torque ISUZU TF SERIES 2004 Workshop Manual

ELECTRICAL-BODY AND CHASSIS 8A-211


8. Remove the wiper linkage
7 from the access hole.






Installation
Follow the removal procedure in the reverse order to install the
wiper motor and linkage.
Pay close attention to the important points mentioned in the
following paragraphs.








Wiper Linkage
Take care not to scratch the painted surfaces of the body when
installing the wiper linkage to the body.
In case crank arm of wiper motor is removed, confirm the
position of auto stop prior to reinstall the crank arm to the wiper
motor.
Crank Arm Nut Torque Nm (kgm/lb ft
)
20  26 (2.0  2.6 / 14.5  18.8)

880R300006





Wiper Blade Position
Confirm the auto stop position of wiper motor prior to the
installation of the wiper blade and arm.
The distance between the vent cowl cover rubber seal

1 and
the wiper blade edge

2 is about 527.5 mm (2.050.3 in) 3
407.5 mm (1.570.3 in).




Wiper Arm Nut
Tighten the wiper arm nut to the specified torque.
Wiper Arm Nut Torque Nm (kgm/lb ft)
27  35 (2.75  3.57/19.94  25.85)


This illustration is based on RHD model

8A-264 ELECTRICAL-BODY AND CHASSIS
Installation

Rubber Seal
Be absolutely sure that the fuel tank unit rubber seal is
correctly seated.



Connector
Be absolutely sure that the fuel tank unit connector is securely
connected.
This will prevent a poor contact and an open circuit.



VEHICLE SPEED SENSOR (INSTALLED
ON THE TRANSMISSION)
Removal
1. Disconnect the connector.
2. Remove the vehicle speed sensor body by rotating it.







Installation
To Install, follow the removal steps in the reverse order, noting
the following point.
Tighten the vehicle speed sensor to the specified torque.
Vehicle Speed Sensor Tightening Torque Nm (kgfm/lb.ft)
25  4.9 (2.5  0.5/18  3.6)

CRUISE CONTROL SYSTEM 8B-3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAIN 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, REFER TO THE SRS
SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHER WISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a faster, use ONLY the
exact part number for that application. Dealer will call out those fasteners that require a replacement after
removal. Dealer will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and joint Clamping force, and may damaged 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.

General Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received.
When the main switch “AUTO CRUISE” is turned on with the vehicle in the running mode, the battery voltage is
applied to the control unit. When a signal from the control unit while the vehicle is in this state, the cruise control
actuator is activated to operate the system. Also, while the system is operating, the “AUTO CRUISE” indicator light
in the meter assembly lights up.





LTW48BSH000101
1. SET/COAST Switch Function
1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at
which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the
stored speed.
2. COAST-down Function: When the SET/COAST switch is kept on while the vehicle in running, the vehicle
decelerates during that time. The speed at which vehicle is running when the control switch is pressed in the
memory, and the vehicle automatically returns to the stored speed.
3. Tap-down Function: When the SET/COAST switch is pressed and released instantaneously while the
vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the
vehicle was running when the SET/COAST was released last is stored in the memory, and the vehicle
automatically returns to this stored speed.

ENGINE MECHANICAL 6A – 1


SECTION 6A
ENGINE MECHANICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A - 4
Torque Specifications ................................................................................................... 6A - 8
Standard Bolts ........................................................................................................... 6A - 8
Special Parts Fixing Nuts and Bolts ........................................................................ 6A - 9
Recommended Liquid Gasket ...................................................................................... 6A - 22
LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement ...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit ........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43

6A – 8 ENGINE MECHANICAL

TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
N ·m (kg ·m/lb ·ft)
8.8
4.8 (4T) (7T) Refined Non-Refined 9.8 (9T) Strength
Class
Bolt
Identification


