2004 ISUZU TF SERIES battery location

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.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-21

5. Remove passenger air bag assembly from vehicle.
Refer to “Passenger Air Bag Assembly Removal “.
6. Clear a space on the ground approximately 183
cm (six feet) in diameter where the fixture with
attached air bag assembly is to be placed fo
r
deployment. A paved outdoor location where
there is no activity is preferred. If an outdoo
r
location is not available, a space on the shop floor
where is no activity and sufficient ventilation is
recommended. Ensure that no loose o
r
flammable objects are within the deployment area.
7. Place the 5-8840-2420-0 on the bench vice. This
is necessary to provide sufficient stabilization o
f
the fixture during deployment.
8. Attach the passenger air bag assembly in the 5-
8840-2420-0.
An air bag assembly must be
mounted such that the bag will deploy upward.
SECURELY HAND–TIGHTEN ALL FASTENERS
PRIOR TO DEPLOYMENT.
901RW199
9. Stretch the SRS Deployment Harness and pigtail
adapter from the 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 air bag assembly to the pigtail adapte
r
on the SRS deployment harness. The SRS
Deployment Harness shall remain shorted and no
t
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 powe
r
source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated
into the air bag assembly connector. Failure to full
y
seat the connectors may leave the shorting bar located
in the air bag assembly connector functioning (shorting
the deployment circuit) and may result in
nondeployment of the air bag assembly.
12.
Verify that the area around the passenger air bag
assembly is clear of all people and loose o
r
flammable objects.
13.
Verify that the passenger air bag assembly is
firmly and properly in 5-8840-2420-0.
14. Notify all people in the immediate area of you
r
intention to deploy the passenger air bag
assembly. 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.
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 air bag assembly.
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 air bag
assembly. 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 passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembl
y
deployed as intended, proceed with Steps 20
through 23.

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:

RESTRAINT CONTROL 9A1-3

Diagnostic Information
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 for 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.


Diagnostic Procedures
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY-POWERED OR AC-POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED, PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
The diagnostic procedures used in this section are
designed to aid in finding and repairing SRS problems.
Outlined below are the steps to find and repair SRS
problems quickly and effectively. Failure to carefully
follow these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect parts
replacement.
1. Perform The “SRS Diagnostic System Check”.
The “SRS Diagnostic System Check” should always
be the starting point of any SRS diagnostics. The
“SRS Diagnostic System Check” checks for prope
r
“AIR BAG” warning lamp operation and checks for
SRS trouble codes using both “Flash Code” and
“Scan Tool” Methods.
2. Refer To The Proper Diagnostic Chart As
Directed By The “SRS Diagnostic System
Check”.
The “SRS Diagnostic System Check” will lead you to
the correct chart to diagnose any SRS problems.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect
parts replacement.

3. Repeat The “SRS Diagnostic System Check”
After Any Repair Or Diagnostic Procedures Have
Been Performed.
Preforming the “SRS Diagnostic System Check”
after all repair or diagnostic procedures will assure
that the repair has been made correctly and that no
other conditions exist.

Diagnostic Codes
The SRS control unit maintains a history record of all
diagnostic codes that have been detected since the
SRS codes were last cleared during service.
1. Active Codes - Faults that are presently detected this
ignition cycle. Active codes are stored in RAM
(Random Access Memory).
2. History Codes - All faults detected since the last time
the history fault memory was cleared. History codes
are stored in EEPROM. (Electronically Erasable
Programmable Read only Memory)

How To Read Trouble Codes
All codes (Active and history) can be read (or cleared)
by using a scan tool or equivalent.
If a PDT is not available, have the vehicle serviced by
HOLDEN dealer.

How To Clear Trouble Codes
Trouble codes can only be cleared by using a Scan
Tool. If a “scan tool” is not available then inform the
owner of the stored codes and suggest that the codes
are cleared upon the next visit to an Isuzu dealership.

Scan Tool Diagnostics
A scan tool can be used to read current and history
codes and to clear all history codes after a repair is
complete. The scan tool must be updated to
communicate with the SRS through a replaceable
cartridge or a manufacturer's update before it can be
used for SRS diagnostics. To use the scan tool,
connect it to the DLC connector and turn the ignition
switch “ON”. Then follow the manufacturer's directions
for communication with the SRS. The scan tool reads
serial data from the SRS control unitSRS control unit
“Serial Data” output (terminal 21) to the DLC connector
(terminal 2).

