62 kg/mm
(94.3 N/mm)
C24SE (ENGINE); 7.94 kg/mm (77.9 N/mm)
Type Gas-sealed. Hydraulic, double acting
Stroke 116.5 mm (4.59 in)
Compressed length 284.0 mm (11.18 in)
Front shock absorber
Extended length 400.5 mm (15.77 in)
Stabilizer bar Diameter 25.0 mm (0.98 in)

4




2 (HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)

4




4 MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)

FRONT SUSPENSION 3C-7
4





2 (High Ride Suspension) and 4





4 Model
RTW340LF000801

The links attach to the vehicle with bolts and bushings at their inner pivot points and to the steering knuckle, which
is part of the front wheel spindle, at their outer points.
The knuckle is mounted to the upper and lower links each of which has a ball joint to permit pivoting of the knuckle
for steering operations. The hub is supported in position on the knuckle spindle by means of the two bearings and
the rotor is mounted to the hub.
The front suspension is an independent type utilizing torsion bar springs (4
4, 4
2 (High ride suspension)) and coil
springs (4
2 (Except High ride suspension)). The torsion bar spring has splines on each end. Height control is
provided on the third crossmember. Both the upper and lower links are pressed steel and the torsion bar is
supported at the ends by lower link in front and by height control arm in rear.

3C-8 FRONT SUSPENSION


FRONT SUSPENSION
(4




2 Except High Ride Suspension)
CONTENTS

Service Precaution............................................. 3C-8
Shock Absorber ................................................. 3C-9
Shock Absorber and Associated Parts ........... 3C-9
Removal ......................................................... 3C-9
Installation....................................................... 3C-10
Shock Absorber with Coil Spring .................... 3C-12
Stabilizer Bar ..................................................... 3C-15
Stabilizer Bar and Associated Parts ............... 3C-15
Removal ......................................................... 3C-15
Inspection and Repair..................................... 3C-15
Installation....................................................... 3C-16
Knuckle .............................................................. 3C-17
Knuckle and Associated Parts........................ 3C-17
Removal ......................................................... 3C-17
Inspection and Repair..................................... 3C-18
Installation....................................................... 3C-18
Upper Control Arm ............................................. 3C-19
Upper Control Arm and Associated Parts ...... 3C-19
Removal ......................................................... 3C-19
Inspection and Repair..................................... 3C-20
Installation....................................................... 3C-20

Lower Control Arm ............................................. 3C-21
Lower Control Arm and Associated Parts ...... 3C-21
Removal ......................................................... 3C-21
Inspection and Repair..................................... 3C-22
Installation ...................................................... 3C-22
Upper Ball Joint ................................................. 3C-23
Upper Ball Joint and Associated Parts ........... 3C-23
Removal ......................................................... 3C-23
Inspection and Repair..................................... 3C-24
Installation ...................................................... 3C-24
Lower Ball Joint ................................................. 3C-25
Lower Ball Joint and Associated Parts ........... 3C-25
Removal ......................................................... 3C-25
Inspection and Repair..................................... 3C-26
Installation ...................................................... 3C-26
Bump Rubber .................................................... 3C-27
Bump Rubber Joint and Associated Parts...... 3C-27
Removal ......................................................... 3C-27
Inspection and Repair..................................... 3C-27
Installation ...................................................... 3C-27
Special Tools .................................................. 3C-28

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 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.