2004 ISUZU TF SERIES Workshop Manual

brake sensor change language wheel torque oil gearbox brake pads replacement

Page 33 of 4264

ISUZU TF SERIES 2004 Workshop Manual SUPPLEMENTAL RESTRAINT SYSTEM 9A-13

SRS Connector Body Face Views

RTW49JMF000201
Legend
(1) SRS control unit
(2) Driver Air Bag Assembly
(3) Passenger Air Bag Assembly (4) “Air Bag”

Page 34 of 4264

ISUZU TF SERIES 2004 Workshop Manual 9A-14 SUPPLEMENTAL RESTRAINT SYSTEM

Repairs And Inspections Required
After An Accident
If any SRS components are damaged, they must be
replaced. If SRS component mounting points are
damaged, t

9A-14 SUPPLEMENTAL RESTRAINT SYSTEM

Repairs And Inspections Required
After An Accident
If any SRS components are damaged, they must be
replaced. If SRS component mounting points are
damaged, they must be replaced.
Never use SRS parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized dealer; they may be used fo
r
SRS repairs.
Do not attempt to service the SRS control unit, the
SRS coil assembly, or the air bag assembly.
Service of these items is by replacement only.

Verify the part number of replacement air bag
assembly.

CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
CAUTION: Proper operation of the sensors and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SRS
control unit, air bag assembly and dimensional
inspection of the steering column. Any visible
damage to the SRS control unit mounting bracket
(s) requires replacement, and the steering column
must be dimensionally inspected, whethe
r
deployment occurred or not.
Accident With Deployment – Component
Replacement And Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
Air bag assembly
SRS control unit

CAUTION: Refer to “SRS control unit
Replacement Guidelines” below for important
information on SRS control unit replacement in
both deployment and non deployment crashes.
SRS coil assembly — Inspect wiring and connecto
r
for any signs of scorching, melting, or damage due
to excessive heat. Replace if damaged. Refer to
section “SRS Coil Assembly” in this manual.
Accident With or Without Deployment –
Component Inspection
Certain SRS system components and rotation parts
must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Steering column —Refer to Inspection Required
“After an Accident” in this manual.
Knee bolsters and mounting points —Inspect fo
r
any distortion, bending, cracking, or other damage.
I/P steering column reinforcement plate —Inspect
for any distortion, bending, cracking, or othe
r
damage.
I/P braces —Inspect for any distortion, bending,
cracking, or other damage.
Seat belts and mounting points — Refer to “Seat
Belts” in Section “Seat Belt” of this workshop
manual.

SRS Control Unit Replacement Guidelines
SRS control unit replacement policy requires
replacement of SRS control unit, after crash involving
air bag deployment when “SRS Warning Lamp” turn
“ON”, “SRS Diagnosis” should be done according to
Section “Restraint Control System.”

Wiring Damage
If any SRS wire harness is damaged, it should be
replaced. Don't repair SRS harness. It is replace only.

SRS Connector (Plastic Body And
Terminal Metal Pin) Damage
If any connector or terminal in the SRS wire harness
(except pigtails) is damaged, it should be replaced.

SRS Wire Pigtail Damage
If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples
of “pigtail” components are the driver air bag
assembly, the passenger air bag assembly, and the
SRS coil assembly.

Page 35 of 4264

ISUZU TF SERIES 2004 Workshop Manual SUPPLEMENTAL RESTRAINT SYSTEM 9A-15

On–Vehicle Service
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
T

SUPPLEMENTAL RESTRAINT SYSTEM 9A-15

On–Vehicle Service
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
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 “LOCK” and remove key.
1. Remove SRS fuse “SRS”, from the side of the
driver side of instrument panel fuse block o
r
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 manual.
4. Disconnect yellow 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
CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
Turn ignition switch to “LOCK” and remove key.
1. Connect yellow connector passenger air bag
assembly.
2. Install glove box assembly. Refer to “Passenger ai
r
bag assembly replacement” in this manual.
3. Connect yellow connector at the base of steering
column.
4. Install “AIR BAG” fuse “SRS” to the side of the
driver side of instrument panel fuse block o
r
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
manual.

Handling / Installation / Diagnosis
1. Air bag assembly should not be subjected to
temperatures above 65
C (150F).
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 sensor pointing
toward the front of the vehicle. It is very 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 replacement.

