power steering ISUZU TF SERIES 2004 Workshop Manual

POWER-ASSISTED STEERING SYSTEM 3B-57

13. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag assembl
y
and remove the air bag assembly. (with SRS air
bag)
060R300041
14. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It removes previously from the spoke bottom.



RTW33BSH000401

15.
Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in thei
r
original position. Move the front wheels to the
straight ahead position, then use steering wheel
remover 5-8521-0016-0 to remove the steering
wheel.
430R300008



430RX005-X

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withdrawn a little by loosening the steering shaft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)

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.

3B-62 POWER-ASSISTED STEERING SYSTEM

Supplemental Restraint System Steering Wheel & Column and
Associated Parts
Main Data and Specifications
Torque Specifications N

m (kg

m/lb ft)


This illustration is based on the RHD model.
RTW43BLF000301
Special Tools

ILLUSTRATION

TOOL NO.
TOOL NAME



5-8521-0016-0
(J-29752)
Steering wheel remover

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-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.

3C-38 FRONT SUSPENSION

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.
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Ba
r
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-8840-
2005-0.
CAUTION: Be careful not to damage the ball joint
boot.



901RW271

11. Remove upper ball joint by using remover 5-8840-
2121-0.
CAUTION: Be careful not to damage the ball joint
boot.

901RW272
12. Remove knuckle assembly.
13. Remove oil seal. If replacement required.
(4
4 Model Only)
14. Remove washer. If replacement required.
(4
4 Model Only)
15. Remove needle bearing by using remover 5-8840-
2000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (4
4 Model Only)





(4

4 Model Only)
RTW340SH00401

FRONT SUSPENSION 3C-45

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.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-8840-
2123-0.



Front
901RW154



Front
901RW155
19. Remove rear bushing by using remover 5-8840-
2124-0.


Front
901RW051




Front
901RW052