ISUZU TF SERIES 2004 Workshop Manual

WORKSHOP MANUAL
TF SERIES
FRAME AND CAB

SECTION 2

FRAME AND BUMPER 2A-1

SECTION 2A
FRAME AND BUMPER
TABLE OF CONTENTS
PAGE
Front Bumper ..................................................................................................................... 2A- 2
Rear Step Bumper ............................................................................................................. 2A- 4
Rear Bumper And Rear Guard ASM ................................................................................. 2A- 7
Frame Dimensions............................................................................................................. 2A- 9

2A-2 FRAME AND BUMPER
FRONT BUMPER
REMOVAL AND INSTALLATION


RTW42ALF000101

Removal Steps



1. Radiator grille


2. Front bumper fascia

3. Bezel (W/O Fog light)

4. Fog light

5. Front bumper flare assembly (W/ Front
wheel extention)

6. Front bumper inpact support assembly

7. Front bumper inpact bar assembly
(Except Europe equipment)
8. Front bumper inpact bar assembly (For
Europe equipment)

9. Fascia support side bracket

10. Fascia support lower bracket

Installation Steps

10. Fascia support lower bracket

9. Fascia support side bracket


8. Front bumper inpact bar assembly (For
Europe equipment)


7. Front bumper inpact bar assembly
(Except Europe equipment)

6. Front bumper inpact support assembly


5. Front bumper flare assembly (W/ Front
wheel extention)



4. Fog light

3. Bezel (W/O Fog light)

2. Front bumper fascia

1. Radiator grille

FRAME AND BUMPER 2A-3



Important Operations - Removal
1. Radiator Grille

Refer to the Radiator Grille in this section.



2. Front Bumper Fascia



Remove the nine clips and four screws.


Disconnect the fog light harness connectors.


Important Operations - Installation






8. Front Bumper Inpact Bar Assembly (For Europe
equipment)
7. Front Bumper Inpact Bar Assembly (Except Europe
equipment)
Tighten the fixing bolts to the specified torque.

Torque N
m(kgf
m/lb
ft)
62 (6.3
/ 46)
This illustration is except Europe equipment model.




5. Front Bumper Flare Assembly
Tighten the fixing nuts to the specified torque.

Torque N
m(kgf
m/lb
in)
7 (0.7
/ 61)






4. Fog Light
Tighten the fixing nuts to the specified torque.

Torque N
m(kgf
m/lb
in)
7 (0.7
/ 61)

2A-4 FRAME AND BUMPER
REAR STEP BUMPER
REMOVAL AND INSTALLATION
RTW32AMF000301

Removal Steps


1. Rear step bumper assembly


2. Side step pad
3. License light


4. Rear bumper center pad
5. Extension harness
6. Back bar / Conner brace
7. Rear bumper
8. Reinforce assembly

Installation Steps

8. Reinforce assembly


7. Rear bumper

6. Back bar / Conner brace
5. Extension harness
4. Rear bumper center pad
3. License light
2. Side step pad


1. Rear step bumper assembly



Important Operations - Removal
1. Rear Step Bumper Assembly

Remove the 3 bolts from each side.

Disconnect the extension harness connector.

FRAME AND BUMPER 2A-5

RTW32ASH000101

2. Side Step Pad

Push out the 4 fixing portions of side step pad from the
back face of the rear step bumper.
RTW32ASH000201

4. Rear Bumper Center Pad


Remove the 2 clips from both end of the center pad.

Push out the 7 fixing portions of center pad from the
back face of the rear step bumper.
RTW32AM H000101






















Important Operations - Installation
7. Rear bumper


Tighten the fixing bolts to the specified torque.
A: Bolt
Torque Nm(kgfm/lbft)
40 (4.1
/ 30)
6. Back Bar / Conner Brace
1) B: Bolt
Torque N
m(kgf
m/lb
ft)
40 (4.1
/ 30)

2) C: Bolt
Torque Nm(kgfm/lbin)
9 (0.9
/ 78)

3) D: Bolt
Torque N
m(kgf
m/lb
ft)
85 (8.7
/ 63)

2A-6 FRAME AND BUMPER
RTW32AMH000201







1. Rear Step Bumper Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 3 fixing bolts on the each side of back bar.

Torque N
m(kgf
m/lb
ft)
150 (15.3
/ 111)

FRAME AND BUMPER 2A-7

REAR BUMPER AND REAR GUARD ASM
REMOVAL AND INSTALLATION


RTW42AMF000201

Removal Steps


1. Rear guard assembly


2. Rear bumper assembly

3. Nut

4. Bolt

5. Bumper bracket

6. Screw

7. Cap

8. Rear bumper

Installation Steps

8. Rear bumper

7. Cap

6. Screw

5. Bumper bracket

4. Bolt


3. Nut


2. Rear bumper assembly


1. Rear guard assembly



Important Operations - Removal
1. Rear Guard Assembly



Remove the 2 bolts from each side.
2. Rear bumper assembly

Remove the 2 bolts from each side.

2A-8 FRAME AND BUMPER






Important Operations - Installation
3. Nut


Tighten the fixing bolts to the specified torque.
Torque N
m (kgf
m/lb
ft)
116 (11.8
/ 85)















RTW42AMH000101







2. Rear Bumper Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 2 fixing bolts on the each side of back bar.

Torque N
m (kgf
m/lb
ft)
150 (15.3
/ 111)

1. Rear Guard Assembly
1) Align the back bar to the frame as follows:


Face A should be contacted with the upper face of the
frame


Face B should be contacted with the rear end of the
frame.
2) Tighten the 2 fixing bolts on the each side of back bar.

Torque N
m (kgf
m/lb
ft)
150 (15.3
/ 111)