boot ISUZU TF SERIES 2004 Workshop Manual

FRONT WHEEL DRIVE 4C1-19

Disassembly
NOTE :
For the left side, follow the same steps as right side.


1. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the DOJ side).
COUTION :
Take care not to damage the bellows during band removal.
2. Remove band (1).



3. Pry off circlip (1) with a screwdriver or equivalent.



4. Remove drive shaft joint assembly.
5. Remove the six balls (1) with a screwdriver or equivalent.

4C1-20 FRONT WHEEL DRIVE
6. Using snap ring pliers, remove the snap ring (1) fastening
the ball retainer to the center shaft.
7. Remove ball retainer, ball guide and bellows.



8. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the UJ side).
CAUTION :
Take care not to damage the bellows during band removal.

9. Remove band (1).
10. Remove bellows.
11. Remove dust seal from UJ.
12. Remove UJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.


Inspection And Repair
Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition are found
through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal

BRAKES 5C-41











Thickness of Disc Pad
Thickness (t) mm(in)

Standard Limit
10.0 (0.394) 1.8 (0.071)

Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.

All four brake pads should be replaced together.

302R300019


Seal and Boot
The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.

5C-44 BRAKES
REAR DRUM BRAKE ASSEMBLY
DISASSEMBLY

First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the “REAR AXLE ” section for the brake drum disassembly procedure.

RTW35CMF000201

MAJOR COMPONENTS
Disassembly Steps

1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster

4. Spring ; Shoe hold
5. Pin ; Shoe hold

6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading

10. Shoe ; trailing
11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate

MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)

19. Piston
20. Cup
21. Boot ; piston

22. Return spring
23. Bleeder
24. Cap ; bleeder

BRAKES 5C-47
REASSEMBLY

RTW35CMF000301

MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)

1. Piston assembly
2. Cup ; piston
3. Return spring



4. Boot ; piston

5. Bleeder
6. Cap ; bleeder

MAJOR COMPONENTS
Reassembly Steps

7. Back plate
8. Cover

9. Wheel cylinder assembly

10. Bolt ; wheel cylinder

11. Shoe ; leading

12. Lever ; parking

13. Washer ; lever

14. Retainer
15. Spring ; lever return



16. Shoe ; trailing

17. Spring ; shoe to shoe, upper

18. Adjust assembly
19. Spring ; shoe to shoe ; lower

20. Lever ; adjuster

21. Ring ; Adjuster lever
22. Spring ; shoe hold

23. Pin ; shoe hold

24. spring ; adjuster

5C-48 BRAKES



Important Operations
Note :


Wash the disassembled parts in clean brake fluid.


Use compressed air to clean the ports.


Protect the disassembled part surfaces from dust and othe
r
foreign material contamination.


Before reassembly, check the part surfaces for dust and
other foreign material contamination.


Be sure to replace the designated parts with new ones.

4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.




Apply brake fluid to the piston and the inner face of the
boots.


Note the direction of piston cup.



5. Bleeder ; Wheel Cylinder
Torque Nm(kgfm/Ibin)
6 - 8 (0.6 – 0.8 / 52 - 69)



9. Wheel Cylinder Assembly
10. Bolt ; Wheel cylinder
Torque N
m(kgf
m/Ib
ft)
7 - 11 (0.7 – 1.1 / 61 - 95)

CLUTCH 7C-35
SLAVE CYLINDER (4J, C24SE)
DISASSEMBLY



Disassembly Steps


1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body




Important Operations
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.

CLUTCH 7C-37
REASSEMBLY



Reassembly Steps


1. Cylinder body
2. Spring


3. Piston and piston cup


4. Push rod
5. Boot







Important Operations
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.


3. Piston and piston Cup
1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.

7C-38 CLUTCH
SLAVE CYLINDER (6VE1)
DISASSEMBLY
206RW004-X

Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup


4. Spring
5. Cylinder body

6E-58 3.5L ENGINE DRIVEABILITY AND EMISSIONS
GENERAL DESCRIPTION FOR
ELECTRONIC IGNITION SYSTEM IGNITION
COILS & CONTROL
A separate coil-at-plug module is located at each spark
plug.
The coil-at-plug module is attached to the engine with
two screws. It is installed directly to the spark plug by an
electrical contact inside a rubber boot.
A three way connector provides 12 volts primary supply
from the ignition coil fuse, a ground switching trigge
r
line from the ECM, and ground.
The ignition control spark timing is the ECM's method o
f
controlling the spark advance and the ignition dwell.
The ignition control spark advance and the ignition dwell
are calculated by the ECM using the following inputs.

Engine speed

Crankshaft position (CKP) sensor

Camshaft position (CMP) sensor

Engine coolant temperature (ECT) sensor

Throttle position sensor

Park or neutral position switch

Vehicle speed sensor

ECM and ignition system supply voltage

Based on these sensor signal and engine load
information, the ECM sends 5V to each ignition coil
requiring ignition. This signal sets in the powe
r
transistor of the ignition coil to establish a grounding
circuit for the primary coil, applying battery voltage to
the primary coil.
At the ignition timing, the ECM stops sending the 5V
signal voltage. Under this condition the power transistor
of the ignition coil is set off to cut the battery voltage to
the primary coil, thereby causing a magnetic field
generated in the primary coil to collapse.
On this moment a line of magnetic force flows to the
secondary coil, and when this magnetic line crosses the
coil, high voltage induced by the secondary ignition
circuit to flow through the spark plug to the ground.

Ignition Control ECM Output
The ECM provides a zero volt (actually about 100 mV to
200 mV) or a 5-volt output signal to the ignition control
(IC) module. Each spark plug has its own primary and
secondary coil module ("coil-at-plug") located at the
spark plug itself. When the ignition coil receives the
5-volt signal from the ECM, it provides a ground path fo
r
the B+ supply to the primary side of the coil-at -plug
module. This energizes the primary coil and creates a
magnetic field in the coil-at-plug module. When the
ECM shuts off the 5-volt signal to the ignition control
module, the ground path for the primary coil is broken.
The magnetic field collapses and induces a high voltage
secondary impulse which fires the spark plug and
ignites the air/fuel mixture.
The circuit between the ECM and the ignition coil is
monitored for open circuits, shorts to voltage, and
shorts to ground. If the ECM detects one of these
events, it will set one of the following DTCs:

P0351: Ignition coil Fault on Cylinder #1

P0352: Ignition coil Fault on Cylinder #2

P0353: Ignition coil Fault on Cylinder #3

P0354: Ignition coil Fault on Cylinder #4

P0355: Ignition coil Fault on Cylinder #5

P0356: Ignition coil Fault on Cylinder #6

Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequency fail at highe
r
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels
and lubricating oils with additives. Some electrode wea
r
will also occur. Engines which are not running properly
are often referred to as “misfiring." This means the
ignition spark is not igniting the air/fuel mixture at the
proper time.
Spark plugs may also misfire due to fouling, excessive
gap, or a cracked or broken insulator. If misfiring
occurs before the recommended replacement interval,
locate and correct the cause.