ISUZU TFS SERIES 1997 Workshop Manual

10-4 CAB
REMOVAL AND INSTALLATION
For RHD model For LHD model
Removal Steps
1. Wiper arm assembly
2. Side moulding
3. Vent cowl cover
4. Windshield stopper
5. Upper moulding
6. Windshield glass
7. Engine hood rear seal
Installation Steps
7. Engine hood rear seal
6. Windshield glass
5. Upper moulding
4. Windshield stopper
3. Vent cowl cover
2. Side moulding
1. Wiper arm assembly

CAB 10-5
Important Operation - Removal
6. 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 of
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 of
wood.
5) W ith the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumferance 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 any
adhesive remaining on the windshield glass.
Important Operations - Installation
7. 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
6. Windshield Glass
1) Clean the windshield glass bonding surface.
2) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at seven (7) locations.

10-6 CAB
4) Apply primer 1 #435-95 or equivalent to the body side
bonding surface. The primer should extend 25 mm (1 in.).
Apply primer #435-40 or equivalent to the windshield glass
side bonding surface.
The primer should extend 15 mm (0.6 in.) from end of the
glass.
Apply the window glass sealing adhesive 2.
If you are using an air gun, air pressure should be maintained
at 147 - 294 kpa.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealer
has been applied.
Adjust the setting of the windshield glass with suction discs.
The center of the windshield glass should be in alignment with
the center of the windshield glass opening.
The clearance between body and upper moulding should be
within 0.5 mm (A).
Both of the clearance for RH and LH should be same. (6 mm
2 mm)
Note:
It is a good idea to perform the windshield installation
procedure from beginning to end without pausing. If you
allow time to elapse between steps, excessive amounts of
adhesive may be extruded from around the windshield.

CAB 10-7
5. Upper Moulding
1) Before installing the windshield moulding (at the upper part
of the windshield), spray hot water at a temperature of
about 140
F (60C) onto the windshield glass and the
adhesive. This will cause curing.
2) Install the upper moulding as soon as hot water has been
applied. Using a roller push moulding in until it bottoms.
4. Windshield Stopper
Do this immediately after completing the gap adjustment.
2. Side Moulding
Use unleaded gasoline and a soft cloth to wipe away any
excess adhesive.
Cure the bonding at a temperature of 68
- 86F (20 - 30C)
for twenty-four hours.
Check that the windshield does not leak water.

10-8 CAB
SLIDING REAR WINDOW ASSEMBLY
DISASSEMBLY
Disassembly Steps
1. Weather strip
2. Packing ; rear window
3. Screw; binding
4. Frame ; rear window
5. Stopper
6. Rear window ; slide
7. Lock assembly with catchback window
8. Glass run
9. Glass ; rear window corner
10. Weather strip ; rear window corner

CAB 10-9
Important Operation - Removal
1. Weather Strip
Remove the weather strip with a knife.
2. Packing ; Rear Window
With a screwdriver or similar tool, remove the window stop.
4. Frame ; Rear Window
Place the window channel in a vertical position and remove the
frame rear by pulling on one end of it with your hand.
6. Rear Window ; Slide
With the window channel held in a vertical position, remove the
rear window ; slide.
9. Glass ; Rear Window Corner
Stand the window channel up and remove the glass ; rear
window corner.

10-10 CAB
REASSEMBLY
Riassembly Steps
1. Weather strip ; rear window corner
2. Glass ; rear window corner
3. Glass run
4. Frame ; rear window
5. Screw; binding
6. Rear window ; slide
7. Stopper
8. Packing ; rear window
9. Lock assembly with catchback window
10. Weather strip

CAB 10-11
Important Operation - Installation
1. Weather Strip ; Rear Window Corner
Using Semedain #560 (or equivalent) adhesive, glue the
weather strip to the complete circumference of the frame,
paying close attention to the corner areas.
2. Glass ; Rear Window Corner
Apply soap and water to the rim as a lubricant.
Place the channel in a vertical position. With your hand, apply
pressure to expand the channel. Insert the window glass in the
center of the channel.
3. Glass Run
Apply Semedain #560 (or equivalent) adhesive to the entire
length of both the upper window glass and the weather strip.
Apply adhesive to both sides of the extreme ends of the lower
portion for a distance of about 50 mm.
There should be no gap between the weather strip rear window
glass channel and the channel.
6. Rear Window ; Slide
Hold the window vertically. Apply an upward pressure to the
channel and insert the rear window slide.
8. Packing ; Rear Window
Apply a fast setting adhesive agent to both sides of the window
atop and insert it into the channel.

10-12 CAB
DOORS
GENERAL DESCRIPTION

CAB 10-13
REMOVAL AND INSTALLATION
Removal Steps
1. Door harness
2. Checker pin
3. Lower hinge
4. Upper hinge
5. Door assembly
Installation Steps
5. Door assembly
4. Upper hinge
3. Lower hinge
2. Checker pin
1. Door harness
Important Operation - Removal
1. Door Harness
Disconnect the door harness.
2. Checker Pin