2004 ISUZU TF SERIES light

BRAKE CONTROL SYSTEM 5A-21

Computer System Service Precautions
The Anti-lock Brake System and Electronic Brake-force
Distribution interfaces directly with the Electronic
Hydraulic Control Unit (EHCU) which is a control
computer that is similar in some regards to the Engine
Control Module. These modules are designed to
withstand normal current draws associated with vehicle
operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the “ON”
position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.

General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System and Electronic Brake-force Distribution
damage.
 If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before
the welding operation begins.
 The EHCU and valve block connectors should
never be connected or disconnected with the
ignition “ON”.
Note:
 If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS and Brake” warning lamp
will illuminate. But actually no trouble exists. When
the DTC is not detected and the ABS and BRAKE
warning lamp is on, “How to erase code” is
performed and a ABS and BRAKE warning lamp
are off.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS) and
Electronic Brake-force Distribution (EBD) System
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS and EBD
to a non-operative state by removing the fuse for the
ABS. After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning Lamp does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case
duplicating the system malfunction during a test drive or
a good description of vehicle behavior from the
customer may be helpful in locating a “most likely”
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most
intermittent problems are caused by faulty electrical
connections or wiring. When an intermittent failure is
encountered, check suspect circuits for:
 Suspected harness damage.
 Poor mating of connector halves or terminals not
fully seated in the connector body (backed out).
 Improperly formed or damaged terminals.

Test Driving ABS Complaint Vehicles
In case that there has been an abnormality in the
lighting pattern of “ABS” warning lamp, the fault can be
located in accordance with the “DIAGNOSIS BY “ABS”
WARNING LAMP ILLUMINATION PATTERN”. In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1.
Start the engine and make sure that the “ABS” W/L
goes OFF. If the W/L remains ON, it means that
the Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
Note: The DTC cannot be cleared if the vehicle speed
does not exceed about 6km/h (4mph) at DTC, even
though the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the
W/L is actuated while driving, read the DTC and
locate the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” .
Note:

Be sure to give a test drive on a wide, even road
with a small traffic.
 If an abnormality is detected, be sure to suspend
the test and start trouble diagnosis at once.

BRAKE CONTROL SYSTEM 5A-27

Actuator Test (Tech 2)
There are 5 different menus available for this test. The
state of each circuit can be tested by using these
menus. Especially when DTC cannot be detected, a
faulty circuit can be diagnosed by testing each circuit by
means of these menus.
Even when DTC has been detected, the circuit tests
using these menus could help discriminate between a
mechanical trouble and an electrical trouble.
In all cases test condition; Engine stops with the key
turned to the “ON” position. To be more specific, the
test is conducted with the brake pedal stepped on after
stepping once and releasing.
 Engine: Stop
 Ignition SW: ON

060L300002

ABS Check Light Test
Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after
stepping once and releasing.
 The circuit is normal if the warning light (lamp) in
the meter panel comes on and goes out in
accordance with Tech2’s instruction.

060L300002

Return Pump Test
Test condition: Engine stops with the key turned to the
“ON” position. To be more specific, the test is
conducted with the brake pedal stepped on after
stepping once and releasing.
Make sure of the working sound of the return pump
relay and return pump.
The circuit is normal if the working sound of the return
pump relay and return pump are made in accordance
with Tech2’s instruction.

060L300002

5A-32 BRAKE CONTROL SYSTEM

Diagnosis By “ABS” Warning Lamp
Illumination Pattern
In the event that there is abnormality in the “ABS”
warning Lamp illumination pattern while the key is in the
ON position or if the warning Lamp is actuated during
driving, trouble should be diagnosed on a illumination
pattern basis as follows:

No. Condition “ABS” Warning Lamp Illumination Pattern Diagnostic
1 Warning Lamp is
actuated normally
Normal
2 Warning Lamp is not
lit
Warning Lamp lighting circuit
trouble. Go to No ABS
Warning Lamp.
3 Warning Lamp
remains ON
Diagnostic trouble codes are
stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to
the flow charts.
4 Warning Lamp is
actuated while driving
Diagnostic trouble codes are
stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to
the flow charts.

