section 8 ISUZU TF SERIES 2004 Workshop Manual

8A-14 ELECTRICAL-BODY AND CHASSIS
Distinction of Circuit by Wire Base Color
Base color Circuits Base color Circuits
B Starter circuit and grounding circuit Y Instrument circuit
W Charging circuit L, O, BR,
R Lighting circuit LG, GR, Other circuits
G Signal circuit P, LB, V




Wire Size
Wire size is specified with the metric gauge system.
The metric gauge system gives the wire size in cross sectional
area measured in square millimeters.


Wire Size Specifications
Normal size Cross sectional area
(mm2) Outside diameter
(mm) Allowable current
(A)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.885 2.2 16
1.25 1.287 2.5 21
2 2.091 2.9 28
3 3.296 3.6 37.5
5 5.227 4.4 53
8 7.952 5.5 67
15 13.36 7.0 75
20 20.61 8.2 97

8A-18 ELECTRICAL-BODY AND CHASSIS


CONNECTOR
The connector pin shape determines whether the connector is
male or female.
The connector housing configuration does not determine
whether a connector is male or female.



The symbol illustrated in the figure is used as connector in the
circuit this section.



Connector is identified with a number.



The applicable terminal number is shown for each connector.



Connector terminal numbers are clearly shown.
Male side connector terminal numbers are in sequence from
upper right to lower left.
Female side connector terminal numbers are in sequence from
upper left to lower right.
NOTE:
For those connectors on which specific terminal numbers
on symbols are shown, the terminal numbers or symbols
are used in the circuit diagram, irrespective of the above
rule.

8A-88 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION

This illustration is based on RHD model
STARTER SWITCH
Removal
1. Steering Lock Assembly

Refer to Section 3B" STEERING COLUMN" for steering
lock assembly removal steps.
2. Starter Switch




Installation
Follow the removal procedure in the reverse order to install the
starter switch.


INSPECTION AND REPAIR


STARTER SWITCH
Switch Connections
Terminal No.

Starter
switch key
position B-62
2
(B2)B-62
4
(ACC)B-62
1
(IG2) B-63
1
(ST) B-63
3
(B1)B-62
3
(IG1)
Removed

OFF
ACC Inserted
ON
START
LOCK

825R300046

Starter relay
Check continuity between the relay terminals.
1 - 4............................. No continuity
(When battery voltage is applied between 2 and 3)
1 - 4............................. Continuity

ELECTRICAL-BODY AND CHASSIS 8A-105
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
C24SE

Removal
1. Lift both the ECM harness connector locking levers and
remove the two harness connectors form the ECM.
2. Remove the four socket head screws securing the ECM to
the mounting bracket.
3. Remove the ECM from the engine compartment
.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-106 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
6VE1
Removal
1. Pull both the red ECM harness connector locks toward the
front of the vehicle, and remove the two harness connectors
form the ECM.
2. Remove the four hex-head screws securing the ECM to the
common chamber.
3. Remove the ECM from the engine compartment.


4. Pull out the ECM.
5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”





Installation
Follow the removal procedure in the reverse order to install the
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

ELECTRICAL-BODY AND CHASSIS 8A-107
REMOVAL AND INSTALLATION


ECM (ENGINE CONTROL MODULE):
4JA1-TC / 4JH1-TC


Removal
1. Remove the passenger side front seat – refer to Section 10
CAB.
2. Remove the passenger side front door opening scuff plate.
3. Raise the carpet to gain access to the four hex-head bolts
securing the ECM and ECM cover to the floorpan
.
4. Remove the four hex-head bolts.
5. Pull the two harness connector locks away from the
harness connectors and then remove the connectors form
the ECM.
6. Remove the ECM from the vehicle.
Refer to the Section 6E-ENGINE of this Manual.
IMPORTANT: The replacement ECM must be programmed.
“SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary”







Installation
Follow the removal procedure in the reverse order to install the
ECM.
Torque passenger seat securing bolts to the specified value –
refer to Section 10 CAB
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

8A-108 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION


FUEL PUMP
Removal
1. Remove the fuel tank.
Refer to the Section 6C-ENGINE FUEL of this Manual.

