2004 Isuzu Rodeo - 02_TFFRM-WE-0431.pdf

WORKSHOP MANUAL TF SERIES

FRAME AND CAB

SECTION 2

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

2A-2 FRAME AND BUMPER

FRONT BUMPER REMOVAL AND INSTALLATION

RTW42ALF000101

Removal Steps

Installation Steps

I 1. Radiator grille I 2. Front bumper fascia 3. Bezel (W/O Fog light) 4. Fog light 5. Front bumper flare assembly (W/ Front wheel extention) 6. Front bumper inpact support assembly 7. Front bumper inpact bar assembly (Except Europe equipment) 8. Front bumper inpact bar assembly (For Europe equipment) 9. Fascia support side bracket 10. Fascia support lower bracket

10. Fascia support lower bracket 9. Fascia support side bracket I 8. Front bumper inpact bar assembly (For Europe equipment) I 7. Front bumper inpact bar assembly (Except Europe equipment) 6. Front bumper inpact support assembly I 5. Front bumper flare assembly (W/ Front wheel extention) I 4. Fog light 3. Bezel (W/O Fog light) 2. Front bumper fascia 1. Radiator grille

FRAME AND BUMPER 2A-3

Important Operations - Removal 1. Radiator Grille Refer to the Radiator Grille in this section.

2. Front Bumper Fascia · Remove the nine clips and four screws. · Disconnect the fog light harness connectors.

Important Operations - Installation 8. Front Bumper Inpact Bar Assembly (For Europe equipment) 7. Front Bumper Inpact Bar Assembly (Except Europe equipment) Tighten the fixing bolts to the specified torque. Torque

N×m(kgf×m/lb×ft)

62 (6.3 / 46) This illustration is except Europe equipment model. 5. Front Bumper Flare Assembly Tighten the fixing nuts to the specified torque. Torque

N×m(kgf×m/lb×in) 7 (0.7 / 61)

4. Fog Light Tighten the fixing nuts to the specified torque. Torque

N×m(kgf×m/lb×in) 7 (0.7 / 61)

2A-4 FRAME AND BUMPER

REAR STEP BUMPER REMOVAL AND INSTALLATION

RTW32AMF000301

Removal Steps

Installation Steps

▲ 1. Rear step bumper assembly ▲ 2. Side step pad 3. License light ▲ 4. Rear bumper center pad 5. Extension harness 6. Back bar / Conner brace 7. Rear bumper 8. Reinforce assembly

8. Reinforce assembly ▲ 7. Rear bumper ▲ 6. Back bar / Conner brace 5. Extension harness 4. Rear bumper center pad 3. License light 2. Side step pad ▲ 1. Rear step bumper assembly

Important Operations - Removal 1. Rear Step Bumper Assembly · Remove the 3 bolts from each side. · Disconnect the extension harness connector.

FRAME AND BUMPER 2A-5 2. Side Step Pad · Push out the 4 fixing portions of side step pad from the back face of the rear step bumper.

RTW32ASH000101

4. Rear Bumper Center Pad · Remove the 2 clips from both end of the center pad. · Push out the 7 fixing portions of center pad from the back face of the rear step bumper.

RTW32ASH000201

Important Operations - Installation 7. Rear bumper · Tighten the fixing bolts to the specified torque. A: Bolt Torque

N×m(kgf×m/lb×ft) 40 (4.1 / 30)

6. Back Bar / Conner Brace 1) B: Bolt Torque

N×m(kgf×m/lb×ft)

40 (4.1 / 30) 2) C: Bolt Torque

N×m(kgf×m/lb×in) 9 (0.9 / 78)

3) D: Bolt Torque

N×m(kgf×m/lb×ft) 85 (8.7 / 63)

RTW32AMH000101

2A-6 FRAME AND BUMPER 1. Rear Step Bumper Assembly 1) Align the back bar to the frame as follows: · Face A should be contacted with the upper face of the frame · Face B should be contacted with the rear end of the frame. 2) Tighten the 3 fixing bolts on the each side of back bar. Torque

N×m(kgf×m/lb×ft) 150 (15.3 / 111)

RTW32AMH000201

FRAME AND BUMPER 2A-7

REAR BUMPER AND REAR GUARD ASM REMOVAL AND INSTALLATION

RTW42AMF000201

Removal Steps

Installation Steps

I 1. Rear guard assembly I 2. Rear bumper assembly 3. Nut 4.