2004 ISUZU TF SERIES content

FRAME AND BUMPER 2A-1

SECTION 2A
FRAME AND BUMPER
TABLE OF CONTENTS
PAGE
Front Bumper ..................................................................................................................... 2A- 2
Rear Step Bumper ............................................................................................................. 2A- 4
Rear Bumper And Rear Guard ASM ................................................................................. 2A- 7
Frame Dimensions............................................................................................................. 2A- 9

SHEET METAL 2B-1

SECTION 2B
SHEET METAL

This section includes items of front end sheet metal that are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance.
When servicing these panes, areas on which this material has been disturbed, should be properly recoated with
service-type anticorrosion material.
TABLE OF CONTENTS
PAGE
Engine Hood Assembly ..................................................................................................... 2B- 2
Engine Hood Lock ............................................................................................................. 2B- 5
Front Fender Panel ............................................................................................................ 2B- 7
Radiator Grille .................................................................................................................... 2B- 10
Rear Body ........................................................................................................................... 2B- 11
Body Mounting ................................................................................................................... 2B- 13
Body Dimension.................................................................................................................2B- 19

GENERAL INFORMATION 0A-1

SECTION 0A
GENERAL INFORMATION
TABLE OF CONTENTS
PAGE
General Repair Instructions ............................................................................................ 0A- 2
Notes on The Format of this Manual .............................................................................. 0A- 3
Identification .................................................................................................................... 0A- 6
Lifting Instructions .......................................................................................................... 0A- 7
Conversion Table............................................................................................................. 0A- 9

GENERAL INFORMATION 0A-9

CONVERSION TABLE
TABLE OF CONTENTS
PAGE
Length ............................................................................................................................... 0A- 9
Area ................................................................................................................................... 0A-11
Volume .............................................................................................................................. 0A-11
Mass.................................................................................................................................. 0A-13
Pressure ........................................................................................................................... 0A-14
Torque............................................................................................................................... 0A-15
Temperature ..................................................................................................................... 0A-16


LENGTH

MILLIMETERS TO INCHES
mm in. mm in. mm in. mm in. 1 0.0394 26 1.0236 51 2.0079 76 2.9921 2 0.0787 27 1.0630 52 2.0472 77 3.0315 3 0.1181 28 1.1024 53 2.0866 78 3.0709 4 0.1575 29 1.1417 54 2.1260 79 3.1102 5 0.1969 30 1.1811 55 2.1654 80 3.1496 6 0.2362 31 1.2205 56 2.2047 81 3.1890 7 0.2756 32 1.2598 57 2.2441 82 3.2283 8 0.3150 33 1.2992 58 2.2835 83 3.2677 9 0.3543 34 1.3386 59 2.3228 84 3.307110 0.3937 35 1.3780 60 2.3622 85 3.346511 0.4331 36 1.4173 61 2.4016 86 3.385812 0.4724 37 1.4567 62 2.4409 87 3.425213 0.5118 38 1.4961 63 2.4803 88 3.464614 0.5512 39 1.5354 64 2.5197 89 3.503915 0.5906 40 1.5748 65 2.5591 90 3.543316 0.6299 41 1.6142 66 2.5984 91 3.582717 0.6693 42 1.6535 67 2.6378 92 3.622018 0.7087 43 1.6929 68 2.6772 93 3.661419 0.7480 44 1.7323 69 2.7165 94 3.700820 0.7874 45 1.7717 70 2.7559 95 3.740221 0.8268 46 1.8110 71 2.7953 96 3.779522 0.8661 47 1.8504 72 2.8346 97 3.818923 0.9055 48 1.8898 73 2.8740 98 3.858324 0.9449 49 1.9291 74 2.9134 99 3.897625 0.9843 50 1.9685 75 2.9528 100 3.9370 101 3.9764 111 4.3701 121 4.7638 131 5.1575102 4.0157 112 4.4094 122 4.8031 132 5.1968103 4.0551 113 4.4488 123 4.8425 133 5.2362104 4.0945 114 4.4882 124 4.8819 134 5.2756105 4.1339 115 4.5276 125 4.9213 135 5.3150106 4.1732 116 4.5669 126 4.9606 136 5.3543107 4.2126 117 4.6063 127 5.0000 137 5.3937108 4.2520 118 4.6457 128 5.0394 138 5.4331109 4.2913 119 4.6850 129 5.0787 139 5.4724
INCHES TO MILLIMETERS
in. mm in. mm 1/64 0.3969 33/64 13.0969 1/32 0.7938 17/32 13.4938 3/64 1.1906 35/64 13.89061/16 1.5875 9/16 14.2875 5/64 1.9844 37/64 14.6844 3/32 2.3813 19/32 15.0813 7/64 2.7781 39/64 15.47811/8 3.1750 5/8 15.8750 9/64 3.5719 41/64 16.2719 5/32 3.9688 21/32 16.6688 11/64 4.3656 43/64 17.06563/16 4.7625 11/16 17.4625 13/64 5.1594 45/64 17.8594 7/32 5.5563 23/32 18.2563 15/64 5.9531 47/64 18.65311/4 6.3500 3/4 19.0500 17/64 6.7469 49/64 19.4469 9/32 7.1438 25/32 19.8438 19/64 7.5406 51/64 20.24065/16 7.9375 13/16 20.6375 21/64 8.3344 53/64 21.0344 11/32 8.7313 27/32 21.4313 23/64 9.1281 55/64 21.82813/8 9.5250 7/8 22.2250 25/64 9.9219 57/64 22.6219 13/32 10.3188 29/32 23.0188 27/64 10.7156 59/64 23.41567/16 11.1125 15/16 23.8125 29/64 11.5094 61/64 24.2094 15/32 11.9063 31/32 24.6063 31/64 12.3031 63/64 25.00311/2 12.7000 1 25.4000

MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION
TABLE OF CONTENTS
PAGE
Maintenance Schedule (For GENERAL EXPORT) ......................................................... 0B- 2
Maintenance Schedule (For EUROPE) ........................................................................... 0B- 5
Severe Conditions Maintenance Schedule (For GENERAL EXPORT) ........................ 0B-11
Severe Conditions Maintenance Schedule (For EUROPE) .......................................... 0B-12
Recommended Fluids and Lubricants (For GENERAL EXPORT)................................ 0B-13
Recommended Fluids and Lubricants (For EUROPE).................................................. 0B-15
Oil Viscosity Chart ........................................................................................................... 0B-16

HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service .......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor ...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier ................................................................................................................... 1- 39
Removal and Installation ............................................................................................ 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE) ...................................................................... 1- 40
Removal and Installation (6VE1) ................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Removal and Installation ............................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Removal and Installation ............................................................................................ 1- 57
Disassembly and Reassembly ................................................................................... 1- 59
Evaporator (With A/C)...................................................................................................... 1- 60
Removal and Installation ............................................................................................ 1- 60
Disassembly and Reassembly ................................................................................... 1- 61

1-46 HEATER AND AIR CONDITIONING

GENERAL REPAIR PROCEDURE
OIL SPECIFICATION

The HFC-134a system requires a synthetic (PAG)
compressor oil.

Compressor (PAG) oil varies according to compressor
model. Be sure to use oil specified for the model of
compressor.
Specified Compressor Oil
DH-PR



HANDLING OF OIL

The oil should be free from moisture, dust, metal powder,
etc.
 Do not mix with other oil.
 The water content in the oil increases when exposed to the
air. After use, seal oil from air immediately.

The compressor oil must be stored in steel containers, not
in plastic containers.

COMPRESSOR OIL CHECK
The Oil used to lubricate the compressor is circulating with the
refrigerant.
Whenever replacing any component of the system or a large
amount of gas leakage occurs, add oil to maintain the original
amount of. oil.

Oil Capacity

Capacity total in
system CR-14 180 cm3 (5.0 fl.oz.)
Compressor
(Service parts)
charging amount
CR-14
180 cm
3 (5.0 fl.oz.)

MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION
(MSG MODELS)
TABLE OF CONTENTS
PAGE
Main Data and Specifications .................................................................................... 7B - 2
General Description.................................................................................................... 7B - 3
Torque Specification .................................................................................................. 7B - 4
Repair Kit .................................................................................................................... 7B - 6
Removal and Installation ........................................................................................... 7B - 7
Disassembly ............................................................................................................... 7B - 15
Inspection and Repair ............................................................................................... 7B - 25
Reassembly ................................................................................................................ 7B - 29
Special Service Tool .................................................................................................. 7B - 42