2004 ISUZU TF SERIES service

SUPPLEMENTAL RESTRAINT SYSTEM 9A-17

Air Bag Assembly Scrapping Procedure
During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal
of a live (undeployed) air bag assembly. This
information covers proper procedures for disposing of
a live air bag assembly.
Before a live air bag assembly can be disposed of, it
must be deployed. A live air bag assembly must not
be disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPE
R
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDEPLOYED
AIR BAG ASSEMBLY 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 LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle” and
“Deployment Inside Vehicle” in this section.

Deployment Outside Vehicle (Driver Air
Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be
returned to useful service after a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of a malfunctioning air bag
assembly is, of course, subject to any required
retention period.
For deployment of a live (undeployed) air bag
assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear
safety glasses during this deployment procedure until
a deployed air bag assembly is scrapped or until an
undeployed air bag assembly is shipped. Before
performing the procedures you should be familiar with
servicing the SRS and with proper handling of the air
bag assembly. Procedures should be read fully
before they are performed.
The following procedure requires use of 5-8840-2468-
06 SRS deployment harness with appropriate pigtail
adapter. Do not attempt procedure without 5-8840-
2468-0 adapter. WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED MAY RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT HARNESS TO ANY POWE
R
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE DRIVER AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT. WEA
R
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to driver air bag
assembly. Refer to “Deployment Outside Vehicle
(Passenger Air Bag assembly)” in this section fo
r
information on passenger air bag assembly scrapping.
1. Turn ignition switch to “LOCK”, remove key and
put on safety glasses.
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage. I
f
harness or pigtail adapter is damaged, discard and
obtain a replacement.
3. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
827RS004
4. Connect the appropriate pigtail adapter to the SRS
deployment harness.
5. Remove the driver air bag assembly from vehicle.
Refer to “Inflator Module Removal” in this manual.

9A-20 SUPPLEMENTAL RESTRAINT SYSTEM

26. Temporarily store the driver air bag assembly with
its trim cover facing up, away from the surface
upon which it rests.

Deployment Outside Vehicle (Passenger
Air Bag Assembly)
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG 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.
Deployment out of the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of an air bag assembly is, of
course, subject to any required retention period.
For deployment of a live air bag assembly out of the
vehicle, the deployment procedure must be followed
exactly. Always wear safety glasses during this
deployment procedure until the deployed air bag
assembly is scrapped. Before performing the
procedures, you should be familiar with servicing the
SRS system and with proper handling of the air bag
assembly. Procedures should be read fully before
they are performed.
The following procedure requires use of 5-8840-2468-
0 SRS Deployment Harness with the appropriate
pigtail adapter. The procedure also requires the use
of 5-8840-2420-0 Passenger Side SRS Module
Deployment Fixture. Do not attempt this procedure
without 5-8840-2468-0 and adapter, and 5-8840-2420-
0.
WARNING: FAILURE TO FOLLOW PROCEDURES
IN THE ORDER LISTED MAY RESULT IN
PERSONAL INJURY. NEVER CONNECT
DEPLOYMENT HARNESS TO ANY POWE
R
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE AIR BAG ASSEMBLY.
DEPLOYMENT HARNESS SHALL REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT. WEA
R
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE. NOTE: This information applies only to passenger ai
r
bag assembly. Information for disposing of a live
driver air bag assembly can be found in “Deployment
Outside Vehicle” (Driver Air Bag Assembly) in this
section.
1. Turn ignition switch to “LOCK” remove key, and
put on safety glasses.
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage. I
f
harness or pigtail is damaged, discard and obtain
a replacement.
3. Short the two SRS Deployment Harness leads
together by fully seating one banana plug into the
other. The SRS Deployment Harness shall
remain shorted and not be connected to a powe
r
source until the air bag is to be deployed.
827RS003
4. Connect the appropriate pigtail adapter to the SRS
Deployment Harness
827RS004

9A-26 SUPPLEMENTAL RESTRAINT SYSTEM

Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2
scan tool user guide.
901RW200
Legent
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
(3) SAE 16/19 Adaptor
(4) DLC Cable
(5) Tech-2

Getting Started
 Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. Insert the Isuzu System PCMCIA card (1) into the
Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5)
4. Make sure of the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC connector.


060R300015
6. Turn on the vehicle ignition switch.
7. Verify the Tech 2 power up display.
060RW009
NOTE:The RS232 Loop back connector is only used
to diagnosis Tech 2. Refer to user guide of the Tech 2.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-27

Service Precautions for SRS
Component Service
CAUTION: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener fo
r
that application. If the correct part number
fastener is not available, a fastener of equal size
and strength (or stronger) may be used. fasteners
that are not reused, and those requiring thread
locking compound will be called out. The correct
torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
WARNING: WHEN PERFORMING SERVICE ON O
R
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
The SRS control unit in Driver–Passenger SRS can
maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
“OFF,” the battery is disconnected, or the fuse
powering the SRS control unit is removed.
Many of the service procedures require removal of the
“SRS” fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the “Disabling
the SRS” procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.

