2004 ISUZU TF SERIES torque

ENGINE DRIVEABILITY AND EMISSIONS 6E–269
HEATED OXYGEN SENSOR (HO2S)
Location
Installed on the ex haust pipe.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the O
2 sensor connector.
3. Loosen and remove the O
2 sensor from the ex haust
pipe.
Inspection
Inspect the louvered end of the sensor for grease, dirt,
ex cessive carbon build up or other contamination.
Installation Procedure
1. Install the O
2 sensor to the ex haust pipe.
2. Tighten the O
2 sensor with specified tightening
torque.
Tightening Torque
Bolt: 42N·m (4.3kgf·m)
3. Connect a O
2 sensor connector to the O2 sensor.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify no exhaust gas leaking from the sensor threads
after replacement.
EVAP CANISTER PURGE VALVE
SOLENOID
Location
On the intake manifold.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a purge solenoid connector from the
purge solenoid.
3. Disconnect two hoses from the purge solenoid
valve.
4. Slide from the bracket and remove the purge
solenoid.
Installation Procedure
1. Insert EVAP purge solenoid valve onto the bracket.
2. Connect two hoses to the purge solenoid valve.
3. Connect a purge solenoid connector to the purge
solenoid.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of two hoses.

6E–276 ENGINE DRIVEABILITY AND EMISSIONS
Oil in the combustion chamber.
The spark plug gap is not set correctly.
If spark plug fouling is ex cessive, check the fuel and al
system for possible causes of trouble. If fuel and al
system are normal, install spark plugs of a higher heat
range which have the same physical dimensions as the
original equipment spark plugs.
The following symptoms are characteristics of spark
plugs that are running too hot:
Fuel mixture is too lean.
Heat range is incorrect.
If vehicle usage does not conform to normal driving
conditions, a more suitable spark plug may be
substituted.
If fuel and al system are normal, in most cases of this
sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as
the original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.0
to 1.1mm (0.039 to 0.043").
5. Adjust the spark gap by bending the grounded
electrode.Installation
1. Tighten the spark plug to the 25N·m (2.5kgf·m).
2. Push the spark plug cable in until it snaps in.
Installation Procedure
1. Install the spark plug to the cylinder head.
2. Tighten the spark plug with specified tightening
torque.
Tightening Torque
Bolt: 25N·m (2.5kgf·m)
3. Connect the spark plug cable to the spark plug.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of spark plug cables for each
cylinders.

ENGINE EXHAUST 6F-1
SECTION 6F
ENGINE EXHAUST
CONTENTS
PAGE
General Description........................................................................................................ 6F- 2
Service Precaution ......................................................................................................... 6F- 4
Exhaust Pipe ................................................................................................................... 6F- 5
Exhaust pipe and Associated parts.......................................................................... 6F- 5
Removal ...................................................................................................................... 6F- 5
Installation .................................................................................................................. 6F- 6
Inspection ................................................................................................................... 6F- 6
Front Exhaust Pipe ......................................................................................................... 6F- 7
Front Exhaust Pipe and Associated Parts ............................................................... 6F- 7
Removal ...................................................................................................................... 6F- 7
Installation .................................................................................................................. 6F- 7
Mid Pipe ........................................................................................................................... 6F- 8
Mid Pipe and associated Parts ................................................................................. 6F- 8
Removal ...................................................................................................................... 6F- 8
Installation .................................................................................................................. 6F- 8
Catalytic Converter (If applicable) ................................................................................. 6F- 9
Catalytic Converter and Associated Parts ............................................................... 6F- 9
Removal ...................................................................................................................... 6F- 9
Installation .................................................................................................................. 6F- 9
3 way Catalytic Converter System ............................................................................ 6F- 10
Exhaust Silencer ............................................................................................................. 6F- 12
Exhaust Silencer and Associated Parts ................................................................... 6F- 12
Removal ...................................................................................................................... 6F- 12
Installation .................................................................................................................. 6F- 13
Main Data and Specifications ........................................................................................ 6F- 14
Torque Specification.................................................................................................. 6F- 15

6F-4 ENGINE EXHAUST


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.

6F-6 ENGINE EXHAUST


Installation
To install, follow the removal steps in the reverse order.










Important - Installation
1. Front Exhaust Pipe Flange Nut
Connect the exhaust pipe to the exhaust manifold.
Front exhaust pipe to manifold nut.
Torque

N
m (kgf
m)
28 (2.9)
Inspection
Make the necessary adjustments, and part replacements if
excessive wear or damage is discover during inspection.

1. Front Exhaust Pipe
2. Center Exhaust Pipe and Catalytic Converter Flange Nut
3. Exhaust Pipe Damper Rubber
4. Exhaust Silencer with Rear Exhaust Pipe

Check the pipes for for corrosion, cracking , damage or
misalignment and repair if required.
Check the damper rubber for deterioration or damage and
repair if required.

ENGINE EXHAUST 6F-7
Front Exhaust Pipe (W/O Catalytic
Converter)
Front Exhaust Pipe and Associated Parts





RTW46F000101
Legend
1. Front Exhaust Pipe Fixing Nuts
2. Front Exhaust Pipe
3. Mid Exhaust Pipe Fixing Nuts










Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove the front exhaust pipe fixing nuts (1).
4. Remove mid pipe fixing nuts (3).
5. Remove front exhaust pipe (2).




Installation
1. Install front exhaust pipe (2) and tighten four nuts (1).
Torque:
Nuts: 28 N




m (2.9 kgf




m)
2. Tighten two nuts (3).
Torque: 43 N




m (4.4 kgf




m)

6F-8 ENGINE EXHAUST
Mid Pipe
Mid Pipe and Associated Parts





RTW46FSF000201
Legend
1. Mid Exhaust Pipe
2. Mid Exhaust Pipe Fixing Nuts
3. Exhaust Silencer Fixing Nuts








Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove mid pipe fixing nuts (2).
4. Remove exhaust silencer fixing nuts (3).
5. Remove the pipe.





Installation
1. Install mid exhaust pipe (1) and tighten four fixing nuts
(2)(3) to the specified torque:
Torque:
Fixing nuts: 43 N




m (4.4 kgf




m)

ENGINE EXHAUST 6F-9
Catalytic Converter (If applicable)
Catalytic Converter and Associated Parts





RTW46FSF000301
Legend
1. Catalytic Converter
2. O
2 Sensor Converter
3. Front Pipe Fixing Nuts
4. Mid Pipe Fixing Nuts








Removal
(2.4L)
1. Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove front pipe fixing nuts (3).
4. Remove mid pipe fixing nuts (4).
5. Remove the O
2 sensor connector (2).
6. Remove the front exhaust pipe with catalytic converter (1).





Installation
1. Install Catalytic Converter (1) and tighten four to the
specified torque:
Torque:
Fixing nuts: 28 N




m (2.9 kgf




m)
2. Tight two nuts (4)
Torque:
Nuts: 43 N




m (4.4 kgf




m)
3. Connect the O
2 sensor connector (2).