Bolt
Diameter

Pitch (mm)
M 6






1.0

M 8






1.25

M 10






1.25

M 12






1.25

M 14






1.5

M 16






1.5

M 18






1.5

M 20






1.5

M 22






1.5

M 24






2.0

* M 10






1.5

* M 12






1.5

* M 14






2.0

* M 16






2.0
5.88 ± 1.96
(0.60 ± 0.20/4.33 ± 1.44)
12.74
4.90
(1.30 ± 0.50/9.40 ± 3.62)
27.44 ± 6.86
(2.80 ± 0.70/20.25 ± 5.06)
61.25 ± 12.25
(6.25 ± 1.25/45.21 ± 9.04)
95.55 ± 19.11
(9.75 ±1.95/70.52 ± 14.10)
130.34 ± 26.46
(13.30 ± 2.70/96.20 ± 19.53)
188.16 ± 37.24
(19.20 ± 3.80/138.87 ± 27.49)
257.74 ± 51.94
(26.30 ± 5.30/190.23 ± 38.33)
332.22 ± 81.34
(33.90 ± 8.30/245.20 ± 60.03)
448.84 ± 90.16
(45.80 ± 9.20/331.27 ± 66.54)
26.46 ± 6.86
(2.70 ± 0.70/19.53 ± 5.06)
56.84 ± 11.76
(5.80 ± 1.20/41.95 ± 8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
124.46 ± 24.50
(12.70 ± 2.50/91.86 ± 18.08) 7.35 ± 2.45
(0.75 ± 0.25/5.43 ± 1.80)
17.15 ± 5.39
(1.75
0.55/12.66
4.00)
36.75 ± 9.31
(3.75 ± 0.95/27.12 ± 6.87)
75.95 ± 15.19
(7.75 ± 1.55/56.06 ± 11.21)
116.13
23.03
(11.85 ± 2.35/85.71 ± 17.00)
169.54 ± 34.30
(17.30 ± 3.50/125.13 ± 25.32)
244.02 ± 49.00
(24.90 ± 5.00/180.10 ± 36.17)
337.12 ± 67.62
(34.40 ± 6.90/248.82 ± 49.41)
453.25 ± 90.65
(46.25 ± 9.25/334.53 ± 66.91)
570.36 ± 140.14
(58.20 ± 14.30/420.96 ± 103.43)
36.26 ± 8.82
(3.70 ± 0.90/26.76 ± 6.50)
70.56 ± 13.72
(7.20 ± 1.40/52.08 ± 10.13)
109.76 ± 21.56
(11.20 ± 2.20/81.01 ± 15.91)
161.70 ± 32.34
(16.50 ± 3.30/119.34 ± 23.87) -

23.52 ± 6.86
(2.40 ± 0.70/17.36 ± 5.06)
49.98 ± 12.74
(5.10 ± 1.30/36.89 ± 9.40)
94.57 ± 19.11
(9.65 ± 1.95/69.80 ± 14.10)
142.10 ± 28.42
(14.50 ± 2.90/104.88 ± 21.00)
199.92 ± 40.18
(20.40 ± 4.10/147.55 ± 29.66)
287.14 ± 57.82
(29.30 ± 5.90/211.93 ± 42.67)
395.92 ± 79.38
(40.40 ± 8.10/292.21 ± 58.59)
530.18 ± 105.84
(54.10 ± 10.80/391.30 ± 78.12)
691.88 ± 138.18
(70.60 ± 14.10/510.65 ± 101.99)
48.02 ± 11.76
(4.90 ± 1.20/35.44 ±8.68)
89.18 ± 17.64
(9.10 ± 1.80/65.82 ± 13.02)
133.28 ± 26.46
(13.60 ± 2.70/98.37 ± 19.53)
191.10 ± 38.22
(19.50 ± 3.90/141.04 ± 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS N ·m (kg ·m/lb ·ft)
Pipe diameter mm
(in) Torque Pipe diameter mm
(in) Torque
4.76 (0.187)
6.35 (0.250)
8.00 (0.315) 15.2 ± 2.45(1.55 ±0.25/11.2 ± 1.8)
26.48 ± 2.94(2.70 ± 0.30/19.5 ± 2.1)
44.14 ± 4.90(4.50 ± 0.50/32.5 ± 3.6) 10.00 (0.394)
12.00 (0.472)
15.00 (0.591) 53.95 ± 4.90(5.50 ± 0.5 /39.7 ± 3.6)
88.29 ± 9.80(9.00 ± 1.0/65.0 ± 7.2)
105.45 ± 12.26(10.75 ± 1.25/77.7 ± 9.0)

ENGINE MECHANICAL 6A – 23

LOCTITE APPLICATION PROCEDURE
LOCTITE Type LOCTITE Color Application Steps
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 270 Green
LOCTITE 271 Red 1. Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.

