2004 ISUZU TF SERIES torque

POWER-ASSISTED STEERING SYSTEM 3B-53

825RS048
4. Install the driver knee bolster assembly.
5. Install the steering lower cover and engine hood
opening lever.
6. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark is no
t
attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
7. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N





m (3.2 – 4.0 kg





m/23 - 29 lb ft)

8. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflato
r
module. (with SRS air bag)
060R300010
9. Connect the horn leads at center of wheel. (without
SRS air bag)
NOTE: Horn leads is letting a bracket type pass.
(Plastic type steering wheel only)



RTW43BSH000301

3B-54 POWER-ASSISTED STEERING SYSTEM

10. Push the born pad area 1-4.
Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb ft)
NOTE: A horn pad is not struck at the time o
f
attachment.



RTW43BSH000401
11. Align the each snap stud of driver air bag to the hole
of steering wheel. (with SRS air bag)
060R300030

060R300020
12. Push the SRS air bag area1 and area2. At that time
confirm the audible noise of each stud. (with SRS ai
r
bag)
060R300036
13. Enable the SRS (Refer to "Enabling the SRS" in this
section). (with SRS air bag)
14. Install driver knee bolster (reinforcement).
15. Install instrument panel lower cover, then install the
engine hood opening lever.
16. Connect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
17. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

System Inspection (with SRS air bag)
Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.

POWER-ASSISTED STEERING SYSTEM 3B-59

Check clearance between capsule and bracket. If must
be within 1mm (0.039 in).
431RW031

Column Universal Joint (between the
power steering unit and the steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the lower second steering shaft.

Shaft Universal Joint (between the lower
second steering shaft and the second
steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the second steering shaft assembly.

Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.

Installation
1. Align the setting marks on the second steering shaft
and the steering column assembly (applied at
disassembly).
2. Connect the steering column assembly to the second
steering shaft. Tighten the bolts to the specified
torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
3. Thread the steering column assembly through the
hole in the dashpanel. Temporarily tighten the
steering column and the second steering shaft fixing
bolt.
4. Connect the lower second steering shaft and the
second steering shaft. Tighten the universal joint
bolts to the specified torque.
Torque: 26 - 36 N




m (2.7 – 3.7 kg




m/20 - 27 lb ft)
5. Tighten the steering column fixing bolt (pedal brkt
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)

6. Tighten the second steering shaft fixing bolt to the
specified torque (This bolt was temporarily tightened
in Step 3)
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
7. Tighten the steering column fixing bolt (dashpanel
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N




m (1.8 – 2.3 kg




m/13 - 17 lb ft)
8. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located
under the steering column.

3B-60 POWER-ASSISTED STEERING SYSTEM

9. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
CAUTION: When turning the SRS coil counte
r
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
826RW014
10. When installing the steering column cover, be sure to
route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
825RW017
Legend
(1) Steering Column Cover
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

11. Install steering wheel and align the setting marks
made when removing.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
12. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N




m (3.2 – 4.0 kg




m/23 - 29 lb ft)
13. Support the module and carefully connect the
module connector and horn lead, then install inflato
r
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 2 - 4 N




m (0.2 – 0.4 kg




m/17 - 35 lb in)
15. Install driver knee bolster (reinforcement).
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
19. Connect the battery "-" terminal cable. (with SRS ai
r
bag)

3B-62 POWER-ASSISTED STEERING SYSTEM

Supplemental Restraint System Steering Wheel & Column and
Associated Parts
Main Data and Specifications
Torque Specifications N

m (kg

m/lb ft)


This illustration is based on the RHD model.
RTW43BLF000301
Special Tools

ILLUSTRATION

TOOL NO.
TOOL NAME



5-8521-0016-0
(J-29752)
Steering wheel remover

FRONT SUSPENSION 3C-1
SECTION 3C
FRONT SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 3C- 2
Torque Specifications ....................................................................................................... 3C- 3
Special Parts Fixing Nuts and Bolts ............................................................................ 3C- 3
Front Suspension .............................................................................................................. 3C- 6
General Description ...................................................................................................... 3C- 6
Front Suspension (4




2 Except High Ride Suspension)............................................. 3C- 8
Front Suspension (4





2 High Ride Suspension, 4





4) ................................................. 3C- 30
Troubleshooting ............................................................................................................ 3C- 54

FRONT SUSPENSION 3C-3
TORQUE SPECIFICATIONS
SPECIAL PARTS FIXING NUTS AND BOLTS

4





2 (Except High Ride Suspension) Model N

m (kgf

m/lb

ft)

RTW440LF001001

3C-8 FRONT SUSPENSION


FRONT SUSPENSION
(4




2 Except High Ride Suspension)
CONTENTS

Service Precaution............................................. 3C-8
Shock Absorber ................................................. 3C-9
Shock Absorber and Associated Parts ........... 3C-9
Removal ......................................................... 3C-9
Installation....................................................... 3C-10
Shock Absorber with Coil Spring .................... 3C-12
Stabilizer Bar ..................................................... 3C-15
Stabilizer Bar and Associated Parts ............... 3C-15
Removal ......................................................... 3C-15
Inspection and Repair..................................... 3C-15
Installation....................................................... 3C-16
Knuckle .............................................................. 3C-17
Knuckle and Associated Parts........................ 3C-17
Removal ......................................................... 3C-17
Inspection and Repair..................................... 3C-18
Installation....................................................... 3C-18
Upper Control Arm ............................................. 3C-19
Upper Control Arm and Associated Parts ...... 3C-19
Removal ......................................................... 3C-19
Inspection and Repair..................................... 3C-20
Installation....................................................... 3C-20

Lower Control Arm ............................................. 3C-21
Lower Control Arm and Associated Parts ...... 3C-21
Removal ......................................................... 3C-21
Inspection and Repair..................................... 3C-22
Installation ...................................................... 3C-22
Upper Ball Joint ................................................. 3C-23
Upper Ball Joint and Associated Parts ........... 3C-23
Removal ......................................................... 3C-23
Inspection and Repair..................................... 3C-24
Installation ...................................................... 3C-24
Lower Ball Joint ................................................. 3C-25
Lower Ball Joint and Associated Parts ........... 3C-25
Removal ......................................................... 3C-25
Inspection and Repair..................................... 3C-26
Installation ...................................................... 3C-26
Bump Rubber .................................................... 3C-27
Bump Rubber Joint and Associated Parts...... 3C-27
Removal ......................................................... 3C-27
Inspection and Repair..................................... 3C-27
Installation ...................................................... 3C-27
Special Tools .................................................. 3C-28

Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.



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, o
r
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.