ISUZU TF SERIES 2004 Workshop Manual

CAB 10-3



Important Operations - Removal
3. Room Mirror
Remove the screw and pull the room mirror to upper side.


8. Windshield Glass
Remove the windshield 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 windshield 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 windshield
glass.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the windshield glass.

10-4 CAB

INSTALLATION


RTW4A0LF001201

Installation Steps


1. Engine hood rear seal
2. Upper moulding

3. Windshield glass
4. Windshield stopper
5. Vent cowl cover
6. Side moulding
7. Room mirror

8. Wiper arm assembly
9. Interior trim panels (Front side)
/Headlining/Instrument panel assembly

CAB 10-5



Important Operations - Installation
1. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.
1 : Seal
2 : Clip
3 : Rear (windshield glass side)
4 : Front

RTW3A0SH000201

3. Windshield Glass
1) Clean the windshield glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off an
y
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at five locations.


Always use new spacer.
4) Install the windshield upper molding.


Peel off the tear-away paper from the windshield uppe
r
molding, and start applying it with one end of the glass
and cut away the surplus at the other end of the glass
for length adjustment.


Always use new upper molding.
5) Temporary install the windshield support.



6) Apply primer
1 Sunstar #435-98 or equivalent to the body
side bonding surface. The primer should extend at least 25
mm (1 in).
Apply primer Sunstar #435-40 or equivalent to the
windshield glass side bonding surface.
The primer should extend 16.5 mm (0.6 in) and 25 mm (1.0
in) from end of the glass.

10-6 CAB




7) Apply the window glass sealing adhesive
2.
If you are using an air gun, air pressure should be
maintained at 147 - 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in) junction a
t
middle of the vase of the glass.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.




8) Adjust the setting of the windshield glass with suction discs.
Set the windshield with sealing adhesive applied to entire
circumference in the body panel. Specifically, adjus
t
windshield support with the upper molding making contact
with the body panel, press the glass, and tighten the
windshield support.



9) Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.
Cure the bonding at a temperature of 68
- 86
F (20
-
30
C) for twenty-four hours.
Check that the windshield does not leak water.









8. Wiper Arm Assembly


Set the wiper arm/blade so that the tips of both blades
are positioned the specified value of
A and Bfrom the
upper edge of the cowl cover as shown in the figure.

A 40 mm (1.57 in)

B 52 mm (2.05 in)


Tighten the wiper arm assembly fixing nuts to the
specified torque.
Torque Nm (kgfm/lbft)
31 (3.1/23)

CAB 10-7
REAR WINDOW ASSEMBLY
REMOVE AND INSTALLATION


Removal Steps
1. Interior trim panels/Headlining
2. Rear defogger connector (W/Rear defogger)

3. Rear window

Installation Steps


3. Rear window
2. Rear defogger connector (W/Rear defogger)
1. Interior trim panels/Headlining

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.

CAB 10-9


5) Apply the rear window glass seling adhesive 2.
If you are using an air gun, air pressure should be
maintained at 147 – 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in.) junction a
t
left corner of the base of the glass.
Note:
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
6) Insert the glass supports into the panel and then push the
glass against the panel to affix it in place.
Wipe away any adhesive that oozes out around the edges.
7) Check that the rear window glass does not leak water.

10-10 CAB
FRONT DOOR ASSEMBLY
REMOVAL AND INSTALLATION



This illustration is based on RHD model


Removal Steps

1. Door harness

2. Checker arm screw

3. Lower hinge bolt
4. Upper hinge bolt
5. Door assembly

Installation Steps
5. Door assembly
4. Upper hinge bolt

3. Lower hinge bolt

2. Check arm screw
1. Door harness




Important Operations - Removal
1. Door Harness
Remove the harness bracket and disconnect the doo
r
harness connectors.

CAB 10-11


2. Check Arm Screw




3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.





Important Operations – Installation
3. Lower Hinge Bolt; Hinge to Door
Torque N

m (kgf

m/lb

ft)
34 (3.5/25)

2. Check Arm Screw; Check Arm to Body
Torque N
m (kgf
m/lb
ft)
24 (2.4/17)

10-12 CAB
DISASSEMBLY



This illustration is based on RHD model
RTW4A0LF000701

Disassembly Steps

1. Switch bezel/Window regulator handle

2. Power window switch

3. Bezel

4. Door mirror cover

5. Door trim panel

6. Tweeter (Required Option)

7. Door mirror assembly

8. Outer waste seal

9. Bracket

10. Speaker assembly

11. Waterproof sheet

12. Inside lever

13. Window glass




14. Window regulator/Power window
regulator

15. Glass run

16. Glass run rear channel / Glass ran rear
channel with Door lock control or Anti
theft (EC)

17. Door lock assembly/Door lock assembly
with super lock

18. Outside handle protector (EUROPE)

19. Outside handle

20. Door lock cylinder protector (EUROPE)

21. Door lock cylinder / Door lock cylinder
with door lock switch (EC)
22. Door harness assembly
23. Anti rattler