2004 ISUZU TF SERIES battery replacement

ENGINE DRIVEABILITY AND EMISSIONS 6E–275
IGNITION COIL
Location
Back of the engine right-hand side.
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the ignition coil connector.
3. Disconnect four spark plug cables from the ignition
coil.
4. Loosen three bolts and remove ignition coil from the
bracket.
Installation Procedure
1. Tighten the ignition coil by three bolts.
2. Connect four spark plug cables to the ignition coil.
3. Connect a ignition coil connector to the ignition coil.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of spark plug cables for each
cylinders.
SPARK PLUGS
Location
Installed on the left-hand side of cylinder head.
Removal Procedure
1. Disconnect the negative battery cable
2. Remove the spark plug cable.
3. Remove the spark plug.
Inspection
1. Check the insulator for cracks. Replace the spark
plug if cracks are present.
2. Check the electrode condition and replace the spark
plug if necessary.
If the spark plug electrodes and insulators are fouled
with carbon or oil, the engine will not operate efficiently.
There are a number of possible causes:
Fuel mix ture is too rich.

6E–276 ENGINE DRIVEABILITY AND EMISSIONS
Oil in the combustion chamber.
The spark plug gap is not set correctly.
If spark plug fouling is ex cessive, check the fuel and al
system for possible causes of trouble. If fuel and al
system are normal, install spark plugs of a higher heat
range which have the same physical dimensions as the
original equipment spark plugs.
The following symptoms are characteristics of spark
plugs that are running too hot:
Fuel mixture is too lean.
Heat range is incorrect.
If vehicle usage does not conform to normal driving
conditions, a more suitable spark plug may be
substituted.
If fuel and al system are normal, in most cases of this
sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as
the original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.0
to 1.1mm (0.039 to 0.043").
5. Adjust the spark gap by bending the grounded
electrode.Installation
1. Tighten the spark plug to the 25N·m (2.5kgf·m).
2. Push the spark plug cable in until it snaps in.
Installation Procedure
1. Install the spark plug to the cylinder head.
2. Tighten the spark plug with specified tightening
torque.
Tightening Torque
Bolt: 25N·m (2.5kgf·m)
3. Connect the spark plug cable to the spark plug.
4. Connect the negative battery cable.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
Verify proper connection of spark plug cables for each
cylinders.

0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS
1. Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2. Raise the vehicle with a jack set against the axle or the frame.
3. Support the vehicle on chassis stands.
4. Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5. Disconnect the grounding cable from the battery before performing service operations.

This will prevent cable damage or burning due to short circuiting.
6. Handle brake fluid and antifreeze solution with great care.

Spilling these liquids on painted surfaces will damage the paint.
7. The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and
obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be
sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the movement for the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.

1-26 HEATER AND AIR CONDITIONING
ON-VEHICLE SERVICE

PRECAUTIONS FOR REPLACEMENT OR
REPAIR OF AIR CONDITIONING PARTS
There are certain procedures, practices and precautions that
should be followed when servicing air conditioning systems:

Keep your work area clean.

Always wear safety goggle and protective gloves when
working on refrigerant systems.
 Beware of the danger of carbon monoxide fumes caused by
running the engine.

Beware of discharged refrigerant in enclosed or improperly
ventilated garages.


Always disconnect the negative battery cable and discharge
and recover the refrigerant whenever repairing the air
conditioning system.

When discharging and recovering the refrigerant, do not
allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.

Keep moisture and contaminants out of the system. When
disconnecting or removing any lines or parts, use plugs or
caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts are
reconnected or installed.

When disconnecting or reconnecting the lines, use two
wrenches to support the line fitting, to prevent from twisting
or other damage.

Always install new O-rings whenever a connection is
disassembled.

Before connecting any hoses or lines, apply new specified
compressor oil to the O-rings.

When removing and replacing any parts which require
discharging the refrigerant circuit, the operations described
in this section must be performed in the following sequence:

1) Using the ACR
4 (HFC-134a Refrigerant Recovery/
Recycling/Recharging/System) or equivalent to
thoroughly discharge and recover the refrigerant.
ACR
4 (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
ACR4 (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
ACR
4 (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3)
After evacuation, charge the air conditioning system and
check for leaks.

