wheel bolts ISUZU TF SERIES 2004 Owner's Manual

ANTI-LOCK BRAKE SYSTEM 5B-7

Electronic Hydraulic Control Unit
Electronic Hydraulic Control Unit and Associated Parts



RHD model LHD model
350R300001-X

Legend


1.
Flare Nut from master cylinder front

2.
Flare Nut to front right wheel cylinder

3. Flare Nut to front left wheel cylinder

4.
Flare Nut to rear wheel cylinder


5.
Electronic Hydraulic Control Unit (EHCU)

6.
Flare Nut from master cylinder rear

7.
Bolt

8.
Front

Removal
1. Disconnect the harness connector.
2. Loosen five flare nuts and remove brake pipes.


After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry o
f
foreign matter.
3. Remove three bracket fixing bolts.

Installation
1. Install EHCU and tighten the bolt to the specified
torque.

Torque : 8 N
m (0.8 kg
m /69 lb in)
2. Tighten the flare nuts to the specified torque.

Torque : 16 N
m (1.6 kg
m /12 lb ft)

3. Connect the harness connector.

ANTI-LOCK BRAKE SYSTEM 5B-11

Rear Wheel Speed Sensor
Rear Wheel Sensor and Associated Parts
420R300008
Legend


1.
Rear Speed Sensor Assembly

2.
Bolt : cable to frame

3.
Connector

4. Bolt : sensor to rear axle


5.
Speed Sensor

6. Bolt : cable to axle

7.
Bolt : sensor to rear axle

8.
Speed Sensor

Removal
1. Disconnect the harness connector (3).
2. Remove the cable fixing bolt (2)(6).
3. Disconnect the cable fixing clips (arrow marked).
4. Remove the speed sensor fixing bolts (4)(7) and
speed sensor (5)(8).

Inspection and Repair
1. Check speed sensor head for presence of foreign
materials; remove any dirt, etc.
2. Check the head for damage, and replace speed
sensor if necessary.

ANTI-LOCK BRAKE SYSTEM 5B-13

Front Speed Sensor Rotor
Front Sensor Rotor and Associated Parts
411R300010
Legend


1.
Sensor Rotor

2.
Hub and Disc


3.
Disc Rotor fixing Bolt

4. Hub and Disc Assembly

Removal
1. Remove the hub and disc assembly (4). (Refer to
the section Front wheel Drive).
2. Remove two disc rotor fixing bolts (3) on a diagonal.
3. Drive out the sensor rotor using a metal bar and
hammer through the two bolt holes.


Discard the used sensor rotor.
4. Install disc rotot fixing bolts and tighten them to the
specified torque.

Torque : 103 N
m (10.5 kg
m /76 lb ft)

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

CAB 10-33
Important Operations
15. Instrument Panel & Crass Beam Assembly
1) Tighten the 4 bolts fixing the cross beam and body panel
to the specified torque.
Torque N
m (kgf
m/lb
ft)
19 (1.9/14)

2) A Bolt: Steering Column to Cross Beam
Torque N
m (kgf
m/lb
ft)
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
Torque N
m (kgf
m/lb
ft)
15 (1.5/11)


3) C Bolt: Parking Brake Bracket to Cross Beam
Torque Nm (kgfm/lbft)
15 (1.5/11)

21. Steering Wheel/Steering Cowl

Tighten the steering wheel fixing nut to the specified
truque.
Torque N
m (kgf
m/lb
ft)
35 (3.6/26)

7C-22 CLUTCH


Important Operations - Removal
1. Transmission Assembly
Refer to “MANUAL TRANSMISSION” of section 7B and 7B1
for “REMOVAL AND INSTALLATION” procedure.


2. Clutch Pressure Plate Assembly
3. Driven Plate Assembly
(1) Use the clutch pilot aligner

1 to prevent the driven plate
assembly

2 from falling free.
Clutch Pilot Aligner : 5-85253-001-0





(2) Loosen the clutch cover bolts in the numerical order shown
in the illustration.
(3) Remove the pressure plate assembly

3 from the flywheel.
(4) Remove the driven plate from the flywheel.

