2004 ISUZU TF SERIES engine remove

SUPPLEMENTAL RESTRAINT SYSTEM 9A-37

SRS Coil 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 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.
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. Remove the SRS air bag assembly. (Refer to
“Driver Air Bag Assembly” in this seciton)


2. Remove the 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 and remove wheel
with 5-8521-0016-0.
5. Feed wiring though the wheel and remove wheel.
6. Remove the steering lower cover and engine hood
opening lever.
7. Remove the driver knee bolster assembly.
8. Remove the steering column cover.
9. Remove air conditioning lower duct.
10.Disconnect the wiring harness connectors located
at the base of steering column.

9A-38 SUPPLEMENTAL RESTRAINT SYSTEM

CAUTION: Never apply force to the steering wheel
in the 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.
11. Remove the combination switch assembly with
SRS coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from
the combination switch assembly.

Installation
1. Install the combination switch assembly with SRS
coil.
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage the
cable in the SRS coil.
826RW014
Legend
(1) Neutral mark

3. Connect the wiring harness connectors located at
the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
825RS048
6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood
opening lever.
8. Install the steering wheel and align the setting
marks.
060R300024

9A-40 SUPPLEMENTAL RESTRAINT SYSTEM

Steering Column
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 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 the 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 and removing wheel
with 5-8521-0016-0.
5. Feed wiring though the wheel and remove wheel.
6. Remove the steering lower cover and engine hood
opening lever.

4B-6 REAR AXLE

RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anaerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer
Note :
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacture's instructions at all
times.

3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon
contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518
between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poor
adhesion will result.



RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.

The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least one hour before continuing the installation procedure.

4C1-6 FRONT WHEEL DRIVE
RECOMMENDED LIQUID GASKET

Type Brand Name Manufacture Remarks

RTV*
Silicon Base ThreeBond 1207B
ThreeBond 1207C

ThreeBond 1215
Three Bond
Three Bond

Three Bond
For Engine Repairs


For Axle Case
Repairs, T/M
Water Base ThreeBond 1141E Three Bond For Engine Repairs

Solvent ThreeBond 1104
BelcoBond 4
BelcoBond 401
BelcoBond 402 Three bond
Isuzu
Isuzu
Isuzu
For Engine Repairs
Anerobic LOCTITE 515
LOCTITE 518 Loctite
Loctite All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.

RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type LOCTITE Color Application Steps

LOCTITE 242
Blue 1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.

LOCTITE 262

Red 2. Apply LOCTITE to the bolts.


LOCTITE 270

Green

LOCTITE 271

Red
3. Tighten the bolts to the specified torque.
4. Wait at least on hour before continuing the installation procedure.

BRAKE CONTROL SYSTEM 5A-21

Computer System Service Precautions
The Anti-lock Brake System and Electronic Brake-force
Distribution interfaces directly with the Electronic
Hydraulic Control Unit (EHCU) which is a control
computer that is similar in some regards to the Engine
Control Module. These modules are designed to
withstand normal current draws associated with vehicle
operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the “ON”
position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.

General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System and Electronic Brake-force Distribution
damage.
 If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before
the welding operation begins.
 The EHCU and valve block connectors should
never be connected or disconnected with the
ignition “ON”.
Note:
 If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS and Brake” warning lamp
will illuminate. But actually no trouble exists. When
the DTC is not detected and the ABS and BRAKE
warning lamp is on, “How to erase code” is
performed and a ABS and BRAKE warning lamp
are off.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS) and
Electronic Brake-force Distribution (EBD) System
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS and EBD
to a non-operative state by removing the fuse for the
ABS. After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning Lamp does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case
duplicating the system malfunction during a test drive or
a good description of vehicle behavior from the
customer may be helpful in locating a “most likely”
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most
intermittent problems are caused by faulty electrical
connections or wiring. When an intermittent failure is
encountered, check suspect circuits for:
 Suspected harness damage.
 Poor mating of connector halves or terminals not
fully seated in the connector body (backed out).
 Improperly formed or damaged terminals.

Test Driving ABS Complaint Vehicles
In case that there has been an abnormality in the
lighting pattern of “ABS” warning lamp, the fault can be
located in accordance with the “DIAGNOSIS BY “ABS”
WARNING LAMP ILLUMINATION PATTERN”. In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1.
Start the engine and make sure that the “ABS” W/L
goes OFF. If the W/L remains ON, it means that
the Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
Note: The DTC cannot be cleared if the vehicle speed
does not exceed about 6km/h (4mph) at DTC, even
though the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the
W/L is actuated while driving, read the DTC and
locate the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” .
Note:

Be sure to give a test drive on a wide, even road
with a small traffic.
 If an abnormality is detected, be sure to suspend
the test and start trouble diagnosis at once.

5A-28 BRAKE CONTROL SYSTEM

Isolation Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuaor Test from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuaor Test Menus.

060L300002
3. Select Isolation Valve from the Valve Select Menus.
4. Step on the brake pedal.
5. Release the brake pedal.
6. Make sure that the Isolation Valve “ON” aimed at by
Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.
7. Conduct Step 2 through Step 5 above on all the
four wheels.

060L300002
CAUTION: When conducting this test, please
observe the following cautions.

1. Do not start the engine.
2. Lift up the vehicle at a level floor.





Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.





When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.

BRAKE CONTROL SYSTEM 5A-29

Dump Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repai
r
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the “ON” position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
parking brake released.
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuator Test Function from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuator Test Menus.

060L300002
3. Select Dump Valve from the Valve Select Meuns.
4. Step on the brake pedal.
5. Make sure that the Dump Valve “ON” aimed at by
Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
harness wiring and H/UNIT. Repair is needed if
abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
four wheels.

060L300002
CAUTION: When conducting this test, please
observe the following cautions.

1. Do not start the engine.
2. Lift up the vehicle at a level floor.





Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.





When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.