engine ISUZU TFS SERIES 1997 User Guide

10-4 CAB
REMOVAL AND INSTALLATION
For RHD model For LHD model
Removal Steps
1. Wiper arm assembly
2. Side moulding
3. Vent cowl cover
4. Windshield stopper
5. Upper moulding
6. Windshield glass
7. Engine hood rear seal
Installation Steps
7. Engine hood rear seal
6. Windshield glass
5. Upper moulding
4. Windshield stopper
3. Vent cowl cover
2. Side moulding
1. Wiper arm assembly

CAB 10-5
Important Operation - Removal
6. Windshield Glass
Remove the windshield 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 of
the piano wire through the adhesive caulking material at the
edge of the windshield glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) W ith the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumferance of the windshield
glass.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the windshield glass.
Important Operations - Installation
7. 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
6. Windshield Glass
1) Clean the windshield glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at seven (7) locations.

CAB 10-27
Important Operations
1. Center Console Assembly
Remove shift knob and 2 fixing screws (front side).
Open the grommet and remove 2 fixing screws (rear
side).
2. ECM cover
3. Glove Box
Remove 2 fixing screws and pulling the handle.
4. Glove Box Cover
Remove 4 fixing screws and pull the cover toward you
and remove the clips at 2 positions.
5. Instrument Panel Passenger Lower Cover Assembly
Remove 3 fixing screws and 1 clip.
6. Instrument Panel Driver Lower Cover Assembly
Remove the engine hood opener 2 fixing screws and 6
fixing screws.
Disconnect the connector of the illumination.
7. Lower Cluster Assembly
Remove 3 fixing clips.
8. Meter Cluster Assembly
Remove 3 fixing screws, 7 clips and switch connectors.
9. Instrument Panel Lower Center Cover Assembly
Remove 7 fixing screws and disconnect the connector of
the cigarette lighter.

10-2 CAB
SERVICING
Engine Hood Lock
Align the engine hood lock with the installation holes.
Engine Hood Striker
Apply a light coat of grease to the striker.
Door Checker Arm and Pin
Apply a light coat of grease to the checker arm and pin.

10-4 CAB
REMOVAL AND INSTALLATION
For RHD model For LHD model
Removal Steps
1. Wiper arm assembly
2. Side moulding
3. Vent cowl cover
4. Windshield stopper
5. Upper moulding
6. Windshield glass
7. Engine hood rear seal
Installation Steps
7. Engine hood rear seal
6. Windshield glass
5. Upper moulding
4. Windshield stopper
3. Vent cowl cover
2. Side moulding
1. Wiper arm assembly

CAB 10-5
Important Operation - Removal
6. Windshield Glass
Remove the windshield 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 of
the piano wire through the adhesive caulking material at the
edge of the windshield glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) W ith the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumferance of the windshield
glass.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the windshield glass.
Important Operations - Installation
7. 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
6. Windshield Glass
1) Clean the windshield glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at seven (7) locations.

CAB 10-27
Important Operations
1. Center Console Assembly
Remove shift knob and 2 fixing screws (front side).
Open the grommet and remove 2 fixing screws (rear
side).
2. ECM cover
3. Glove Box
Remove 2 fixing screws and pulling the handle.
4. Glove Box Cover
Remove 4 fixing screws and pull the cover toward you
and remove the clips at 2 positions.
5. Instrument Panel Passenger Lower Cover Assembly
Remove 3 fixing screws and 1 clip.
6. Instrument Panel Driver Lower Cover Assembly
Remove the engine hood opener 2 fixing screws and 6
fixing screws.
Disconnect the connector of the illumination.
7. Lower Cluster Assembly
Remove 3 fixing clips.
8. Meter Cluster Assembly
Remove 3 fixing screws, 7 clips and switch connectors.
9. Instrument Panel Lower Center Cover Assembly
Remove 7 fixing screws and disconnect the connector of
the cigarette lighter.

CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[ 7C- 2
General Description......................................................................................................... 7C-3
Torque Specification ...........................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-8
Servicing<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[...... 7C- 13
Clut<0046004b0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011001100110011[........ 7C- 15
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 15
Inspection and Repair................................................................................................. 7C- 20
Clutch Control .................................................................................................................. 7C- 27
Removal and Installation .......................................<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[ 7C- 27
Master Cylinder (Except 6VD1 Engine) .......................................................................... 7C- 30
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-30
Inspection and Repair................................................................................................. 7C- 31
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-32
Master Cylinder (6VD1 LHD Model) ................................................................................ 7C- 33
Disassembly and Reassembly ................................................................................... 7C- 33
Slave Cylinder (Except 6VD1 Engine) ............................................................................ 7C- 35
Disassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-35
Inspection and Repair................................................................................................. 7C- 36
Reassembly <0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
1100110011[<0011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100110011001100
11001100110011001100110011001100110011[ 7C-36
Hydraulic Damper Cylinder (Except 6VD1 Engine) ....................................................... 7C- 40
Inspection and Repair................................................................................................. 7C- 40
Troubleshooting .............................................................................................................. 7
C- 41
Special Service Tool ........................................................................................................ 7C-50
INDEX

7C-2 CLUTCH
MAIN DATA AND SPECIFICATIONS
ENGINEHEC Engine
Series with
MSG4JA1HEC Engine
Series with
MUA4JB1T 4JG2T 6VD1
Type Dry single plate with diaphragm
Size mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Clamping force kg(lb) 500 (1103) 500 (1103) 560 (1235) 640 (1411) 735 (1621)
(N) (4903) (4903) (5492) (6276) (7208)
Pressure plate
Outside diameter mm(in) 215 (8.465) 225 (8.858) 240 (9.449) 250 (9.843) 260 (10.24)
Inside diameter mm(in) 150 (5.906) 154 (6.063) 160 (6.299) 160 (6.299) 170 (6.70)
Driven plate
Thickness mm(in)
at free 8.4 (0.331) 8.6 (0.339) 8.0 (0.315) 8.2 (0.323) 8.3 (0.327)
at compressed 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 7.8 (0.307) 8.0 (0.315) 8.0 (0.315)
CLUTCH CONTROL LHD RHD
Type Hydraulic
Pedal free play mm(in) 5.0-15.0 (0.2-0.6)
Pedal height mm(in)
4JG2T 185.5-195.5 (7.30-7.70)
Others 178-188 (7.01-7.40) 216-226 (8.50-8.90)
Master cylinder
BoreStroke mm(in) 15.8735 (0.6251.38)
Slave cylinder
BoreStroke mm(in)
HEC Engine Series for
LHD/4JA120.6416 (0.8130.63)
HEC Engine Series for
RHD/4JB1T/4JG2T22.2215 (0.8750.59)
6VD1 22.2217 (0.8750.67)

CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
HEC Engine Series4J Engine Series
6VD1
The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven
plate assembly.
The clutch pedal is connected to the shift block through the clutch shaft and the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction
necessary to engage the clutch.
Depressing the clutch pedal moves the shift fork against the shift block.
The shift block forces the release bearing against the diaphragm to overcome the force of the diaphragm spring and
separate the driven plate from the flywheel and pressure plate to disengage the clutch.
Except 6VD1 (3.2L) engine model, the conventional push-type clutch is used.
For 6VD1 (3.2L) engine model, the pull-type clutch is employed. The pull-type clutch is disengaged by pulling the
release lever (release bearing) to disengage the pressure plate.