Disconnect the fuel pipe.





Installation
Follow the removal procedure in the reverse order to install the
fuel pump.
Pay close attention to the important points mentioned in the
following paragraphs.



Rubber Seal
Be absolutely sure that the fuel pump rubber seals correctly
seated.

Connector
Be absolutely sure that the fuel pump connector is securely
connected.
This will prevent a poor contact and an open circuit.

ELECTRICAL-BODY AND CHASSIS 8A-129
Installation
Follow the removal procedure in the reverse order to install the
headlight.
Pay close attention to the important points mentioned in the
following paragraphs.


Connector
Be absolutely sure that the headlight connector is securely
connected.
This will prevent a contact and an open circuit.

This illustration is based on RHD model

LIGHTING SWITCH
Removal
1. Disconnect the battery ground cable.
2. Remove the steering wheel
1.
Refer to the “STEERING” Section of this manual.
3. Remove the Instrument panel lower cover
2.
4. Remove the steering column cover
3.


This illustration is based on RHD model
5. Disconnect the connector.
6. Remove the lighting switch from the steering shaft.





Installation
Follow the removal procedure in the reverse order to install the
lighting switch.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that the lighting switch connector is securely
connected.
This will prevent a poor contact and an open circuit.


Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
Wire damage will result.

ELECTRICAL-BODY AND CHASSIS 8A-131


LICENSE PLATE LIGHT
Removal
1. Remove the lens cover 1 and the connector 2.
2. Pull the bulb
3 to remove it.



Installation
Follow the removal procedure in the reverse order to install the
license plate light.
Pay close attention to the important points mentioned in the
following paragraphs.



Bulb
Be absolutely sure that the license plate light bulb is correctly
installed.
This will prevent a poor contact and open circuit.



HEADLIGHT BEAM SWITCH
(COMBINATION SWITCH)
Removal
1. Disconnect the battery ground cable.
2. Remove the screws on the lower part of the steering wheel.
3. Remove the horn pad.
4. Remove the wiring connector.
5. Remove the steering wheel fixing nuts.
6. Remove the steering wheel.
Refer to the "STEERING" Section of this manual.
7. Remove the Instrument panel lower cover.
8. Remove the steering column cover.
9. Disconnect the connector.
10. Remove the headlight beam switch (lever) from the steering
shaft (combination switch).


Installation
Follow the removal procedure in the reverse order to install the
headlight beam switch (lever).
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that the headlight beam switch connector is
securely connected.
This will prevent a poor contact and an open circuit.

8A-132 ELECTRICAL-BODY AND CHASSIS

Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
Wire damage will result.


AIMING OF HEADLIGHT
Check and adjust the inflation pressures, clean the headlight,
park the vehicle on a level surface and insure that vehicle is at
curb weight.


VERTICAL ADJUSTMENT
Use a screwdriver for vertical adjustment.



HORIZONTAL ADJUSTMENT
Use a screwdriver horizontal adjustment.


Installation
To install, follow the removal steps in the reverse order.
Noting the following point:
1. After installing the headlight, be sure to adjust the headligh
t
aim.

HEADLIGHT ADJUSTMENT
Preparation
Place the vehicle with 1 person in driver seat on a level surface
and check to see if the inflation pressure of the tires is correct,
the lenses are clean, the battery is sufficiently charged, and
adjust to place vehicle by using the screen.
1. Set a vertical screen on a level surface.
2. Toward the screen
1from the bulb center mark of the
headlight, extend parallel lines to the floor. Mark point
A
and B on the screen at the intersection of parallel line and
the screen.
3. Draw vertical lines through point
A and B on the screen.