Lead ISUZU TF SERIES 2004 Owner's Manual

10-8 CAB

Important Operation - Removal
3. Rear Window Glass
Remove the glass, carefully following the steps listed below :
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end o
f
the piano wire through the adhesive caulking material at the
edge of the rear window glass.
4) Secure the other end of the piano wire to another piece o
f
wood.




5) With the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the rear windo
w
glass.
6) Lift the rear window glass from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the rear window glass.
8) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the rear window glass.


Important Operation - Installation
3. Rear Window Glass
1) Clean the rear window glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Install the fastener tape to body panel flange.



4) Apply primer 1 sunster #435-40 or equivalent to the rear
window glass side bonding surface.
The primer should extend 23 mm (0.9 in.) form end of the
glass.

ELECTRICAL-BODY AND CHASSIS 8A-179

HORN SWITCH
Removal
1. Disconnect the battery ground cable.
2. Disable the SRS (Refer to “Disabling the SRS”in this
section).
3. Check the both side hole of the steering cover.


4. Check the position of the pins in a hole. Push the pin in the
direction of an arrow.


5. Push the four pins at 56 mm bar.

6. Cancel the lock four pins.
7. Disconnect the SRS air bag connector and horn lead
connector located behind the air bag assembly and remove
the air bag assembly.

Installation
1. Connect the SRS bag connector and horn lead connector.
2.
Align the each snap stud of driver air bag to the hole of
steering wheel.

ELECTRICAL-BODY AND CHASSIS 8A-209

High Speed Inspection
1. Clamp the wiper motor in a vise.
The moving parts must be clear of the vise.
2. Connect the connector terminals to the battery.
Refer to the illustration.
3. Check the wiper motor high speed operation.


Auto-Stop Inspection
1. Clamp the wiper motor in a vise.
The moving parts must be clear of the vise.
2. Connect the connector terminals to the battery.
Refer to the illustration.
3. Check the wiper motor low speed operation.
4. Disconnect the positive battery terminal.
This will stop the motor.



5. Connect the connector terminals No. 3 and No. 6 with a
lead wire.
Refer to the illustration.
6. Reconnect the positive battery terminal to connecto
r
terminal No. 4.
This will restart the motor.
Refer to the illustration.
7. Check the auto-stop operation.







Washer Motor Inspection
1. Fill the washer tank with washing solution.
2. Disconnect the motor connector.
3. Apply battery voltage to the washer motor connector.
4. Check the washer motor operation.

ENGINE ELECTRICAL 6D – 11



RTW46DSH000301
7. Rotor Assembly
1. Remove the rotor from front cover assembly.

Remove the front cover stator and rectifier.




RTW46DSH000701
8. Front Cover Assembly
1. Remove the front cover bearing retainer screws.
2. Remove the bearing.




RTW46DSH000801
9. Rear rotor bearing

Re-use improper parts.
10. Rectifier
1. Disconnect the stator coil leads between each rectifier
by melting the solder connection.
Hold the lead wire between the solder and the rectifier
with a pair of long nose pliers.
This will prevent heat transfer and resultant damage to
the rectifier.



RTW46DSH000401

ENGINE ELECTRICAL 6D – 19


RTW46DSH000401
Important Operations
2. Rear rotor bearing

Re-use improper parts.


5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.



RTW46DSH002101







3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque Nm (kgm/lbft)
83.3  98.0 (8.5  10.0 / 61  72)





RTW46DSH006001
Remove the tape from the splines.









RTW46DSH004901
The rear ball bearing is pressed into the wheel eccentric
groove. The bearing ring projects from the groove.

During installation, rotate the bearing to the point of
minimum bearing ring projection.

Inspect the rear cover bearing box and replace it if it is
damaged.

ENGINE ELECTRICAL 6D – 23


DISASSEMBLY



RTW460LF000201
Disassembly Step
1.
Lead wire
14. Armature
2.
Bolt 15. Bolt
3.
Magnetic switch assembly 16. Bearing retainer
4.
Torsion spring 17. Pinion assembly
5.
Plunger 18. Pinion stopper clip
6.
Dust cover 19. Pinion stopper
7.
Magnetic switch 20. Return spring
8.
Screw 21. Pinion shaft
9.
Through bolt 22. Clutch
10.
Rear cover 23. Dust cover
11.
Motor assembly 24. Shift lever
12.
Brush holder 25. Gear case
13.
Yoke

6D – 24 ENGINE ELECTRICAL


RTW46DSH002601
Important Operations
1. Lead Wire
Disconnect the lead wire at the magnetic switch.



RTW46DSH002701
3. Magnetic Switch Assembly
Remove the magnetic switch bolts, then remove the
switch from the shift lever.



RTW46DSH002801
Remove the torsion spring from the magnetic switch.




RTW46DSH002901
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.



RTW46DSH003001
11. Motor Assembly
Remove the four brushes from the brush holders.

ENGINE ELECTRICAL 6D – 27


RTW46DSH003701
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two
commutator segments.
2 Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the commutator.
If there is not, the armature must be replaced.




RTW46DSH003801
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.



RTW46DSH003901
2. Use the circuit tester to check the field winding
continuity.
1 Hold one circuit tester probe against the “M”
terminal lead wire.
2 Hold the other circuit tester probe against the field
winding brush.
There should be continuity.
If there is no continuity, the yoke must be replaced.

ENGINE ELECTRICAL 6D – 29
REASSEMBLY



RTW46DLF000601


Reassembly Steps
1.
Magnetic switch assembly
14. Pinion stopper
2.
Magnetic switch 15. Pinion stopper clip
3.
Dust cover 16. Bearing retainer
4.
Plunger 17. Bolt
5.
Torsion spring 18. Motor assembly
6.
Shift lever
19. Armature
7.
Gear case 20. Yoke
8.
Dust cover 21. Brush holder
9.
Bolt 22. Rear cover
10.
Pinion assembly 23. Screw
11.
Clutch 24. Through bolt
12.
Pinion shaft 25. Lead wire
13.
Rerurn spring

ENGINE ELECTRICAL 6D – 31






24. Through Bolt
Install the through bolts in the rear cover and tighten them
to the specified torque.
Through Bolt Torque Nm (kgm/lbft)
8.1 (0.83/6.00)

065RY00044


RTW46DSH002601






25. Lead Wire
Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque Nm (kgm/lbft)
8.6 (0.88/6.40)







RTW46DSH005801












Inspection After Assembly
Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play mm (in)
0.1 – 2.0 (0.004 – 0.078)