2004 ISUZU TF SERIES engine oil

3B-8 POWER-ASSISTED STEERING SYSTEM

6. Fully close the shutoff valve. Record the highest
pressures.


If the pressure recorded is within 9300-9800 kPa
(95-100 kg/cm
2/1350-1420 psi), the pump is
functioning within its specifications.


If the pressure recorded is higher than 9800 kPa
(100 kg/cm
2/1420 psi), the valve in the pump is
defective.


If the pressure recorded is lower than 9300 kPa (95
kg/cm
2/1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the powe
r
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and fron
t
suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.


Inspect belt for tightness.


Inspect pulley for looseness or damage. The pulle
y
should not wobble with the engine running.


Inspect hoses so they are not touching any othe
r
parts of the vehicle.


Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130
F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.

Flushing The Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.

3B-24 POWER-ASSISTED STEERING SYSTEM

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail. The parts with minor scores may be reused after
lapping the face.

Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Needle bearing fitting
face must be free from damage and wear.

O-ring, Oil Seal, Retaining Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N




m (2.2-2.7 kg




m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 7.8-12 N




m (0.8-1.2 kg




m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N




m (5.0-7.0 kg




m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N




m (1.5-2.0 kg




m/11-14 lb ft)

3B-28 POWER-ASSISTED STEERING SYSTEM

Inspection and Repair
Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.

Rotor
442RS002
Check that the groove in the vane is free from excessive
wear and that the vane slides smoothly. When par
t
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Vane
442RS003
Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.

Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finge
r
nail.
The parts with minor scores may be reused after lapping
the face.

Relief Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.

O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connecto
r
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.

POWER-ASSISTED STEERING SYSTEM 3B-43

Combination Switch
Combination Switch and Associated Parts


This illustration is based on the RHD model.
RTW43BLF000601
Legend
(1) Steering Column Cover
(2) Steering Wheel
(3) Inflator Module or Horn Pad
(4) Combination Switch and SRS Coil Assembly
(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)


Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4.
Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Remove the engine hood opening lever, then
remove instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).

3B-50 POWER-ASSISTED STEERING SYSTEM

CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Remove the engine hood opening lever and
steering lower cover.
6. Remove driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)
8. Check the both side hole of the steering cover. (with
SRS air bag)
060R300025
9. Check the position of the pins in a hole. Push the
pin in the direction of an arrow. (with SRS air bag)
060R300032

10. Push the four pins at 
5
6 mm bar. (with SRS ai
r
bag)
060R300031
11. Cancel the lock four pins. (with SRS air bag)
12. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
430R300009

3B-56 POWER-ASSISTED STEERING SYSTEM

CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to become uncentered which
will cause damage to the SRS coil assembly. (with
SRS air bag)
5. Remove the engine hood opening lever and
steering lower cover.
6. Remove the driver knee bolster (reinforcement).
7. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)
8. Check the both side hole of the steering cover. (with
SRS air bag)
060R300025
9. Check the position of the pins in a hole. Push the
pin in the direction of an arrow. (with SRS air bag)
060R300032

10. Push the four pins at 
5
6 mm bar. (with SRS ai
r
bag)
060R300031
11. Cancel the lock four pins. (with SRS air bag)
12. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
430R300009

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)

3C-2 FRONT SUSPENSION
MAIN DATA AND SPECIFICATIONS
4




2 (EXCEPT HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, coil spring
with stabilizer bar.
Coil spring Spring Rate 4JH1-TC / 4JA1-TC / 4JA1-L (ENGINE); 9.62 kg/mm
(94.3 N/mm)
C24SE (ENGINE); 7.94 kg/mm (77.9 N/mm)
Type Gas-sealed. Hydraulic, double acting
Stroke 116.5 mm (4.59 in)
Compressed length 284.0 mm (11.18 in)
Front shock absorber
Extended length 400.5 mm (15.77 in)
Stabilizer bar Diameter 25.0 mm (0.98 in)

4




2 (HIGH RIDE SUSPENSION) MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)

4




4 MODEL
Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Length 1142 mm (44.96 in) Torsion bar spring
Diameter 29.0 mm (1.14 in)
Type Gas-sealed. Hydraulic, double acting
Stroke 121.0 mm (4.76 in)
Compressed length 257.0 mm (10.12 in)
Front shock absorber
Extended length 378.0 mm (14.88 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)