Diagnostic Trouble Codes (DTCs)
When the warning lamp in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.

BRAKE CONTROL SYSTEM 5A-41

Brake Pedal Feed Is Abnormal

Step Action
Value(s) Yes No
1 Is the stop light actuated when the brake pedal is
depressed?
- Go to Step 2 Go to Step 3
2 1. Turn the ignition switch off.
2. Disconnected EHCU connector.
Is the check voltage for EHCU connector terminals
when brake pedal is depressed than battery voltage?
- Go to Step 4 Harness NG
between stop
light SW and
EHCU.
Go to Step 6
3 Is stop light fuse normal?
- Go to Step 5 Replace stop
light fuse.
Go to Step 6
4 Is the check continuity between EHCU connector to
body grounded?
- Go to Step 6 Repair body
grounded
harness.
Go to Step 6
5 Is stop light switch operation normal?
- Repair stop
light harness.
Go to Step 6 Replace stop
light switch.
Go to Step 6
6 Reconnect all components, ensure all components
are properly mounted.
Was this step finished?
- Repeat the
“Basic
diagnostic
flow chart” Go to Step 6

PARKING BRAKE SYSTEM 5D-1

SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS

Service Precaution .......................................... 5D-1
Service Precaution ....................................... 5D-1
General Description ...................................... 5D-1
Parking Brake Lever ........................................ 5D-2
Parking Brake Lever Assembly and
Associated Parts (Bench Seat) .................. 5D-2
Removal ....................................................... 5D-3
Installation............................................................
5D-3
Front Parking Brake Cable....................................
5D-5
Front Parking Brake Cable and Associated
Parts (Bench Seat).........................................
5D-5
Removal...............................................................
5D-6
Installation............................................................
5D-6
Parking Brake Lever...............................................
5D-8
Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair ................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting ............................................ 5D-13


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

General Description
Pulling up the parking brake lever by hand will set the
parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/leve
r
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8

14 notches with 30kg (bench seat) o
r
6

8 notches with 30kg (bucket seat). Refer to “Parking
Brake Adjustment" in this section.

CAB 10-31



13.Ashtray Case

Pull out the ashtray case.
14. Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15. Control Lever Assembly


Remove the 2 fixing screws.
17.Ashtray Bracket


Remove the 3 fixing screws and illumination connector.


Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21. Passenger Air Bag



Remove 2 fixing bolts, 2 fixing nuts and connector.
22. Side Ventilation Grille.

Pull out the grilles and disconnect switch connecto
r
(Driver’s side).
23. Vent Duct Assembly/Defroster Nozzle Assembly


Refer to section 1 “HVAC” for defroster nozzle and
ventilation duct removal steps.




25. Instrument Panel


Remove the clip and 6 fixing bolts.
26. Cross Beam

CAB 10-39
HEADLINING
REMOVAL AND INSTALLATION


This illustration is based on RHD model



EXTEND CAB Model
Removal Steps

1. Interior trim panels

2. Sunvisor/Sunvisor holder

3. Spot light

4. Assist grip
5. Hole cover

6. Coat hook

7. Dome light

8. Headlining


Installation Steps
8. Headlining
7. Dome light
6. Coat hook
5. Hole cover
4. Assist grip
3. Spot light
2. Sunvisor/Sunvisor holder
1. Interior trim panels

10-40 CAB
REMOVAL AND INSTALLATION



This illustration is based on RHD model
RTW3A0LF001101

REGULAR CAB Model
Removal Steps


1. Interior trim panels

2. Sunvisor/Sunvisor holder

4. Assist grip
5. Hole cover

7. Dome light

8. Headlining


Installation Steps
8. Headlining
7. Dome light
5. Hole cover
4. Assist grip
2. Sunvisor/Sunvisor holder
1. Interior trim panels