lock ISUZU TF SERIES 2004 Workshop Manual

ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (C24SE)
CONTENTS

Service Precaution............................................... 6H-1
Accelerator Pedal Control Cable...................... 6H-2
Removal.............................................................. 6H-2
Inspection........................................................... 6H-3
Installation.......................................................... 6H-3




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 o
r
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.

6H-2 ENGINE SPEED CONTROL SYSTEM (C24SE)
Accelerator Pedal Control Cable

RHD MODEL


RTW46HLF000501

Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from
accelerator control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in indirection an arro
w
90
.

ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-3
4. Remove the accelerator control cable from the
throttle.




LHD MODEL

RTW46AMH000101

Inspection
Check the following items and replace the control
cable if any abnormality is found.
 The control cable should move smoothly.
 The control cable should not be bent or kinked.
 The control cable should not be damage o
r
corrosion.
Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam o
f
engine.
3. Install accelerator control cable to accelerato
r
bracket.
1) Rotate the ratchet ring in direction an arrow 90

until both white marking are aligned.
2) Confirm marking of outer cap must be uppe
r
side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.

6J-2 INDUCTION

Service Precaution
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, or 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.


RTW46JSH000101










Air Cleaner Filter
NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.

Removal
1. Remove positive ventilation hose connector.
2. Remove intake air temperature sensor.
3. Remove mass air flow sensor.
4. Remove air cleaner duct assembly.
5. Remove air cleaner element.

Inspection
Check the air cleaner filter for damage or dust clogging.
Replace if it is damaged, or clean if it is clogged.



Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.

SHEET METAL 2B-1

SECTION 2B
SHEET METAL

This section includes items of front end sheet metal that are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance.
When servicing these panes, areas on which this material has been disturbed, should be properly recoated with
service-type anticorrosion material.
TABLE OF CONTENTS
PAGE
Engine Hood Assembly ..................................................................................................... 2B- 2
Engine Hood Lock ............................................................................................................. 2B- 5
Front Fender Panel ............................................................................................................ 2B- 7
Radiator Grille .................................................................................................................... 2B- 10
Rear Body ........................................................................................................................... 2B- 11
Body Mounting ................................................................................................................... 2B- 13
Body Dimension.................................................................................................................2B- 19

SHEET METAL 2B-5
ENGINE HOOD LOCK
REMOVAL AND INSTALLATION



This illustration is based on the RHD model.
RTW42BMF000101

Removal Steps
Installation Steps


1. Radiator grille


4. Control cable


2. Engine food lock assembly
3. Hood lock control lever
3. Hood lock control lever


2. Engine food lock assembly


4. Control cable
1. Radiator grille



Important Operations - Removal
1. Radiator Grille
Refer to the Radiator Grille in this section.


2. Engine Hood Lock Assembly

Apply setting marks (1) to the hood lock assembly and the
body prior to removal.

4. Control Cable
Pull out the control cable toward the passenger compartment.

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)

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-5

7. Measurement criteria are defined by the terms "standard" and "limit".

A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.
"Limit" is an absolute value.

A measurement falling outside the "limit" indicates that the applicable part or parts must be repaired or replaced.
8. Components are parts are listed in the singular form throughout the Workshop Manual.
9. The following directional criteria are used throughout the Workshop Manual:

Front:

The cooling fan side of the engine.
Right:

The right-hand side of the engine viewed from the flywheel.

Left:
The left-hand side of the engine viewed from the flywheel.

Rear:

The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine towards the rear.

The engine's rotation is clockwise viewed from the front of the engine.

HEATER AND AIR CONDITIONING 1-27

REPAIR OF REFRIGERANT LEAKS
Refrigerant Line Connections


RTW410SH000101
Install new O-ring, if required. When disconnecting or
connecting lines, use two wrenches to prevent the connecting
portion from twisting or becoming damaged.


When connecting the refrigerant line at the block joint, securely
insert the projecting portion of the joint portion into the
connecting hole on the unit side and secure with a bolt.




Apply specified compressor oil to the O-rings prior to
connecting.

CAUTION:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply oil specified for the
model of compressor.



O-rings must be closely aligned with raised portion of
refrigerant line.