suspension ISUZU TF SERIES 2004 User Guide

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.

4C1-42 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4




2 Except High Ride Suspension Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure.

RTW34CLF000801
Disassembly Steps
1. Bolt


2. Brake caliper


3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer


8. Outer bearing


9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor


13. Bolt


14. Wheel pin

4C1-50 FRONT WHEEL DRIVE
FRONT HUB AND DISC
(4




4, 4




2 High Ride Suspension,
4





4 Rigid Hub, 4





4 Shift On the Fly Model)
DISASSEMBLY
Refer to SECTION 3E “WHEEL AND TIRE” for wheel removal procedure

411R300011

Disassembly Steps
1. Bolt
2. Hub cap
3. Snap ring and shim (4
4 model only)
4. Flange (4
4 model only)
5. Lock washer


6. Hub nut


7. Hub and disc assembly


8. Outer bearing
9. Oil seal
10. Inner bearing
11. ABS sensor rotor


12. Bolt


13. Wheel pin

4C1-68 FRONT WHEEL DRIVE
4





2 Model
1. WANDERS AND PULLS

Checkpoint Trouble Cause Countermeasure


Adjust the wheel bearing
preload

Too tight
NG

Adjust the front alignment

Front alignment

Incorrect


Steering unit

Tighten or replace

Loose or worn
NG NG

Suspension

Tighten or replace


Replace or adjust the inflation


Front or rear suspension parts
loose or broken


Tire

Worn or improperly inflated

OK
NG NG OK OK
OK

Wheel bearing preload

4C1-72 FRONT WHEEL DRIVE
5. WANDERS AND PULLS

Checkpoint Trouble Cause Countermeasure


Adjust the wheel bearing
preload

Too tight
NG

Adjust the front alignment

Front alignment

Incorrect


Tighten or replace

Steering unit

Loose or worn
NG NG
OK OK

Tighten or replace


Replace or adjust the inflation


Suspension

Front or rear suspension parts
loose or broken


Tab

Worn or improperly inflated

NG NG
OK OK

Wheel bearing preload

5C-22 BRAKES

RTW35CSH001001






Operation
1) Outline
When the LSPV (Load Sensing Proportioning Valve)
detects a change in load weight, the load sensing spring
stretches.
Its reaction force is transmitted to the bottom of the load
sensing valve to secure an optimum rear wheel cylinde
r
fluid pressure break point in proportion to the actual load
weight.
Besides, if the front brake system should fail, the device is
designed to prevent the master cylinder fluid pressure from
decreasing and to apply it directly to the rear wheel cylinde
r
to obtain a sufficient braking performance.

RTW35CSH001101

2) Bellow cutting point.
The Force (F) keeps the main piston (1) the rest position.
The inlet pressure (A) and outlet pressure (B) are the same
as well as the inlet pressure (C) from front master cylinder.
The bypass piston (2) is kept on rest position by equilibrium
of the pressures (A) and (C) and the bypass spring load (3).

RTW35CSH001201

3) Cutting point.
The cutting point is given by relation between force (F), tha
t
is the load applied by suspension of the vehicle and the
main piston area (1). The cutting point is achieved when the
force generated by hydraulic pressure is upper than the
force (F) given by the load suspension. The main piston (1)
moves from the rest position closing the valve. In this
moment the inlet pressure (A) is upper than the outle
t
pressure (B). The bypass piston (2) continues on the res
t
position by equilibrium of (A) and (C) pressure.

5C-24 BRAKES

RTW35CSH000201
3) Rear wheel cylinder fluid pressure measurement
Step on the brake pedal until the fluid pressure of the
front wheel cylinder gets to 9.8Mpa (100kg/cm
2), and
check the rear wheel cylinder fluid pressure. (Read the
value of the front wheel cylinder fluid pressure 2
seconds after the measurement. When measuring the
L.S.V fluid pressure, keep the brake pedal pressed
down without stepping it down twice or releasing it.)
Rear Wheel Cylinder Fluid Pressure MPa (kg/cm
2)

2WD 6.77
0.83 (69.0
8.5)
2WD (With High Ride
Suspension), 4WD 6.77

0.83 (69.0

8.5)

RTW35CSH000401
2. Oil Pressure Adjustment
1) LSPV spring length adjustment
Loosen the adjust nut of the LSPV spring joint, and
adjust the length of the LSPV spring.
When the oil pressure is insufficient, turn the adjust nu
t
clockwise to extend the span “A”. When the oil pressure
is too high, turn the adjust nut counterclockwise to
reduce the span “A”.


