reverse ISUZU TF SERIES 2004 Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 1068 of 4264
8A-410 ELECTRICAL-BODY AND CHASSIS
ANTI THEFT INDICATOR
Removal
1. Disconnect the battery ground cable.
RTW3A0SH001301
2. Remove the side ventilation grille.
RTW08ASH000101
3. Disconnect the indicator connector and screw from the
backside of the side ventilation grille to remove the anti thef
t
indicator.
Installation
To install, follow the removal steps in the reverse order, noting
the following point.
1. Push in the switch with your fingers until it locks securely.
Page 1103 of 4264
CRUISE CONTROL SYSTEM 8B-5
Brake Switch
RTW3A0MH000101
Removal
1. Disconnect the battery ground cable.
2. Remove the brake switch.
Disconnect the connector (1).
Loosen lock nuts of the switch (2).
Remove the switch by turning it (3).
Installation
To install, follow the removal steps in the reverse order, noting
the following points.
1. Check to see if the brake pedal has been returned by the
return spring to the specified position.
2. Turn the switch clock-wise until the tip of the threaded
portion of the brake switch contacts the pedal arm.
RTW3A0SH000901
3. Turn the switch counter-clock-wise until the space between
the tip of the threaded portion and the pedal arm is 0.2 to
1.2 mm (0.01-0.06 in.) as shown in the figure.
Page 1104 of 4264
8B-6 CRUISE CONTROL SYSTEM
Adjustment
1. Check to be sure that the brake pedal has been completely
returned by the return spring.
2. Disconnect the switch connector.
RTW3A0SH001201
3. Release the lock (2) by turning the switch (1) counter-clock-
wise.
4. After doing so, pull the pedal arm (3) to you a little so tha
t
the pedal arm is not pushed in.
5. Making the pedal arm not movable with one hand, push in
the whole switch with the other hand until the plunger of the
switch is pushed in and the switch itself hits the rubber o
f
the pedal arm.
In the condition, turn the switch clock-wise until "click"
sound is made and lock it.
By doing this, the switch is adjusted at 0.2 to 1.2mm (0.01-
0.06 in.) clearance.
Clutch Switch
Removal and Installation
Refer to the Clutch Control removal and installation steps in
Clutch section.
Adjustment
1. Turn the clutch switch or stopper bolt 1 until the switch bolt
or stopper bolt just touches the clutch pedal arm.
2. Adjust clutch switch or stopper bolt by backing it out half a
turn, and measure the clearance (L) between the clutch
pedal arm and the clutch switch bolt end or stopper bolt.
3. Lock the lock nut
2.
4. Connect the clutch switch connector.
Clutch switch and clutch and clutch pedal clearance
mm (in)
Limit 0.5-1.5 (0.020-0.059)
Starter Switch
431R300001
Removal
1. Steering Lock Assembly
Refer to the Steering Lock assembly removal steps o
f
"Steering Column" in Power-Assisted Steering System
section.
2. Starter Switch
Installation
Follow the removal procedure in the reverse order to install the
starter switch.
Page 1105 of 4264
CRUISE CONTROL SYSTEM 8B-7
Cruise Control Main Switch
Removal
1. Disconnect the battery ground cable.
RTW3A0SH001301
2. Remove the side ventilation grille.
RTW3A0SH001401
3. Disconnect the switch connector and push the lock from the
backside of the side ventilation grille to remove the cruise
control main switch.
Installation
To install, follow the removal steps in the reverse order, noting
the following point.
1. Push in the switch with your fingers until it locks securely.
Cruise Control Switch (Combination Switch)
Removal and Installation
Refer to the Lighting Switch (Combination Switch) removal and
installation steps of Lighting System in Body and Accessories
section.
Page 1106 of 4264
8B-8 CRUISE CONTROL SYSTEM
Cruise Control Unit
RTW3A0SH001101
Removal
1. Disconnect the battery ground cable.
2. Remove the dash side trim panel (LH) (1).
3. Disconnect the connector.
4. Remove a fixing nut to remove the cruise control unit (2).
Installation
To install, follow the removal steps in the reverse order.
Cruise Actuator
Actuator Cable Diagram
RTW3A0SF000301
Legend
(1) Cruise Actuator Assembly
(2) Cruise Control Cable
(3) Accelerator Cable
(4) Throttle Link (Cruise Control Side)
Page 1107 of 4264
CRUISE CONTROL SYSTEM 8B-9
RTW3A0SH001001
Removal
1. Disconnect the battery cable.
2. Remove the cruise actuator Assembly (4).
Disconnect the connector (3).
Remove the cable end (1) from the throttle link (cruise
control side).
Loosen a fixing nut of the cruise control cable (2).
Remove fixing screws of the actuator (5).
Installation
To install, follow the removal steps in the reverse order, noting
the following point.
1. Take care not to bend the cable excessively.
RTW3A0SH001501
Adjustment
After installing the cruise actuator, the following steps must be
carried out for cruise control cable adjustment.
1. Install the cruise control cable end (3) to the throttle link (4).
2. Put the screw portion of the cable in the bracket (5).
3. Put the nut (1) to the bracket and then tighten the nut (2).
CAUTION: Don't move a position of the nut (1) from
supplied condition.
4. If the distance between the throttle link (4) and the throttle
link lever (6) is out of the specified range, loosen the nut (2)
to adjust it.
Mode Switch
Removal and Installation
Refer to the Mode Switch removal and installation steps in
Automatic Transmission section.
Page 1180 of 4264
6A – 40 ENGINE MECHANICAL
140R300001
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).
RTW46ASH000501
Remove the fuel hose from injection pump (EURO III
only).
27. Exhaust Pipe
Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.
28. Engine Assembly
1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine
compartment.
Installation
To reassemble, follow the removal steps in the reverse
order.
022R300002
F06R300008
Page 1345 of 4264
ENGINE ELECTRICAL 6D – 7
GENERATOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
P1010002
Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.
Generator
1. Remove the vacuum pump hose.
2. Remove the generator bolt and the generator from the bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque N m (kg m/Ib ft)
40 (4.1/30)
Page 1360 of 4264
6D – 22 ENGINE ELECTRICAL
STARTER MOTOR
REMOVAL AND INSTALLATION
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Important Operations - Removal
Starter Motor
1. Disconnect the battery cable and the ground cable at the battery terminals.
2. Disconnect the magnetic switch cable at the terminal bolts.
3. Disconnect the battery cable at the starter motor and the ground cable at the cylinder body.
4. Remove the starter motor from the engine.
Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque N m (kg m/lb ft)
85 (8.7/63)
3. Reconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
4. Reconnect the battery cable and the ground cable at the battery terminals.
Page 1799 of 4264
EXHAUST SYSTEM 6F – 5
Important Operations – Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque Nm (kgm/lbft)
67 (6.8/49)
2. Middle pipe Nut (4
4 only)
Connect the middle pipe to the front pipe.
Torque Nm (kgm/lbft)
43 (4.4/32)
3. Silencer Front Nut
Connect the silencer to the front or middle pipe.
Torque Nm (kgm/lbft)
43 (4.4/32)