window ISUZU TF SERIES 2004 Workshop Manual

9A-24 SUPPLEMENTAL RESTRAINT SYSTEM

23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deploymen
t
harness to their full length.
25. Completely cover windshield area and front doo
r
window openings with a drop cloth, blanket or
similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's
glass or interior.
26. Notify all people in the immediate area that you
intend to deploy the air bags. The deployment will
be accompanied by a substantial noise which ma
y
startle the uninformed.
27. Separate the two ends of the driver deploymen
t
harness wires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deplo
y
the air bags.
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver ai
r
bag assembly. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested.
29. Separate the two ends of the passenge
r
deployment harness wires.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.

30.Connect the passenger deployment harness wires
to a power source to immediately deploy the
passenger air bag assembly. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.(Driver air bag
assembly) Put on a pair of shop gloves and safet
y
glasses to protect your hands and eyes from
possible irritation and heat when handling the
deployed air bag assembly. After an air bag
assembly has been deployed, the surface of the
air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products o
f
the chemical reaction. Sodium hydroxide dust
(similar to 30. lye soap) is produced as a b
y
product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric
moisture and is converted to sodium carbonate
and sodium bicarbonate (baking soda). Therefore,
it is unlikely that sodium hydroxide will be present
after deployment.(Passenger air bag assembly)
The passenger inflator requires no special
precaution after deployment. 95% of the
particulate emission are potassium chloride (KLC),
which is commonly sold as an edible salt-
substitutes. even if water is applied. Post
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not products any hazardous products. As with an
y
dusty environment, safety goggles, dust mask and
gloves should be worn.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE AIR BAG
ASSEMBLY TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES COULD RESULT IN FIRE O
R
PERSONAL INJURY.
After an air bag assembly has been deployed, the
metal canister and surrounding areas of the ai
r
bag assembly will be very hot. Do not touch the
metal areas of the air bag assembly for about 30
minutes after deployment. If the deployed air bag
assembly must be moved before it is cool, wea
r
gloves and handle by the air bag or trim cover.
31. Short the driver deployment harness wires b
y
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and clean
off any fragments or discard drop cloth entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.

FRONT WHEEL DRIVE 4C1-23
13. Align the track on the ball (1) retainer with the window in
the cage, and install the six balls into position.




14. Pack 150g of the specified grease in DOJ case, then install
drive shaft joint assembly. After reassembly, move the DOJ
longitudinally several times to get to fit.

15. Install the circlip (1) so that open ends are positioned away
from the ball groove.
Discard the used circlip and install a new one.


Legend
1. Outer Case
2. Circlip
3. Open Ends



16. Install band. After installation, check that the bellows is free
from distortion.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified valve.
For both sides on UJ bellows.

CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE
Windshield.......................................................................................................................... 10- 2
Rear Window Assembly .................................................................................................... 10- 7
Front Door Assembly ........................................................................................................ 10- 10
Rear Door Assembly (Crew Cab) ...................................................................................... 10- 20
Instrument Panel................................................................................................................ 10- 28
Floor Console..................................................................................................................... 10- 34
Console Box (Without Floor Console) ............................................................................. 10- 38
Headlining .......................................................................................................................... 10- 39
Interior Trim Panels ...........................................................................................................10- 44
Fuel Filler Lid Opener Lever/Cable................................................................................... 10- 55
Quarter Glass (Extend Cab) .............................................................................................. 10- 70
Font Seat ............................................................................................................................ 10- 71
Rear Seat (Crew Cab) ........................................................................................................ 10- 74
Jump Seat (Extend Cab) ................................................................................................... 10- 75
Front Seat Belt ................................................................................................................... 10- 76
Rear Seat Belt (Crew Cab) ................................................................................................ 10- 80
Rear Seat Belt (Extend Cab) ............................................................................................. 10- 84
Front Wheel Extension ...................................................................................................... 10- 87
Rear Wheel Extension ....................................................................................................... 10- 88
Tail Gate Assembly ............................................................................................................ 10- 89

CAB 10-5



Important Operations - Installation
1. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.
1 : Seal
2 : Clip
3 : Rear (windshield glass side)
4 : Front

RTW3A0SH000201

3. Windshield Glass
1) Clean the windshield glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at five locations.


Always use new spacer.
4) Install the windshield upper molding.