201RS017


220RW088-X

4. Release Bearing (6VE1)
5. Shift Fork (6VE1)

(1) Remove the release bearing (1) from the transmission
case.
(2) Remove the shift fork snap pin (2).
(3) Remove the shift fork pin and shift fork (3) from the fulcrum
bridge.
6VE1 4JH1-TC, C24SE

CLUTCH 7C-23
015RW053
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Remove flywheel assembly and crankshaft bearing. Do no
t
remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding
hammer 5-8840-0019-0 (J-23907) to remove the crankshaf
t
bearing



Important Operations - Installation
Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
installation procedure.

015RW054
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Install flywheel assembly and crankshaft bearing. Use the
installer 5-8840-0125-0 (J-26516-A) and driver handle 5-
8840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RS047
(2) Install new flywheel fixing bolts in the order illustrated and
tighten them to the specified torque.
N
m (kg
m/lb ft)

6VE1 54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.

CLUTCH 7C-25


(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly

4 with the flywheel
knock pin

5.
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque N
m (kgf
m/lb
ft)
18 
3 (1.8 
0.3 / 13.0 
2.2)

201RS017




(8) Remove the clutch pilot aligner.
Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.


4JH1-TC, C24SE
6VE1

CLUTCH 7C-27
201R300011


Clutch Set Force
1. Invert the pressure plate assembly.
2. Place a metal sheet “A” on the pressure plate.
3. Compress the pressure plate assembly until the distance
“B” becomes specified.
Thickness and Distance mm(in
)

A B
6VE1 8.2 (0.323) 12 (0.472)
4JA1T(L) 7.8 (0.307) 20 (0.787)
4JA1TC/
4JH1TC 7.8 (0.307) 18 (0.71)
C24SE 8.0 (0.315) 7.9 (0.311)
4. Note the pressure plate gauge reading.
Driven Plate Clamping Load N (kg/Ib)

Standard
6VE1 7200 (734/1618)
4JA1T(L) 5070 (517/1140)
4JA1TC/4JH1TC 6300 (642/1415)
C24SE 5500 (561/1237)

RTW37CSH000101
Diaphragm Spring Finger Height
1. Place a new driven plate or the appropriate spacer beneath
the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this.

Use a bench press to press down on the assembly from the
top.
 Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 - 98 N
(11 - 22 lb) in direction of release, when clutch cover assembly
is bolted to the flywheel.

6 – 14 TROUBLESHOOTING
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step Action Value(s) Yes No
1 Was the excessive noise coming from the
turbocharger? —
Go to Step 2 Go to Step 10
2 Inspect the fixing bolts and bands.
Was any problem found? — Tighten the
loose parts Go to Step 3
3 Was the intake or exhaust system gasket damaged?— Replace the
damaged
gasket. Go to Step 4
4 Inspect rotation parts condition.
Was the turbine wheel rotation rough? — Replace the
turbocharger. Go to Step 5
5 Inspect the turbine wheel.
Was the turbine wheel rubbing against housing? — Replace the
turbocharger. Go to Step 6
6 Was the turbine wheel damaged? — Replace the
turbocharger. Go to Step 7
7 Were there carbon deposits in the turbine or
compressor housing? — Clean or
replace the
turbocharger. Go to Step 8
8 Inspect the oil supply condition.
Was the oil feed pipe clogged? — Repair or
replace the oil
feed pipe. Go to Step 9
9 Was the turbine shaft bearing worn? — Replace the
turbocharger. Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved

11. Rotating Part Wear of Turbocharger
Step Action Value(s) Yes No
1 Inspect engine oil.
Was it contaminated with foreign materials? — Replace the
engine oil Go to Step 2
2 Was the recommended engine oil grade/viscosity
being used? API CD or
ISUZU
genuine/
10W–30
Go to Step 3 Replace the
engine oil
3 Was the oil feed pipe restricted? — Clean or
replace the oil
feed pipe Go to Step 4
4 Was the oil seal of turbocharger defective? — Replace the oil
seal Go to Step 5
5 Was the center housing oil drain passage clogged? — Clean center
housing or
replace the
turbocharger Go to Step 6
6 Was there oil sludge and/or coking on the turbine
shaft? — Replace the
turbocharger Go to Step 7
7 Are any DTC stored? — Go to indicated
DTC Solved