2004 ISUZU TF SERIES engine remove

BRAKE CONTROL SYSTEM 5A-83

Step Action
Value(s) Yes No
6 1. Remove the G-sensor.
2. Reconnect G-sensor and EHCU
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Observe the G-sensor reading on Tech 2.
If G-sensor inclines, reading voltage will change.
Is the reading voltage between specified value? 1.0 - 4.0V Go to Step 7 Go to Step 8
7 1. Ignition "OFF".
2. Install the G-sensor.
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Select "Display DTCs" with the Tech 2.
Are any DTCs stored? - Go to Step 8 Verify repair
8 1. Replace G-sensor.
2. Select "Display DTCs" with the Tech 2.
Note: Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech2.
Are any DTCs stored? - Go to Step 9 Verify repair
9 Replace EHCU.
Note : Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2WD model or 4WD model)
Was the action complete? - Verify repair -

BRAKE CONTROL SYSTEM 5A-89

Step Action Value(s) Yes No
4 1. Ignition "OFF".
2. Check for a poor condition at the EHCU harness
connector.
3. Check the EHCU circuit for an open, short to
ground, or short to voltage. Also, check the EHCU
ignition feed circuit for an open or short to ground
and the EHCU ground circuit for an open or short
to voltage.
4. If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 9
5 1. Ignition "OFF," disconnect the EHCU and G-
sensor.
2. Check the circuit between EHCU and G-sensor.
(short to ground, or short to voltage.)
3. If a problem is found, repair as necessary.
Was a problem found? - Verify repair
Go to Step 6 Go to Step 6
6 1. Remove the G-sensor.
2. Reconnect G-sensor and EHCU
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Observe the G-sensor reading on Tech 2.
If G-sensor inclines, reading voltage will change.
Is the reading voltage between specified value? 1.0 – 4.0 V Go to Step 7 Go to Step 8
7 1. Ignition "OFF".
2. Install the G-sensor.
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Select "Display DTCs" with the Tech 2.
Are any DTCs stored? - Go to Step 8 Verify repair
8 1. Replace G-sensor.
2. Select "Display DTCs" with the Tech 2.
Note: Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech2.
Are any DTCs stored? - Go to Step 9 Verify repair
9 Replace EHCU.
Note : Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2WD model or 4WD model)
Was the action complete? - Verify repair -

5C-26 BRAKES


A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the master
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinder
and brakes, then the brake system served by the disconnected
pipe must be bled.

1. Set the parking brake completely, then start the engine.
NOTE :
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.

3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation
4. Always use new brake fluid for replenishment.
5. In replenishing rake fluid, take care that air bubbles do no
t
enter the brake fluid.


When the master cylinder is replaced or overhauled, firs
t
bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.


Bleeding the Master Cylinder
6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with
your finger, where the pipe was disconnected then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake
pedal returns completely.
10. Repeat steps 7 through 9 until the brake fluid comes out o
f
the delivery port during step 7.
NOTE : Do not allow the fluid level in the reservoir to go below
the half-way mark.
11. Reconnect the brake pipe (1) to the master cylinder and
tighten the pipe.
12. Depress the brake pedal slowly once and hold it depressed.
13. Loosen the rear wheel brake pipe (1) at the master cylinder.
14. Retighten the brake pipe, then release the brake pedal
slowly.

CAB 10-29

Important Operations
1. Front Console Assembly


Refer to Floor Consol in this section.



2. Glove Box


Remove 2 fixing screws and pulling the handle.



3. Instrument Panel Driver Lower Cover Assembly
1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.




4. Driver Knee Bolster Assembly


Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 “Supplemental Restraint System
(SRS) - AIR BAG”

5. Driver Air Bag
6. Steering Wheel/Steering Cowl


Refer to Section 3B “STEERING COLUMN” for steering
lock assembly removal steps.




7. Meter Cluster Assembly


Pull out the 4 clip positions.

ELECTRICAL-BODY AND CHASSIS 8A-19
Battery-1

BATTERY
Inspection
1. Check the battery terminals 1 for corrosion.
2. Check the battery cables
2 for looseness.
3. Check the battery case
3 for cracks and other damage.
4. Check the battery electrolyte level.

Battery-2

Battery Replacement
1. Disconnect the battery ground cable 1.
2. Disconnect the battery positive cable
2.
3. Remove the battery clamp
3.
4. Remove the battery
Caution:
It is important that the battery ground cable be removed
first.
Removing the battery positive cable first can result in a
short circuit.


Jump Starting the Engine with a Booster Battery
The following description assumes that you are using a booster
battery mounted on a second vehicle.
The listed steps (with some minor modifications) are also
applicable if you are using a naked booster battery or special
battery charging equipment.

ELECTRICAL-BODY AND CHASSIS 8A-21

Caution:
Do not attach the booster cable to the discharged battery
negative terminal.

11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.

ELECTRICAL-BODY AND CHASSIS 8A-105
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
C24SE

Removal
1. Lift both the ECM harness connector locking levers and
remove the two harness connectors form the ECM.
2. Remove the four socket head screws securing the ECM to
the mounting bracket.
3. Remove the ECM from the engine compartment
.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-106 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
6VE1
Removal
1. Pull both the red ECM harness connector locks toward the
front of the vehicle, and remove the two harness connectors
form the ECM.
2. Remove the four hex-head screws securing the ECM to the
common chamber.
3. Remove the ECM from the engine compartment.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.