2004 ISUZU TF SERIES stop start

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-42 SUPPLEMENTAL RESTRAINT SYSTEM

4. Tighten the universal joint to the specified torque.
Torque: 31 N




m (3.2 kg




m/23 lb ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on
the base of steering column.
11. 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 to the
cable in the SRS coil.
826RW014
Legend
(1) Neutral mark

12.Install 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
13.Install the steering wheel and align the setting
marks.

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-26 BRAKE CONTROL SYSTEM

DATA LIST (Tech 2)
The data displayed by DATA LIST are as follows:


Strings Units Description 2WD 4WD
Front Left Wheel Speed km/h (MPH)
Front Right Wheel Speed km/h (MPH)
Rear Left Wheel Speed km/h (MPH)
Rear Right Wheel Speed km/h (MPH) Start the vehicle and make sure of linear
change in each wheel speed
Brake Switch Open/Closed Brake switch is “closed” when brake pedal is
stepped on.
ABS Warning Lamp On/Off To be “Off” usually
EBD Warning Lamp On/Off To be “Off” usually
ABS Stop State On/Off To be “Off” usually
ABS Relay Active/Inactive To be “Active” usually
Return Pump Active/Inactive To be “Inactive” usually
DTC Status No DTC To be “No DTC” usually
4 Wheel Drive Status Yes/No To be “Yes” usually
-
FL Dump Valve Commanded
(Front Left) Active/Inactive
FL Isolation Valve Commanded
(Front Left) Active/Inactive
FR Dump Valve Commanded
(Front Right) Active/Inactive
FR Isolation Valve Commanded
(Front Right) Active/Inactive
Rear Dump Valve Commanded Active/Inactive
Rear Isolation Valve Commanded Active/Inactive
FL Dump Valve Feedback
(Front Left) Active/Inactive
FL Isolation Valve Feedback
(Front Left) Active/Inactive
FR Dump Valve Feedback
(Front Right) Active/Inactive
FR Isolation Valve Feedback
(Front Right) Active/Inactive
Rear Dump Valve Feedback Active/Inactive
Rear Isolation Valve Feedback Active/InactiveEach valve is “Active” when each valve is
opereted.
G-Sensor Output V 2.0~3.0V when vehicle speed is 0 km/h (flat
place) -
Battery Voltage V The voltage value currently supplied to EHCU
Diagnostics Connector Open/Closed Diagnostics connector is “Open” when
diagnostics connector is connected.

BRAKE CONTROL SYSTEM 5A-33

How to display and erase DTCs:
Note:
 DTCs can be displayed also by TECH 2 use
“Diagnostic Trouble Codes“ mode.
1. How to start DTC display:
 Confirm that the vehicle has come to a
complete stop (with the wheels standing still)
and that the brake pedal is not depressed.
(Unless these two condition are satisfied, DTC
display cannot be started.)
 With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN
ON.

The DLC is located behind the driver side kick panel

















This illustration is based on RHD model
350L300005

 Keep #12 terminal connected with #4 terminal
or # 5 terminal (GND) during DTC display. (If
#12 terminal is separated from #4 terminal or #
5 terminal (GND) during display, display will
stop.)
2. DTC display:
 DTC is displayed by blinking warning lamp.
 Double-digit display.
 First, normal DTC 12 is displayed three times
and then any other DTCs are displayed three
times. (If no other DTCs have been stored, the
display of DTC 12 will be repeated.)
3. How to erase code:
 Conduct brake switch ON/OFF operation 6 or
more times within 3 seconds of self-diagnosis
startup.
 The code cannot be erased if more than 3
seconds have passed since self-diagnosis
startup, or if self-diagnosis has started with
brake switched on (brake pedaled).
B05RW0005

BRAKES 5C-31

ADJUSTMENT PROCEDURE OF BRAKE PEDAL



The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.

RTW35CSH000601


Brake Pedal - Height
Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)

Pedal free play (L1) 6-10 (0.23 - 0.39)
M/T 174-186 (6.85-7.32)
RHD
LHD
A/T 176-188 (6.93-7.40) Height (L2)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c)
Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.



Lock Nut Torque N

m(kgf

m/lb
 
ft)
12 - 18 (1.2 – 1.8 / 9 - 13)

d) Install the stop lamp switch.

