ad blue ISUZU TF SERIES 2004 Workshop Manual

SUPPLEMENTAL RESTRAINT SYSTEM 9A-23

5. Strip 13 mm (1/2 inch) of insulation from yellow –
green and yellow – black wire lead of the
connector.
6. Cut two 900 cm (30 feet) deployment wires from
0.8 mm
2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the drive
r
deployment harness.
7. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND BE NOT
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AI
R
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deploymen
t
wire.
12. Connect the deployment harness to the driver ai
r
bag assembly, yellow connector at the base of the
steering column. Route deployment harness ou
t
the driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE
IS CONNECTED TO IT.
Connecting the deployment wires to the powe
r
source should always be the final step in the air
bag assembly deployment procedure.
Failure to follow procedures in the order listed
could result in personal injury.
13. Disconnect passenger air bag assembly, yello
w
connector located behind glove box assembly.

14.Cut the passenger air bag assembly harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
15. Strip 13 mm (1/2 inch) of insulation from blue–
white and pink–blue wire lead of the connector.
16. Cut two 900 cm (30 feet) deployment wires from
0.8 mm
2 (18 gauge) or thicker multi–strand wire.
These wires will be used to fabricate the
passenger deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the ai
r
bag is to be deployed.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AI
R
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
20. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
22. Connect the deployment harness to the passenge
r
air bag assembly, yellow connector located behind
the glove box assembly. Route deployment
harness out the passenger side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
PO
WER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT WIRES
SHOULD ALWAYS BE THE FINAL STEP IN THE
AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.

4A-16 PROPELLER SHAFT
401RS011







Universal Joint Reassembly
1. Set the propeller shafts.

Be sure to set the propeller shaft yoke by aligning the
setting marks made during dissassembly.
2. Spider
 Be sure to install the spider by aligning the setting marks
made during disassembly.
3. Needle Roller Bearing
1) Apply a molybdenum-disulfide grease or a multi-purpose.
type grease NLGI No.2 to inside of the bearing cap.
Grease Amount g(oz)
Approx. 1.2 (0.042)

401RS012









2) Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that snap ring can
be installed in its groove.

CAUTION:

  The needle roller bearing cannot be installed smoothly
if it is set at an incorrect angle with the flange.

  Excessive hammering will damage the needle rolle
r
bearing.

401R300003








3) Align setting marks and join the yokes.
NOTE:
Assemble the spider and spline yoke so that their grease
fittings are arranged on the same side.(4

4)
4. Snap ring
NOTE:
Discard used snap rings and install new ones.

When the bearing cap is in position, select and attach a snap
ring of suitable thickness so that the end play of the spider pin
is held within 0.1mm (0.004in).
mm(in)

Snap ring thickness Identification color
1.50 (0.059) Light Blue
1.53 (0.060) White
1.56 (0.061) Pink
1.59 (0.063) Yellow
1.62 (0.064) Green
1.65 (0.065) Brown
1.68 (0.066) Not colored
NOTE:
Be sure to use snap rings of the same thickness on both sides.

4A-26 PROPELLER SHAFT
401RS012

3. Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that the snap ring
can be installed in its groove.
CAUTION:
The needle roller bearing cannot be installed smoothly if it
is set at an incorrect angle with the flange and excessive
hammering will damage the needle roller bearing.

401RS028

4. Align setting marks (1) and join the yokes.
5. Install snap ring.
NOTE:
Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a snap
ring of suitable thickness so that the end play of the spider pin
is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
1.50 mm (0.059 in); Light Blue
1.56 mm (0.061 in); Prink
1.53 mm (0.060 in); White
1.59 mm (0.063 in); Yellow
1.62 mm (0.064 in); Green
1.65 mm (0.065 in); Brown
1.68 mm (0.066 in); Not colored

NOTE:
Be sure to use snap rings of the same thickness
on both sides.

4B-6 REAR AXLE

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacture's instructions at all
times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon
contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518
between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poor
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least one hour before continuing the installation procedure.

4B-30 REAR AXLE

Gear Tooth Contact Pattern Check and Adjustment
1. Apply a thin coat of Prussian blue or equivalent to
the faces of the 7–8 teeth of the ring gear. Check
the impression of contact on the ring gear teeth
and make necessary adjustment as described in
illustration if the contact is abnormal.




425RS038
Legend

1.
Heel
2.
Toe
3.
Concave Side(Coast)
4.
Convex Side(Drive)

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

4C1-40 FRONT WHEEL DRIVE


18. Bolt
Bolt Torque N

m (kgf

m/lb

ft)

98.1
9.8 (10.0
1.0/72.3
7.2)


Measure the amount of run-out of the ring gear at its rear face.
mm(in)
Standard Limit
0.02 (0.001) 0.05 (0.002)



Gear Tooth Contact Pattern Check and Adjustment
Apply a thin coat of prussian blue or equivalent to the faces of
the 7 - 8 teeth of the ring gear. Check the impression of
contact on the ring gear teeth and make necessary adjustment
as described below if the contact is abnormal.

ELECTRICAL-BODY AND CHASSIS 8A-13
PARTS FOR ELECTRICAL CIRCUIT


WIRING
Wire Color
All wires have color-coded insulation.
Wires belonging to system's main harness will have a single
color.
Wires belonging to a system's sub-circuits will have a colored
stripe.
Striped wires use the following code to show wire size and
colors.
Example: 0.5 G
/ R
Red (Stripe color)
Green (Base color)
Wire size (0.5mm
2)
Abbreviations are used to indicate wire color within a circuit
diagram.
Refer to the following table.


Wire Color-Coding
Color-Coding Meaning Color-Coding Meaning
B Black BR Brown
W White LG Light green
R Red GR Grey
G Green P Pink
Y Yellow LB Light blue
L Blue V Violet
O Orange

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green

8A-422 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
C-1
Gray
Side turn lamp-RH C-22
Front turn lamp-RH
C-2
Silver
Engine room-RH ground C-23
NOT USED
C-3
(6VE1)
(4JH1-TC)

INT Relay C-24
Triple pressure switch
C-4
Light-
blue
Front wiper motor C-25
NOT USED
C-5
~
C-16 NOT USED C-26
Black
Head lamp-LH
C-17
Gray
Front wiper motor C-27
Clearance lamp-LH
C-18

Clearance lamp-RH C-28
~
C-29 NOT USED
C-19
Black
Head lamp-RH C-30

BlackEngine hood switch
C-20
(6VE1)
(4JH1-TC)

Horn ; high note C-31
~
C-34 NOT USED
C-21
Black
Horn ; Low note C-35
Gray Side turn lamp-LH