Basic Knowledge Required
Before using this section of the Service Manual, there is
some basic knowledge which will be required. Without
this knowledge, you will have trouble using the
diagnostic procedures in this section. Use care to
prevent harm or unwanted deployment. Read all

ELECTRICAL-BODY AND CHASSIS 8A-1
SECTION 8A
ELECTRICAL-BODY AND CHASSIS
TABLE OF CONTENTS
PAGE
General Information ........................................................................................................ 8A- 4
Notes for Working on Electrical Items .......................................................................... 8A- 5
Symbols and Abbreviations ........................................................................................... 8A- 11
Symbols ...................................................................................................................... 8A- 11
Abbreviations ............................................................................................................. 8A- 12
Parts for Electrical Circuit .............................................................................................. 8A- 13
Wiring .......................................................................................................................... 8A- 13
Fuse ............................................................................................................................. 8A- 15
Fusible Link ................................................................................................................ 8A- 15
Relay ............................................................................................................................ 8A- 16
Diode ........................................................................................................................... 8A- 17
Connector ................................................................................................................... 8A- 18
Battery ......................................................................................................................... 8A- 19
Reading the Circuit Diagram .......................................................................................... 8A- 22
Parts Location ............................................................................................................ 8A- 22
Circuit Diagram ........................................................................................................... 8A- 23
Connector List ............................................................................................................. 8A- 23
Main Data and Specifications ........................................................................................ 8A- 24
Bulb Specifications .................................................................................................... 8A- 24
Relay and Fuse ................................................................................................................ 8A- 26
Relay and Fuse Box Location ................................................................................... 8A- 26
Relay Location ............................................................................................................ 8A- 28

8A-16 ELECTRICAL-BODY AND CHASSIS


RELAY
Battery and load location may require that a switch be placed
some distance from either component.
This means a longer wire and a higher voltage drop
1. The
installation of a relay between the battery and the load reduces
the voltage drop
2.
Because the switch controls the relay, amperage through the
switch can be reduced.


Relay Specifications and Configurations
Name/
Color Rated
voltage/ Coil
resistance Internal circuit Name/
color Rated
Voltage/Coil
resistance Internal circuit
1T
(MICRO
ISO)
/Black 12V
Approx. 92
Minimum
operating
voltage: 7V at
20C (77F)

1M (MINI
ISO)
/Black 12V Approx.
94 Minimum
operating
voltage: 7V at
20C (77F)

1M
(MICRO
ISO)
/Black 12V
Approx. 132-3
 Minimum
operating
voltage: 7V at
20C (77F)

1M
(power)/
Black 12V Approx.
94 Minimum
operating
voltage: 7V at
20C (77F)

* Relay contact shown in the wiring diagram indicates condition before actuation.

CRUISE CONTROL SYSTEM 8B-3
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAIN 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 OTHER WISE UNNEEDED SRS SYSTEM REPAIRS.

CAUTION: Always use the correct fastener in the proper location. When you replace a faster, use ONLY the
exact part number for that application. Dealer will call out those fasteners that require a replacement after
removal. Dealer 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 joint Clamping force, and may damaged 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
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received.
When the main switch “AUTO CRUISE” is turned on with the vehicle in the running mode, the battery voltage is
applied to the control unit. When a signal from the control unit while the vehicle is in this state, the cruise control
actuator is activated to operate the system. Also, while the system is operating, the “AUTO CRUISE” indicator light
in the meter assembly lights up.





LTW48BSH000101
1. SET/COAST Switch Function
1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at
which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the
stored speed.
2. COAST-down Function: When the SET/COAST switch is kept on while the vehicle in running, the vehicle
decelerates during that time. The speed at which vehicle is running when the control switch is pressed in the
memory, and the vehicle automatically returns to the stored speed.
3. Tap-down Function: When the SET/COAST switch is pressed and released instantaneously while the
vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the
vehicle was running when the SET/COAST was released last is stored in the memory, and the vehicle
automatically returns to this stored speed.

6E–228 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored.
If the EGR EVRV circuit is open or short ground circuit,
DTC P0400 (Symptom Code 4) is stored.
If the EGR EVRV circuit is short to voltage circuit, DTC
P0400 (Symptom Code 8) is stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
EGR valve sticking.
Faulty intake air duct connection.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the DTC P0400 display on the Tech2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
Flash
CodeCode Symptom
CodeMIL DTC Name DTC Setting Condition Fail-Safe (Back Up)
32 P0400 3 ON Ex ha ust Ga s Recircula tio n
Flow Excessive Detected1. Intake air temperature is
between 15 deg.C and 100
deg.C.
2. Engine coolant tempera-
ture is betwee n 55 de g.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Baro me tric pre ssure is
betwee n 850hpa a nd
1100hpa.
4. Small amount of mass air
flo w. (Desired ma ss air flo w
- mass air flow is more than
150mg/strk)Fuel inje ctio n qua ntity is
reduced.
4 ON Ex ha ust Ga s Recircula tio n
Circuit Sho rt to Ground or
Ope n CircuitEGR EVRV circuit open or
sho rt to ground circuit.Fuel inje ctio n qua ntity is
reduced and EGR EVRV 10%
conditio ns a s substitute.
5 ON Ex ha ust Ga s Recircula tio n
Flow Insufficient Detected1. Intake air temperature is
betwee n 15de g.C and 100
deg.C.
2. Engine coolant tempera-
ture is betwee n 55 de g.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
3. Baro me tric pre ssure is
betwee n 850hpa a nd
1100hpa.
4. Large mount of mass air
flo w. (Desire d ma ss air
flo w - mass a ir flow is
below 150 mg/strk)Fuel inje ctio n qua ntity is
reduced.
8 ON Ex ha ust Ga s Recircula tio n
Circuit Sho rt to BatteryEGR EVRV circuit sho rt to
voltage circuit.Fuel inje ctio n qua ntity is
reduced & EGR EVRV 10%
conditio ns a s substitute.