ANTITHEFT SYSTEM 11B – 3
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, REFER 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, or 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.
DTC20 Broken wire to door lock actuators ............................................................ 11B – 42
DTC21 Remote key 1 with random code out of capture range ............................ 11B – 43
DTC22 Remote key 2 with random code out of capture range ............................ 11B – 44
DTC23 Remote key 3 with random code out of capture range ............................ 11B – 45
DTC24 Remote key 4 with random code out of capture range ............................ 11B – 46
DTC25 Remote key 5 with random code out of capture range ............................ 11B – 47
DTC28 Input immobiliser short circuit to ground .................................................. 11B – 48
DTC29 Broken wire to immobiliser ......................................................................... 11B – 49
DTC31 Actuator driver door defect ......................................................................... 11B – 50
DTC32 Actuator passenger door defect .................................................................. 11B – 51
DTC36 Broken wire to driver door........................................................................... 11B – 52
DTC37 Broken wire to passenger door ................................................................... 11B – 53
DTC41 Driver door micro switch unlock defect ..................................................... 11B – 54
DTC42 Driver door micro switch lock defect .......................................................... 11B – 55
DTC43 Driver door micro switch dead lock defect ................................................ 11B – 56
DTC44 Passenger door micro switch lock defect................................................... 11B – 57
DTC45 Passenger door micro switch unlock defect .............................................. 11B – 58
DTC47 Battery voltage for door lock actuators is missing ................................... 11B – 59
DTC50 A/D converter defect or battery voltage less than 9 volt ......................... 11B – 60
DTC51 E E P ROM defect .......................................................................................... 11B – 61
DTC52 E E P ROM not programmed by ISUZU ...................................................... 11B – 62
DTC55 Control unit defect ........................................................................................ 11B – 63
DTC123 Output flasher short circuit to grpund or broken wire ........................... 11B – 64
DTC125 Output alarm horn broken wire ................................................................ 11B – 65

ANTITHEFT SYSTEM 11B – 59
DTC 47 Battery Voltage For Door Lock Actuators Is Missing
Step Action Value (s) Yes No
1
2
3
4
5
6
7Was the Antitheft System Check
performed?
Recheck the DTC.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Check the DTC on the Tech-2.
Is DTC 47 stored?
Check the antilock system voltage.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Observe to display system voltage data with
the Tech-2.
Is the voltage near the specified value ?
1. Key position is “OFF”.
2. Check the battery voltage.
3. If a problem found, repair as necessary.
(Chage battery)
Was the problem found?
Check the door lock motor output voltage.
1. Key position is “OFF”.
2. Connect a digital volt meter to measure
voltage.
between ACU terminal 7 and body ground.
3. Key position is “ON”.
4. Observe to display voltage with the DVM.
5. Door lock ON.
Is the voltage near the specified value ?
1. Check the door lock motor circuit for an open,
short to ground, or short to voltage.
Also, check the door lock motor connector for
damage.
2. If a problem found, repair as necessary.
Was the problem found?
Replace the antitheft control unit (ACU).
IMPORTANT:The replacement ACU must be
programmed the security data by the Tech-2.
Was the action complete?—
—
12V
—
12V
—
—Go to Step 2
Go to Step 3
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Verify repairGo to antitheft
System Check
Refer to
Diagnostic Aids
Go to Step 4
Refer to
Diagnostic Aids
Go to Step 7
—
—

11B – 60 ANTITHEFT SYSTEM
DTC 50 A/D Converter Defect Or Battery Voltage Less Than 9 Volt
Step Action Value (s) Yes No
1
2
3
4
5
6Was the Antitheft System Check
performed?
Recheck the DTC.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Check the DTC on the Tech-2.
Is DTC 50 stored?
Check the antilock system voltage.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Observe to display system voltage data with
the Tech-2.
Is the voltage near the specified value ?
1. Key position is “OFF”.
2. Check the battery voltage.
3. If a problem found, repair as necessary.
(Chage battery)
Was the problem found?
1. Check the ignition feed circuit for an open,
short to ground.
Also, check the ACU ground circuit for
damage.
2. If a problem found, repair as necessary.
Was the problem found?
Replace the antitheft control unit (ACU).
IMPORTANT:The replacement ACU must be
programmed the security data by the Tech-2.
Was the action complete?—
—
12V
—
—
—Go to Step 2
Go to Step 3
Go to Step 7
Verify repair
Verify repair
Verify repairGo to antitheft
System Check
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Refer to
Diagnostic Aids
—

7A2-36 TRANSMISSION CONTROL SYSTEM (AW30–40LE) (V6 3.5L)

Diagnostic Aids

Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
DTC P0560 – System Voltage Error
Step Action Value(s) YES NO
1
Was the powertrain On-Board Diagnostic (OBD)
System Check performed? — Go to Step 2 Go to OBD
System Check
2 Using a DVM, measure the battery voltage at the
battery.
Is the battery voltage greater than the specified
value? 11.5 V Go to Step 3 Charge battery,
then go to Step
3
3

1. Install a Tech 2.

2. Select “Ignition Volts" on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.

4. Load the electrical system by turning on the
headlights, high blower, etc.
Is the ignition voltage approximately equal to the
specified value? 2000 RPM
12.8-14.1 VGo to Step 4 Go to
Starting/Chargi
ng
4

1. Ignition “OFF".

2. Disconnect the TCM connector at the TCM.

3. Using a DVM, measure the battery voltage at the
TCM connector C-94.
Is it approximately equal to battery voltage? — Check for
excessive
curren draw
with ignition
“OFF" engine
“OFF". Go to Step 5
5

1. Check for faulty connections at the TCM harness
terminals.

2. Repair as necessary.
Was a repair necessary? — Verify repair Go to Step 6
6 Check for an open battery feed circuit to the TCM.
Is the action complete? — Verify repair Go to Step 7
7 Replace the TCM.
Important:
The replacement TCM must be
programmed. (Refer to SPS for procedure.)
Is the action complete? — Verify repair —