wheel torque ISUZU TF SERIES 2004 Owner's Guide

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-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)

5C-10 BRAKES
TORQUE SPECIFICATIONS
FRONT WHEEL BRAKE Nm(kgfm/lbft)
E05R300016

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-48 BRAKES



Important Operations
Note :


Wash the disassembled parts in clean brake fluid.


Use compressed air to clean the ports.


Protect the disassembled part surfaces from dust and othe
r
foreign material contamination.


Before reassembly, check the part surfaces for dust and
other foreign material contamination.


Be sure to replace the designated parts with new ones.

4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.




Apply brake fluid to the piston and the inner face of the
boots.


Note the direction of piston cup.



5. Bleeder ; Wheel Cylinder
Torque Nm(kgfm/Ibin)
6 - 8 (0.6 – 0.8 / 52 - 69)



9. Wheel Cylinder Assembly
10. Bolt ; Wheel cylinder
Torque N
m(kgf
m/Ib
ft)
7 - 11 (0.7 – 1.1 / 61 - 95)

5C-50 BRAKES












20. Lever ; adjuster
21. Ring ; Adjuster lever


Apply grease to the lever ; adjuster sliding surface.
Install the lever ; adjuster and the ring to the shoe ;
trailing.


Be sure to use new ring.

P1010008B


23. Pin ; shoe hold
24. Spring ; shoe hold

Install the brake drum.


Install the rear wheel.


If the wheel cylinder has been removed, the brake
system must be bled.


Pump the brake pedal 10 times. Check that there is little
or no stroke length variation as the pedal is pumped.


Adjust the lining clearance.




Brake Line
Torque N
m(kgf
m/Ib
ft)
13 - 19 (1.3 - 1.9 / 9 - 14)

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-13


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

5D-10 PARKING BRAKE SYSTEM

Removal
1. Remove wheel and tire.
2. Remove brake drum.
3. Remove tension pin (1) and shoe clamp spring (2).
4. Remove return spring (3).
5. Remove shoe assemblly with parking brake leve
r
(4).
6. Remove shoe assembly with adjuster lever (5) and
spring (6).
7. Remove parking brake inner cable from parking
brake lever (4).
8. Use offset box wrench (12mm hex.) to compress
locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.





311RS012

Legend
(1) Offset Box Wrench (12mm hex)
9. Remove nut (8) to fix the cable (7) on the leaf
spring.
10. Take out parking brake rear cable (7) from the
back plate.
11. Remove bolt (9) and nut (10).
12. Disconnect T-end (11) from the equalizer of front
cable.

Installation
NOTE: Be sure to use the new shoe clamp spring (2)
and the new adjuster lever clip (14).
1. Apply grease (multipurpose type grease) to the
connecting portion of the rear cable (11) and
equalizer (13). (aroow mark).
2. Install parking brake outer cable in back plate and
inner cable in parking brake lever (4).
3. Install return spring (3).
4. Install shoe clamp spring (2) and tension pin (1)
5. Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever (4) and spring
(6). ---- snap action
6. Install nut (8) and tighten it to the specified torque.
Torque: 7N




m (0.7 kg




m/61 lb in)
7. Connect T-end (11) with equalizer (13) through
outer cable retainer (12).
8. Install nut (10) and tighten it to the specifed
torque.
Torque: 15 N





m (1.5 kg





m/11 lb ft)
9. Install bolt (9) and tighten it to the specified
torque.
Torque: 7 N




m (0.7 kg




m/61 lb in)
10. Install brake drum.
11. Install wheel and tire.
12. Pull parking brake lever with a force equivalent to
poerating force: 490 N (50 kg/110 lb), 10 times fo
r
conditioning.
13. Adjust parking brake lever adjusting nut so that
parking brake lever goes through 8

14 (bench
seat) or 6

8 (bucket seat) notches, when pulled
with a operation force of 294N (30 kg/66 lb).
14. Check brake for no drag.

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)

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.