Peel off the tear-away paper from the windshield uppe
r
molding, and start applying it with one end of the glass
and cut away the surplus at the other end of the glass
for length adjustment.


Always use new upper molding.
5) Temporary install the windshield support.



6) Apply primer
1 Sunstar #435-98 or equivalent to the body
side bonding surface. The primer should extend at least 25
mm (1 in).
Apply primer Sunstar #435-40 or equivalent to the
windshield glass side bonding surface.
The primer should extend 16.5 mm (0.6 in) and 25 mm (1.0
in) from end of the glass.

10-6 CAB




7) Apply the window glass sealing adhesive
2.
If you are using an air gun, air pressure should be
maintained at 147 - 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in) junction a
t
middle of the vase of the glass.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.




8) Adjust the setting of the windshield glass with suction discs.
Set the windshield with sealing adhesive applied to entire
circumference in the body panel. Specifically, adjus
t
windshield support with the upper molding making contact
with the body panel, press the glass, and tighten the
windshield support.



9) Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.
Cure the bonding at a temperature of 68
- 86
F (20
-
30
C) for twenty-four hours.
Check that the windshield does not leak water.









8. Wiper Arm Assembly


Set the wiper arm/blade so that the tips of both blades
are positioned the specified value of
A and Bfrom the
upper edge of the cowl cover as shown in the figure.

A 40 mm (1.57 in)

B 52 mm (2.05 in)


Tighten the wiper arm assembly fixing nuts to the
specified torque.
Torque Nm (kgfm/lbft)
31 (3.1/23)

CAB 10-7
REAR WINDOW ASSEMBLY
REMOVE AND INSTALLATION


Removal Steps
1. Interior trim panels/Headlining
2. Rear defogger connector (W/Rear defogger)

3. Rear window

Installation Steps


3. Rear window
2. Rear defogger connector (W/Rear defogger)
1. Interior trim panels/Headlining

10-8 CAB

Important Operation - Removal
3. Rear Window Glass
Remove the glass, carefully following the steps listed below :
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end o
f
the piano wire through the adhesive caulking material at the
edge of the rear window glass.
4) Secure the other end of the piano wire to another piece o
f
wood.




5) With the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the rear windo
w
glass.
6) Lift the rear window glass from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the rear window glass.
8) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the rear window glass.


Important Operation - Installation
3. Rear Window Glass
1) Clean the rear window glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Install the fastener tape to body panel flange.



4) Apply primer 1 sunster #435-40 or equivalent to the rear
window glass side bonding surface.
The primer should extend 23 mm (0.9 in.) form end of the
glass.

CAB 10-9


5) Apply the rear window glass seling adhesive 2.
If you are using an air gun, air pressure should be
maintained at 147 – 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in.) junction a
t
left corner of the base of the glass.
Note:
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
6) Insert the glass supports into the panel and then push the
glass against the panel to affix it in place.
Wipe away any adhesive that oozes out around the edges.
7) Check that the rear window glass does not leak water.

10-12 CAB
DISASSEMBLY



This illustration is based on RHD model
RTW4A0LF000701

Disassembly Steps

1. Switch bezel/Window regulator handle

2. Power window switch

3. Bezel

4. Door mirror cover

5. Door trim panel

6. Tweeter (Required Option)

7. Door mirror assembly

8. Outer waste seal

9. Bracket

10. Speaker assembly

11. Waterproof sheet

12. Inside lever

13. Window glass




14. Window regulator/Power window
regulator

15. Glass run

16. Glass run rear channel / Glass ran rear
channel with Door lock control or Anti
theft (EC)

17. Door lock assembly/Door lock assembly
with super lock

18. Outside handle protector (EUROPE)

19. Outside handle

20. Door lock cylinder protector (EUROPE)

21. Door lock cylinder / Door lock cylinder
with door lock switch (EC)
22. Door harness assembly
23. Anti rattler

CAB 10-13


Important Operations
1. Switch Bezel/Window Regulator Handle

Remove the 2 screws and disconnect the connectors.




To remove the regulator handle, remove the clip at the
root of the handle by using wire.




2. Power Window Switch

Remove the 3 screws.


3. Bezel

Remove the screw.



4. Door Mirror Cover

Pull out the upper clip, and then take out the cove
r
upward.



5. Door Trim Panel

Pull out the trim panel at the 8 clip positions (Powe
r
window type).