torque ISUZU TF SERIES 2004 Workshop Manual

2B-4 SHEET METAL


2. Hood Hinge Bolts


Tighten the engine hood hinge fixing bolts to the specified
torque.

Torque N
m(kgf
m/lb
in)
10 (1.0
/ 87)

2B-6 SHEET METAL


Important Operations - Installation
4. Control Cable

Reroute the control cable to its original position, and check and
see if the lock assembly and control lever work normally.


2. Engine Hood Lock Assembly

Adjustment
1) Install the engine hood lock assembly (4) and temporaril
y
tighten the bolts securing it.
2) Close the hood.
3) Position the hood so that the stepped portion between the
hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
4) Final tighten the bolts securing the engine hood lock
assembly.



5) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified
torque.

Torque N
m(kgf
m/lb
in)
10 (1.0
/ 87)

2B-8 SHEET METAL


Important Operations - Removal
1. Radiator Grille

Refer to the Radiator Grille in this section.





4. Inner liner

Remove the inner liner fixing screws.





5. Front bumper facia

Refer to the Front Bumper in this section.




7. Front fender panel

Remove the eight fixing bolts.









Important Operation - Installation
7. Front Fender Panel


1) Tighten the front fender panel fixing bolts to the
specified torque.

Torque Nm(kgfm/lbin)
10 (1.0
/ 87)

2B-12 SHEET METAL


Important Operations - Removal
4. Fuel Filler Pipe and Evaporator Hose




7. Rear Body Assembly

Attach lifting wires to the rear body hooks and raise the rear
body.

Note:
In lifting up rear body, take care not to dash it against cab
body.




Important Operation – Installation
6. Bolt; Frame to Body

Torque Nm(kgfm/lbft)
54 (5.5
/ 40)

2B-14 SHEET METAL








Important Operations – Installation
Bolt : A
Torque N
m(kgf
m/lb
ft)
50 (5.1
/ 37)

Bolt : B,C
Torque N
m(kgf
m/lb
ft)
72 (7.3
/ 53)

Bolt : D,E,H,I
Torque N
m(kgf
m/lb
ft)
54 (5.5
/ 40)

NOTE :
Discard used the mounting bolts D,E,H,I shown in the
figure and install new one.

2B-16 SHEET METAL








Important Operations – Installation
Bolt : A
Torque N
m(kgf
m/lb
ft)
50 (5.1
/ 37)

Bolt : B,C
Torque N
m(kgf
m/lb
ft)
72 (7.3
/ 53)

Bolt : D,G,H
Torque N
m(kgf
m/lb
ft)
54 (5.5
/ 40)

NOTE :
Discard used the mounting bolts D,G,H shown in the
figure and install new one.

2B-18 SHEET METAL






Important Operations – Installation
Bolt : A
Torque N
m(kgf
m/lb
ft)
50 (5.1
/ 37)

Bolt : B,C/D
Torque N
m(kgf
m/lb
ft)
72 (7.3
/ 53)

RTW32BSH000401






Bolt : E-1
Torque N
m(kgf
m/lb
ft)
116 (11.8
/ 85)

Bolt : E-2
Torque Nm(kgfm/lbft)
168 (17.1
/ 124)


Bolt : F,H,I
Torque Nm(kgfm/lbft)
54 (5.5
/ 40)

NOTE :
Discard used the mounting bolts G,H shown in the figure
and install new one.

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and
obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be
sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the movement for the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.

GENERAL INFORMATION 0A-3

NOTES ON THE FORMAT OF THIS MANUAL
1. Find the applicable Section by referring to the index at the front of the Workshop Manual binder.
2. The following technical service information is included in this Section:


Identification


Maintenance schedules


Recommended Iubricants


Recommended fuels


Oil viscosity charts
3. Individual Sections of this Workshop Manual are divided into the following categories:


Main data and specifications


Torque specifications


Recommended liquid gasket


Loctite application procedure


Servicing


Removal and installation


Disassembly


Inspection and repair


Reassembly


Troubleshooting
4. Each "Major Components" page of this Workshop Manual has an exploded view of the applicable area.
A brief explanation of the notation used follows:

0A-4 GENERAL INFORMATION
5. Below is a sample of the Workshop Manual text following the " Major Components " page.
A brief explanation of the notation used follows:


6. The following symbols appear throughout the Workshop Manual.

They tell you at a glance the type of service operation to perform.

........
Removal ........
Adjustment
........
Installation ........
Cleaning
........
Disassembly ........
Important operation requiring extra care
........
Reassembly ........
Specified torque
........
Alignment ........
ISUZU special tool(s) required or recommended
........
Directional indication ........
Other special tool(s) required or recommended
........
Inspection ........
Lubrication (Oil)
........
Measurement ........
Lubrication (Grease)
........
Torque Angle Method ........
Liquid gasket application