Note:
Pedal height (L
2) must be 80 mm (3.14 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.

331R300005


How to connect the CLEVICE of BOOSTER ROD with PEDAL
ARM. and how to adjust the PEDAL SW.
After connecting the CLEVIS of BOOSTER ROD with PEDAL
ARM, adjust the PEDAL SW mounted (PDA) to PEDAL
BRACKET by the procedure explained still more bellow.
1. Set the hole of the CLEVIS of BOOSTER&M/CYL ROD
with the hole of the PEDAL ARM.
2. Enter the PIN; PUSH ROD to PEDAL to these holes
from left side of the PEDAL.
3. Enter and fix the PIN; SANP PIN FIX to the DITCH o
f
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SWITCH counter-
clock-wise.

8A-2 ELECTRICAL-BODY AND CHASSIS
PAGE
Fuse and Slow Blow Fuse Location (Relay and Fuse Box) .................................... 8A- 31
Fuse Location ............................................................................................................. 8A- 33
Diode Location ........................................................................................................... 8A- 34
Fuse Block Circuit ...................................................................................................... 8A- 35
Fuse Block Circuit (C24SE) ....................................................................................... 8A- 35
Fuse Block Circuit (6VE1) ......................................................................................... 8A- 37
Fuse Block Circuit (4JA1-TC/4JH1-TC) - RHD ......................................................... 8A- 39
Fuse Block Circuit (4JA1-TC/4JH1-TC) – LHD ......................................................... 8A- 41
Fuse Block Circuit (4JH1-L) ...................................................................................... 8A- 43
Grounding Point ............................................................................................................. 8A- 45
Ground Point .............................................................................................................. 8A- 45
Ground Point Location .............................................................................................. 8A- 61
Main Cable harness Routing .......................................................................................... 8A- 63
C24SE / 6VE1 / 4JA1-L / 4JH1-TC .............................................................................. 8A- 63
Instrument Harness .................................................................................................... 8A- 71
System Repair .................................................................................................................8A- 73
Start and Charging ..................................................................................................... 8A- 73
Engine Control Module (ECM) ................................................................................... 8A- 89
Exhaust Gas Recalculation (EGR): 4JA1-L Only ...................................................... 8A- 109
Lighting ....................................................................................................................... 8A- 114
Front Fog Light ........................................................................................................... 8A- 136
Rear Fog Light ............................................................................................................ 8A- 144
Head Light Leveling ................................................................................................... 8A- 149
Illumination ................................................................................................................. 8A- 154
Hazard Warning Flasher, Turn Signal Light, Back Up Light,
Horn and Stop Light ................................................................................................. 8A- 161
Dome Light, Spot Light and Warning Buzzer .......................................................... 8A- 181
Windshield Wiper and Washer .................................................................................. 8A- 196
Transmission Control Module (TCM) ....................................................................... 8A- 214
Meter, Warning Light and Indicator Light ................................................................ 8A- 223
Heater and Air Conditioning ...................................................................................... 8A- 281
Power Door Lock ....................................................................................................... 8A- 293

ELECTRICAL-BODY AND CHASSIS 8A-195
INSPECTION AND REPAIR




R-9 R-10
R-1 R-6



DOOR SWITCH
Door Switch Connections

Connector
SW No.
R-9 R-10
R-1 R-6
position Terminal No.
1 Body Ground
PUSHED
RELEASED





WARNING BUZZER
1. Warning Buzzer Circuit


Warning function Operational conditions
Taillights left on The buzzer sounds when both the tail relay and the FRT door switch-drive
side are turned on. To stop the sound of the buzzer, turn on the starter
switch.




Harness side
B-45


2. Warning Buzzer Harness Side Connector Circuit
Disconnect the warning buzzer connector and check
continuity and voltage between the warning buzzer harness
side connector terminals.

Terminal
NO. Wire
color Connecting to Check itemConnecting
terminal Check condition Standard
3 G/R Tail relay 3-Ground Lighting SW “ON” Approx. 12V
6 Y Fuse CB-5 Voltage
6-Ground Starter SW “ON” Approx. 12V

Door SW Open Continuity
(FRT-LH)
Continuity Close No continuity
2 B Ground 2-Ground - Continuity
FRT door-LH 1-Ground 1
B/W