2004 ISUZU TF SERIES seats

9A-22 SUPPLEMENTAL RESTRAINT SYSTEM

20.The passenger inflator requires no special
precaution after deployment. 95% of the
particulate emission are potassium ckloride (KLC),
which is commonly sold as an edible salt-
substitutes. even if water is applied. Pos
t
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not produce any hazardous products. As with an
y
dusty environment, safety goggles, dust mask and
gloves should be worn.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY
TO COOL BEFORE HANDLING ANY METAL
PORTION OF IT. DO NOT PLACE THE DEPLOYED
INFLATOR MODULE NEAR ANY FLAMMABLE
OBJECTS. FAILURE TO FOLLOW PROCEDURES
MAY RESULT IN FIRE OR PERSONAL INJURY.
AFTER AN AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE AIR BAG
ASSEMBLY WILL BE HOT. DO NOT TOUCH THE
METAL AREAS OF THE AIR BAG ASSEMBLY FO
R
ABOUT THIRTY MINUTES AFTER DEPLOYMENT.
IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE
MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag
assembly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot ai
r
bag assembly canister. The pigtail adapter and
SRS deployment harness are designed to be
reused. They should, however, be inspected fo
r
damage after each deployment and replaced if
necessary.
22. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for a
t
least 30 minutes.
23. Wash your hands with mild soap and wate
r
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deplo
y
after following the above procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and tha
t
its two banana plugs have been shorted together
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag
assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE BAG UP
AND AWAY FROM THE SURFACE. THIS IS
NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL
INJURY.
26. Temporarily store the air bag assembly with the
bag facing up, away from the surface upon which it
rests.

Deployment Inside Vehicle (Vehicle
Scrapping Procedure)
Deployment inside vehicle is proper when the vehicle
is to be destroyed or salvaged for component parts.
This includes, but is not limited to, the following
situations:
1. The vehicle has completed its useful life.
2. The vehicle has been damaged beyond repair in a
nondeployment type accident.
3. The vehicle has been stripped or damaged beyond
repair in a theft.
4. The vehicle will be salvaged for component parts
to be used on a vehicle with a different Vehicle
Identification Number (VIN) as opposed to being
rebuilt as same VIN. Never use SRS components
from another vehicle.
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR B
AG ASSEMBLIES MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL. DISPOSAL IN ANY MANNE
R
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
1. Turn ignition switch to “LOCK,” remove key and
put on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver air bag assembly, yellow
connector located at the base of the steering
column.
4. Cut the driver air bag assembly yellow harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.

FRONT WHEEL DRIVE 4C1-47

Important Operations
1. Wheel Pin
(1) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats
completely.

(3) Align index marks and install hub to disc.


2. Bolt
Torque N

m (kgf

m/lb

ft)
103 
10 (10.5 
1/75.9 
7.2)



3. ABS sensor rotor
(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.


4. Inner Bearing and Outer Race
5. Oil Seal

Outer Bearing Outer Race
(1) Install the bearing outer race by driving into the hub.
Installer (Outer) : 5-8822-0053-0 (J-29016)
Installer (Inner) : 5-8822-0054-0 (J-29015)
Drive handle : 5-8840-0007-0 (J-8092)

4C1-54 FRONT WHEEL DRIVE

Important Operations
1. Wheel Pin
(1) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats
completely.

(3) Align index marks and install hub to disc.


2. Bolt
Torque N
m (kgf
m/lb
ft)
103 
10 (10.5 
1/75.9 
7.2)



3. ABS sensor rotor
(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.


4. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2119-0
(J-36829)
Grip : 5-8840-0007-0
(J-8092)

FRONT WHEEL DRIVE 4C1-63

13. Wheel Pin
(1) Place hub on a wood workbench or a block of wood,
approx. 6” by 6” to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats
completely.

(3) Align index marks and install hub to disc.


14. Bolt
Torque N
m (kgf
m/lb
ft)
103 
10 (10.5 
1/75.9 
7.2)



15. ABS sensor rotor
(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip : 5-8840-0007-0
Refer to the section Brake.


16. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2119-0
(J-36829)
Grip : 5-8840-0007-0
(J-8092)

ENGINE MECHANICAL (6VE1 3.5L) 6A-53
Disassembly
NOTE:

During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.

Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaf
t
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5884024460 valve spring compresso
r
and 5884025470 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).



014RW042
5. Remove spark plug (1).
CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.


Inspection and Repair
1. Cylinder head gasket and mating surfaces for
leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
Insufficient torque on head bolts
Improper installation
Loose or warped cylinder head
Missing dowel pins
Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:

  Do not attempt to weld the cylinder head.
Replace it.

  Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. I
f
the surfaces are “out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if i
t
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)



011RW019

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-59
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds
under light engine loads can keep the spark plug
temperatures so low that these deposits are not burned
off. Very rich fuel mixtures or poor ignition system
output may also be the cause. Refer to DTC P0172.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits o
f
combustion by products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the cente
r
electrode. If the fouling is found in only one or two
cylinders, valve stem clearances or intake valve seals
may be allowing excess lubricating oil to enter the
cylinder, particularly if the deposits are heavier on the
side of the spark plug facing the intake valve.



TS23995
Excessive gap means that the air space between the
center and the side electrodes at the bottom of the
spark plug is too wide for consistent firing. This may be
due to excessive wear of the electrode during use.
A
check of the gap size and comparison to the gap
specified for the vehicle in Maintenance and Lubrication
will tell if the gap is too wide. A spark plug gap that is
too small may cause an unstable idle condition.
Excessive gap wear can be an indication of continuous
operation at high speeds or with engine loads, causing
the spark to run too hot. Another possible cause is an
excessively lean fuel mixture.



TS23992
Low or high spark plug installation torque or improper
seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact fo
r
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table.
Low torque may result in poor contact of the seats due
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poo
r
contact between the seats. In extreme cases, exhaus
t
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result o
f
improper installation, damage during spark plug heat
shock to the insulator material. Upper insulators can be
broken when a poorly fitting tool is used during
installation or removal, when the spark plug is hit from
the outside, or is dropped on a hard surface. Cracks in
the upper insulator may be inside the shell and no
t
visible. Also, the breakage may not cause problems
until oil or moisture penetrates the crack later.

ENGINE DRIVEABILITY AND EMISSIONS 6E–55
Low or high spark plug installation torque or improper
seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table.
Low torque may result in poor contact of the seats due
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poor
contact between the seats. In ex treme cases, ex haust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug re-
gapping, or heat shock to the insulator material. Upper
insulators can be broken when a poorly fitting tool is
used during installation or removal, when the spark plug
is hit from the outside, or is dropped on a hard surface.
Cracks in the upper insulator may be inside the shell
and not visible. Also, the breakage may not cause
problems until oil or moisture penetrates the crack later.A broken or cracked lower insulator tip (around the
center electrode) may result from damage during re-
gapping or from “heat shock” (spark plug suddenly
operating too hot).
Damage during re-gapping can happen if the gapping
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
“Heat shock” breakage in the lower insulator tip
generally occurs during several engine operating
conditions (high speeds or heavy loading) and may
be caused by over-advanced timing or low grade
fuels. Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped, then

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and
obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be
sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the movement for the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.