Page 36 of 4264

ISUZU TF SERIES 2004 Workshop Manual 9A-16 SUPPLEMENTAL RESTRAINT SYSTEM

Air Bag Assembly Handling /
Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) a

Page 37 of 4264

ISUZU TF SERIES 2004 Workshop Manual SUPPLEMENTAL RESTRAINT SYSTEM 9A-17

Air Bag Assembly Scrapping Procedure
During the course of a vehicles useful life, certain
situations may arise which will necessitate the disposal
of a live

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.

Page 38 of 4264

ISUZU TF SERIES 2004 Workshop Manual 9A-18 SUPPLEMENTAL RESTRAINT SYSTEM

WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH O
R
OTHER SURFACE, ALWAYS FACE THE AIR BAG
AND TRIM

9A-18 SUPPLEMENTAL RESTRAINT SYSTEM

WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH O
R
OTHER SURFACE, ALWAYS FACE THE AIR BAG
AND TRIM COVER UP AND AWAY FROM THE
SURFACE. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.
6. Place the driver air bag assembly on a work bench
or other surface away from all loose or flammable
objects with its trim cover facing up, away from the
surface.
060R300028
7. Clear a space on the ground about 183 cm (six
feet) in diameter where the driver air bag assembl
y
is to be deployed. A paved, outdoor location
where there is no activity is preferred. If an
outdoor location is not available, a space on the
shop floor where there is no activity and sufficien
t
ventilation is recommended. Ensure no loose or
flammable objects are within the deployment area.

060R300029
8. Place the driver air bag assembly, with its trim
cover facing up, on the ground in the space just
cleared.
9. Stretch the SRS deployment harness and pigtail
adapter from the driver air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.
11. Connect the driver air bag assembly to the pigtail
adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not
be connected to a power source until the air bag is
to be deployed. The driver air bag assembly will
immediately deploy the air bag when a powe
r
source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated
into the driver air bag assembly connector. Failure to
fully seat the connectors may leave the shorting ba
r
located in the driver air bag assembly connecto
r
functioning (shorted) and may result in nondeployment
of the driver air bag assembly.
12.
Verify that the area around the driver air bag
assembly is clear of all people and loose o
r
flammable objects.
13.
Verify that the driver air bag assembly is resting
with its trim cover facing up.
14. Notify all people in the immediate area that you
intend to deploy the driver air bag. The
deployment will be accompanied by a substantial
noise which may startle the uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.

Page 39 of 4264

ISUZU TF SERIES 2004 Workshop Manual SUPPLEMENTAL RESTRAINT SYSTEM 9A-19

NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
f

SUPPLEMENTAL RESTRAINT SYSTEM 9A-19

NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.

NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deplo
y
the driver air bag.

WARNING: 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.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the driver ai
r
bag. Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the driver air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If 19. the driver air bag assembly did
deploy, proceed with Steps 20 through 23.
20. Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible
irritation and heat when handling the deployed
driver air bag assembly. After the air bag assembl
y
has been deployed, the surface of the air bag may
contain a powdery residue. This power consists
primarily of cornstarch (used to lubricate the bag
as it inflates) and by products of the chemical
reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with the atmospheric moisture and
is converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikel
y
that sodium hydroxide will be present after
deployment.
WARNING: SAFETY PRECAUTIONS MUST BE
OBSERVED WHEN HANDING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE INFLATOR
MODULE TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN FIRE O
R
PERSONAL INJURY.
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
THE METAL AREAS OF THE DRIVER AIR BAG
ASSEMBLY FOR ABOUT TEN MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED DRIVER AI
R
BAG ASSEMBLY MUST BE MOVED BEFORE IT IS
COOL, WEAR GLOVES AND HANDLE BY THE AI
R
BAG OR TRIM COVER.
21. Disconnect the pigtail adapter from the driver ai
r
bag assembly as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SRS deployment harness due to
possible contact with the hot driver air bag
assembly canister. The pigtail adapter can be
reused. They should, however, be inspected fo
r
damage after each deployment and replaced i
f
necessary.
22. Dispose of the deployed driver air bag assembl
y
through normal refuse channels after it has cooled
for at least 30 minutes.
23. Wash your hands with mild soap and wate
r
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the driver air bag assembly did not
deploy after following these procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and that
its two banana plugs have been shorted togethe
r
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the driver ai
r
bag assembly.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE
INFLATOR MODULE UNATTENDED ON A BENCH
OR OTHER SURFACE, ALWAYS FACE THE BAG
AND TRIM COVER UP AND AWAY FROM THE
SURFACE. THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AI
R
BAG TO EXPAND IN THE UNLIKELY E
VENT OF
ACCIDENTAL DEPLOYMENT. FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.

Page 40 of 4264

ISUZU TF SERIES 2004 Workshop 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 (Passe

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

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