3. Tighten the bolts to the specified torque.
4. Wait at least one hour before continuing the installation procedure.

LOCTITE 515 Violet 1. Completely remove lubricant and moisture from the connecting
surfaces.
The surfaces must be perfectly dry.
2. Apply a 2.0 – 2.5 mm bead of LOCTITE to one of the connecting
surfaces.
There must be no gaps in the bead.
3. Tighten the bolts to the specified torque.
4. Let the joined parts set for at least thirty minutes.

ENGINE MECHANICAL 6A – 31
VALVE CLEARANCE ADJUSTMENT
1. Bring the piston in either the No. 1 cylinder or the No. 4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.

014RY00014











2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.

Rocker Arm Shaft Bracket Nut Torque N·m (kg·m /lb·ft)
54 (5.5/40)


014RY00015
8. Check for play in the No. 1 intake and exhaust valve
push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
If the No. 1 cylinder intake and exhaust valve push
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.

014RY00016
Adjust the No.1 or the No. 4 cylinder valve clearances
while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold) mm (in)
0.4 (0.016)

9. Loosen each valve clearance adjusting screw as
shown in the illustration.
10. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.


014RY00017


11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360.
14. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
15. Adjust the clearances for the remaining valves as
shown in the illustration.

6A – 32 ENGINE MECHANICAL









































COMPRESSION PRESSURE
MEASUREMENT
1. Start the engine and allow it to idle until the coolant
temperature reaches 70 – 80 C (158 – 176 F).
2. Remove the following parts.
 Leak off pipe
 Injection nozzle holder bracket
 Injection nozzle holder
3. Install the following parts.
 Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
 Injection nozzle holder bracket

Injection nozzle holder bracket Bolt Torque
N·m (kg·m /lb·ft)
37 (3.8/27)

Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0


4. Turn the engine over with the starter motor and take
the compression gauge reading.

Compression Pressure MPa (kg/cm
2 /psi) at 200 rpm
Standard Limit
3.0 (31.0/441) 2.1 (21.7/309)




5. Repeat the procedure (Steps 3 and 4) for the
remaining cylinders.
If the measured value is less than the specified limit,
refer to “Troubleshooting” in this Manual.
F06XL056
901R100003

6A – 38 ENGINE MECHANICAL
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.

7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness
Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model)
Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model)
Remove the shift lever from the floor.

14. Transmission member
1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts
fixing the transmission member to the chassis frame.


15. Torque converter bolt (for A/T model)
1) Remove the under cover under the torque converter
housing.
2) Rotate the flywheel by using tire lever or some other
tool, and then remove the torque converter bolts.
16. Transmission coupling bolt
1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer)
Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..

F06R300007 P1010025

ENGINE MECHANICAL 6A – 81

Connecting Rod Bearing Inside Diameter
1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening
method.


Connecting Rod Bearing Cap Bolt Torque N·m (kg·m/Ib ft)
4JA1T (L),
4JA1TC 78-88 (8.0/57 – 9.0/65)
1st step ; 29.0–29.2 (3.00/22.0–3.01/22.2)4JH1TC
2nd step ; 45
-60

3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.



Crankpin and Bearing Clearance
If the clearance between the measured bearing inside diameter
and the crankpin exceeds the specified limit, the bearing
and/or the crankshaft must be replaced.


Crankpin and Bearing Clearance mm (in)
Standard Limit
4JA1T (L),
4JA1TC 0.029-0.066
(0.0011-0.0026) 0.100(0.0039)
4JH1TC 0.029-0.083
(0.0011-0.033) 0.100 (0.0039)






Clearance Measurements (With Plastigage)
Crankshaft Journal and Bearing Clearance
1. Clean the cylinder body, the journal bearing fitting surface,
the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30
to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal
across the full width of the bearing.
6. Install the bearing caps with the bearing.








7. Tighten the bearing caps to the specified torque.


Crankshaft Bearing Cap Bolt Torque mm (in)
167 (17/123)
Do not allow the crankshaft to turn during bearing cap
installation and tightening.
8. Remove the bearing cap.



015RY00012
015RY00013 015RY00011