2) After adjustment, tighten the lock nut securely.
Lock Nut Torque N
m (kg
m/lb in)
11-20 (1.1-2.0/95-174)

5C-28 BRAKES


27. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in the
reservoir and replenish up to the “MAX" level as necessary.
28. Attach the reservoir cap.
29. Stop the engine.




05007-1


BRAKE LINE (HOSES AND PIPES)

Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or parts replacement if these
abnormal conditions are found through inspection.

All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and
bent when working with then, and pay special attention to all
the brake lines not to damage them when repairing o
r
replacing other parts (axle, suspension, etc).

Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints,
retighten or replace these parts.
This procedure must be performed whenever brake lines
are installed.

After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–79
–Are there areas subjected to vibration or
movement (engine, transmission or
suspension)?
–Are there areas ex posed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
–Are there common mounting areas with other
systems/components?
–Have previous repairs been performed to wiring,
connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
–Does the vehicle have aftermarket or dealer-
installed equipment (radios, telephone, etc.)
Step 2: Isolate the problem
At this point, you should have a good idea of what could
cause the present condition, as well as could not cause
the condition. Actions to take include the following:
Divide (and separate, where possible) the system or
circuit into smaller sections
Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
For two or more circuits that do not share a common
power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
Loose connections:
–Open/high resistance in terminals, splices,
connectors or grounds
Incorrect connector/harness routing (usually in new
vehicles or after a repair has been made):
–Open/high resistance in terminals, splices,
connectors of grounds
Corrosion and wire damage:
–Open/high resistance in terminals, splices,
connectors of grounds
Component failure:
–Opens/short and high resistance in relays,
modules, switches or loads
Aftermarket equipment affecting normal operation of
other systems
You may isolate circuits by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another part
Operating shared circuits and eliminating those that
function normally from the suspect circuit
If only one component fails to operate, begin testingat the component
If a number of components do no operate, begin tests
at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Technical equipment (for data analysis)
Ex perience
Technical Assistance
Circuit testing tools
5d. Intermittent Diagnosis
By definition, an intermittent problem is one that does
not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
Faulty electrical connections and wiring
Malfunctioning components (such as sticking relays,
solenoids, etc.)
EMI/RFI (Electromagnetic/radio frequency
interference)
Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
ex ternal and internal system conditions to duplicate the
problem.
What you should do
Step 1: A cquire information
A thorough and comprehensive customer check sheet
is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
Step 2: A nalyze the intermittent problem
Analyze the customer check sheet and service history
file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.

6A-26 ENGINE MECHANICAL (6VE1 3.5L)
Exhaust Manifold LH
Removal
1. Disconnect battery ground cable.
2. Disconnect O
2 sensor connector.
3. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end o
f
exhaust front pipe.




RTW36FSH000201
5. Remove heat protector two fixing bolts then the
heat protector.
6. Remove a bolt on engine LH side for ai
r
conditioner (A/C) compressor bracket and loosen
two bolts for A/C compressor then move A/C
compressor to front side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Installation
1. Install exhaust manifold and tighten exhaust
manifold fixing nuts to the specified torque with
new nuts.
Torque: 52 N




m (5.3 kg




m/38 lb ft)
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 N




m (6.8 kg




m/49 lb ft)
Nuts: 43 N




m (4.4 kg




m/32 lb ft)




RTW36FSH000201
4. Install the torsion bar and readjust the vehicle
height. Refer to installation and vehicle heigh
t
adjustment procedure for front suspension.
5. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
Torque : 40 N




m (4.1 kg




m/30 lb ft)
6. Reconnect O
2 sensor connector.
7. Install air cleaner duct assembly.