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Page 1276 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6A – 136 ENGINE MECHANICAL

RTW36ASH000601
Removal
1. Radiator Grille
Refer to removal procedure in Sheet Metal section.

RTW36ASH000501
2. Front Bumper Fascia

Page 1416 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–44 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
RELAY A ND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
No .RELAY
(4JA1-TC/4JH1-TC)
X -1 RELAY; TAIL LIGHT
X -2 RELAY; FRT F OG LI GHT
X -

Page 1452 of 4264

ISUZU TF SERIES 2004 Workshop Manual 6E–80 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested i

6E–80 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Nex t, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Hints
You can isolate a circuit by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Substitute a known good part from the parts
department or the vehicle system
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the nex t page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Bulletins
Digital multimeter (with a MIN/MAX feature)
Tech II and Tech II upload function
Circuit testing tools (including connector kits/
harnesses and jumper wires)
Ex perience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.For parts and sensors, apply slight vibration to the part
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CA UTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CA UTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
A lack of understanding by the customer
A conflict between customer ex pectations and
vehicle design intent
A system performance that is unacceptable to the
customer
What you should do
You can verify that a system is operating as designed
by:
Reviewing service manual functional/diagnostic
checks
Ex amining bulletins and other service information for
supplementary information
Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer ex pectation and system
operation, you should ex plain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:

Page 2027 of 4264

ISUZU TF SERIES 2004 Workshop Manual 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-31

RELAY AND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX

RELAY
NO. Relay name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4

Page 2063 of 4264

ISUZU TF SERIES 2004 Workshop Manual 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-67
What you should do
Step 1: Acquire information
A thorough and comprehensive customer check sheet
is critical to intermittent problem diagnosis. You sho

3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-67
What you should do
Step 1: Acquire information
A thorough and comprehensive customer check sheet
is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.

Step 2: Analyze the intermittent problem
Analyze the customer check sheet and service history
file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.

Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components
/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Next, confine the problem into a smalle
r
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.

Hints
You can isolate a circuit by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another
If only component fails to operate, begin testing
the component
If a number of components do not operate, begin
test at areas of commonality (such as powe
r
sources, ground circuits, switches, main
connectors or major components)
Substitute a known good part from the parts
department or the vehicle system
Try the suspect part in a known good vehicle See
Symptom Simulation Tests on the next page fo
r
problem simulation procedures. Refer to service
manual sections 6E and 8A for information abou
t
intermittent diagnosis. Follow procedures for basic
circuit testing in service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Bulletins
Digital multimeter (with a MIN/MAX feature)
Tech 2 and Tech 2 upload function
Circuit testing tools (including connecto
r
kits/harnesses and jumper wires)
Experience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complain
t
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector join
t
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.
For parts and sensors, apply slight vibration to the par
t
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier o
r
similar tool while monitoring the system for a
malfunction.
CAUTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or unde
r
conditions of high humidity. In this case, apply water in
a light spray on the vehicle to duplicate the problem.
CAUTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.

Page 2607 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–31
RELAY A ND FUSE BOX LOCATION (LHD & RHD)
RELAY & FUSE BOX
RELAY
No. Relay Name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-

Page 2641 of 4264

ISUZU TF SERIES 2004 Workshop Manual ENGINE DRIVEABILITY AND EMISSIONS 6E–65
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
w

ENGINE DRIVEABILITY AND EMISSIONS 6E–65
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Nex t, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Hints
You can isolate a circuit by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Substitute a known good part from the parts
department or the vehicle system
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the nex t page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Bulletins
Digital multimeter (with a MIN/MAX feature)
Tech II and Tech II upload function
Circuit testing tools (including connector kits/
harnesses and jumper wires)
Ex perience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.For parts and sensors, apply slight vibration to the part
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CA UTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CA UTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
A lack of understanding by the customer
A conflict between customer ex pectations and
vehicle design intent
A system performance that is unacceptable to the
customer
What you should do
You can verify that a system is operating as designed
by:
Reviewing service manual functional/diagnostic
checks
Ex amining bulletins and other service information for
supplementary information
Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer ex pectation and system
operation, you should ex plain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:

Page 2894 of 4264

ISUZU TF SERIES 2004 Workshop Manual 2A-2 FRAME AND BUMPER
FRONT BUMPER
REMOVAL AND INSTALLATION

RTW42ALF000101

Removal Steps

1. Radiator grille

2. Front bumper fascia

3. Bezel (W/O Fog light)

4. Fog ligh

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