power steering ISUZU TF SERIES 2004 User Guide

4C1-16 FRONT WHEEL DRIVE
17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.


Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.

RTW34CSH000101
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 N·m (17.2kg·m/124 lb ft)



4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.

5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

FRONT WHEEL DRIVE 4C1-17
NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.

6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly. (With
shift on the fly)
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
Torque : 98 N·m (10.0kg·m/73 lb ft)

9. Install lower bolts and nuts of the shock absorber, tighten it
to the specified torque.
Torque : 93 N·m (9.5kg·m/69 lb ft)
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
Torque : 50 N·m (5.1kg·m/37 lb ft)
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing
preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
Torque : 155 N·m (15.8kg·m/115 lb ft)
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to the
specified torque.
Refer to Lower Control Arm in Suspension section.

8B-6 CRUISE CONTROL SYSTEM
Adjustment
1. Check to be sure that the brake pedal has been completely
returned by the return spring.
2. Disconnect the switch connector.



RTW3A0SH001201

3. Release the lock (2) by turning the switch (1) counter-clock-
wise.
4. After doing so, pull the pedal arm (3) to you a little so tha
t
the pedal arm is not pushed in.
5. Making the pedal arm not movable with one hand, push in
the whole switch with the other hand until the plunger of the
switch is pushed in and the switch itself hits the rubber o
f
the pedal arm.
In the condition, turn the switch clock-wise until "click"
sound is made and lock it.
By doing this, the switch is adjusted at 0.2 to 1.2mm (0.01-
0.06 in.) clearance.

Clutch Switch


Removal and Installation
Refer to the Clutch Control removal and installation steps in
Clutch section.

Adjustment
1. Turn the clutch switch or stopper bolt 1 until the switch bolt
or stopper bolt just touches the clutch pedal arm.
2. Adjust clutch switch or stopper bolt by backing it out half a
turn, and measure the clearance (L) between the clutch
pedal arm and the clutch switch bolt end or stopper bolt.
3. Lock the lock nut
2.
4. Connect the clutch switch connector.

Clutch switch and clutch and clutch pedal clearance
mm (in)

Limit 0.5-1.5 (0.020-0.059)


Starter Switch

431R300001
Removal
1. Steering Lock Assembly

Refer to the Steering Lock assembly removal steps o
f
"Steering Column" in Power-Assisted Steering System
section.
2. Starter Switch

Installation
Follow the removal procedure in the reverse order to install the
starter switch.

ENGINE MECHANICAL 6A – 39

18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.


19. Fan

P1010034
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC) from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box from engine room.
3) Remove the two air ducts from inter cooler (4JA1TC/4JH1TC).

21. Power Steering Pump Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor 1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air conditioner compressor along with piping on the body
side.
23. Engine Control Cable Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).

24. Vacuum Piping Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).

25. Engine Harness 1) Remove following connectors from engine.

TPS connector

Oil pressure switch connector

Thermo switch connector

Injection pump connector

Engine earth

Thermometer unit connector

TDC sensor
2) Remove the clips fixing engine harness.
P1010009

ENGINE MECHANICAL 6A – 43

ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS


RTW36AMF000401

Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch
16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold

ENGINE MECHANICAL 6A – 45



4JA1L
RTW46ASH001001
4. EGR Valve
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.




4JA1TC RTW46ASH000901
5. Oil Level Gauge
1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level
gauge.


6. Fuel Filter Assembly (Except EURO III model)
1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.

7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.



4JH1TC RTW36ASH001201
8. Fuel Injection Pipe with Clip
1) Loosen the injection pipe sleeve nuts at pump side
and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.

9. Power Steering Oil Pump Bracket


RTW36ASH000701
10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Remove the intake manifold with gasket.

11. Engine Mounting Bracket and Foot
12. Injection Pump Cover

6A – 118 ENGINE MECHANICAL

INSTALLATION
EXTERNAL PARTS





RTW36AMF000701
Installation Steps
1.
Exhaust Manifold 18. Engine Mounting Bracket and
2.
Oil Cooler with Oil Filter Foot
3. Generator Bracket 19. Intake Manifold
4. Water Inlet Pipe 20. Power Steering Oil Pump
5.
Generator and Adjusting Plate Bracket
6.
Vacuum Pump Oil Return Hose 21. Fuel Injection Pipe with Clip
7.
Compressor Bracket 22. Fuel Filter Bracket (Except
EURO III)
8. Turbocharger 23. Fuel Filter Assembly (Except
EURO III)
9. Catalytic Converter 24. Oil Level Gauge
10. Heat Protector 25. EGR Valve
11. Cooling Fan Pulley 26-1. EGR Pipe
12. Oil Cooler Water Pipe 26-2. EGR Cooler (EURO III model
only)
13. Fuel Leak Off Pipe 27. Intake Pipe and Throttle Body
(4JA1TC/4JH1TC only)
14. Oil Pressure Warning Switch 28. Clutch Assembly or Flex Plate
15. Starter Motor
16. Injection Pump
17. Injection Pump Cover

6A – 124 ENGINE MECHANICAL
20. Power Steering Oil Pump Bracket
Oil Pump Braket Nut and Bolt Torque N·m(kg·m/Ib ft)
1M10
1.25
37 (3.8/28)
2
3M8
1.25
18 (1.8/13) (Bolt ID:8)






040R300005























21. Fuel Injection Pipe with Clip
1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) N·m(kg·m/Ib ft)
40 (4.1/30)

Injection Pipe Sleeve Nuts N·m(kg·m/Ib ft)
29 (3.0/22)

Injection Pipe Clip Nuts N·m(kg·m/Ib ft)
8 (0.8/6)




















22. Fuel Filter Bracket (Except EURO III model)
Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)

23. Fuel Filter Assembly (Except EURO III model)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque N·m(kg·m/Ib ft)
21 (2.1/15)








24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque N·m(kg·m/Ib ft)

M8 19 (1.9/14)
M6 8 (0.8/6)

431RY00013

FUEL SYSTEM 6C – 19
INJECTION PUMP

REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.



Removal
1. Battery
Remove the battery from the battery tray.



6C-1
2. Drive Belt 1) Loosen the adjust bolt of the power steering pump pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly


P1010003
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.


5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the intake throttle.
6. Fan

6C – 20 FUEL SYSTEM

7. Power Steering Pump Bracket


6C-4 8. Throttle Position Sensor Harness Connector
(4JA1TC/4JH1TC only)
Disconnect the harness connector from the throttle
position sensor.

9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.

11. Fuel Filter Assembly (Except EURO III model)
6C-5
12. Fuel Filter Bracket (Except EURO III model)
13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.

16. Intake Manifold
1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
17. Injection Pump Cover (4JA1TC/4JH1TC only)