Disabling The SRS
Removal
Turn the ignition switch to “OFF” and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
1. Remove SRS fuse “SRS” from left dash side lowe
r
fuse block or disconnect battery.
2. Disconnect yellow connector at the base o
f
steering column.
3. Remove glove box assembly; Refer to “Passenge
r
air bag assembly replacement” in this section.
4. Disconnect passenger air bag assembly yello
w
connector behind the glove box assembly.
CAUTION: With the “SRS” fuse removed and
ignition switch “ON,” the “AIR BAG” warning lamp
will be “ON.” This is normal operation and does
not indicate an SRS malfunction.
Enabling The SRS
Installation
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow connector passenger air bag
assembly.
2. Install glove box assembly. Refer to “Passenge
r
Air Bag Assembly Replacement” in this section.
3. Connect yellow connector at the base of the
steering column.
4. Install “AIR BAG” fuse “SRS” to left dash side
lower fuse block or connect battery.
Turn ignition switch to “ON” and verify that the “AIR
BAG” warning lamp flashes seven times and then
turns “OFF.” If it does not operate as described,
perform the “SRS Diagnostic System Check” in this
section.

Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 65

C (150

F).
2. Air bag assembly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the SRS control unit
pointing toward the front of the vehicle. It is ver
y
important for the SRS control unit to be located flat
on the mounting surface, parallel to the vehicle
datum line. It is important that the SRS control unit
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures ma
y
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacements.

Inspections Required After An Accident
CAUTION: Certain SRS components must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of “Air Bag”
deployment, visually inspect all of the following
components and replace as required:

9A-28 SUPPLEMENTAL RESTRAINT SYSTEM

– Driver air bag assembly
– Passenger air bag assembly
– Steering wheel
– SRS coil assembly
– Steering column
– Knee bolster and instrument panel mounting
attachments
– Driver seat and belt
– Passenger seat and belt
– SRS control unit
SRS control unit always should be checked according
to “SRS Control Unit Replacement Guidelines.”
CAUTION: Refer to “SRS control unit Replacement
Guidelines” below for important information on
SRS control unit replacement in both deployment
and non–deployment crashes.
Inspect SRS coil assembly wiring and steering wheel
for any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to steering wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SRS control unit, the SRS
harness, the SRS coil assembly, the air bag assembly,
the steering wheel, or the steering column. Service of
these items is replacement only. Verify replacement
part numbers.
CAUTION: Proper operation of the SRS control
unit and supplemental restraint system (SRS)
requires that any repairs to the vehicle structure
return it to its original production configuration.

SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit. When removing the cable harness, do not
pull the cables otherwise, cable disconnection
may occur. When connect the SRS connector,
insert the connector completely. Imperfect locking
may cause malfunction of SRS circuit.


Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
827RW028

9A-30 SUPPLEMENTAL RESTRAINT SYSTEM

SRS Control Unit
5. Remove the three SRS control unit fixing bolts and
remove SRS control unit.


RTW49JSH000101
Legent
(1) SRS control unit
(2) SRS Harness
(3) Connector Position Assurance

Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SRS control
unit. NEVER STRIKE OR JAR SRS control unit.
UNDER SOME CIRCUMSTANCES, IT COULD
CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY OR IMPROPER OPERATION
OF THE SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . SRS control unit MOUNTING BRACKET
BOLTS MUST BE CAREFULLY TORQUED TO
ASSURE PROPER OPERATION. NEVER POWE
R
UP THE SRS WHEN SRS control unit IS NOT
RIGIDLY ATTACHED TO THE VEHICLE. THE SRS
control unit COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
WARNING: PROPER OPERATION OF THE SRS
CONTROL UNIT REQUIRES THE SRS CONTROL
UNIT TO BE RIGIDLY ATTACHED TO THE
VEHICLE STRUCTURE AND THAT THE ARROW
ON THE SENSOR BE POINTING TOWARD THE
FRONT OF THE VEHICLE.
SRS control unit is specifically calibrated and is keyed
to the SRS control unit location SRS wiring harness.
Caution should be used to ensure proper location of
the SRS control unit. The keying of the SRS control
unit to its location and wiring harness connectors
should never be modified in the field.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in
this section).
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. Remove the front console assembly and
disconnect wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SRS
control unit harness connector.

Installation
1. Install the SRS control unit on bracket and fixing
bolts and tighten the fixing bolts to the specified
torque.
Torque: 7




2 N
 m (0.7




0.2 kg
 m/61 lb in)
2. Connect the SRS control unit harness connecto
r
and after that, put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfe
r
lever knob.

9A-32 SUPPLEMENTAL RESTRAINT SYSTEM

Driver Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVE
R
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AI
R
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND TRIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
VERTICAL. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspec
t
coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
has been damaged, replace it.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in
this section).



2. Check the both side hole of the steering cover.
060R300025
3. Check the position of the pins in a hole. Push the
pin in the direction of an arrow.
060R300032

SUPPLEMENTAL RESTRAINT SYSTEM 9A-35

Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVE
R
CARRY AIR BAG ASSEMBLY BY THE WIRES O
R
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AI
R
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN
VERTICAL. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
In the event deployment has occurred, inspect coil
assembly wire for any signs of scorching, melting o
r
any other damage due to excessive heat. If the coil
has been damaged, replace it.

Removal
1. Remove the SRS air bag assembly. (Refer to
“Driver Air Bag Assembly” in this section)

2. Remove steering wheel attachment nut.

060R300009
3. Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the tires to the straight ahead position before
removing the steering wheel. Install steering wheel
puller onto steering wheel and remove steering
wheel with 5-8521-0016-0.
5. Feed wiring through the wheel and remove wheel.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.