Leads ISUZU TF SERIES 2004 User Guide

ENGINE ELECTRICAL 6D1-3

Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as a
cracked or broken case, which would permit electrolyte loss.
Replace the battery if obvious physical damage is discovered
during inspection.
Check for any other physical damage and correct it as
necessary.


2. Hydrometer Check


3. Fluid Level Check
The fluid level should be between the upper level line (2) and
lower lever line (3) on side of battery.
a. CORRECT FLUID LEVEL - Charge the battery.
b. BELOW LOWER LEVEL - Replace battery.



4. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE - Go to Step 5.
b. VOLTAGE IS UNDER 12.4V - Go to procedure (2)
below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate no
higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE - Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to 15V and
charge for 10 - 15 hours. Then go to Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V - Continue
charging at the same rate for an additional 3-1/2 hours.
Then go to Step 5.
d. VOLTAGE BELOW 12V - Replace Battery.

6D3-18 STARTING AND CHARGING SYSTEM
Reassembly
Generator
(a) Press new bearing onto slipring end of the rotor taking care
to aplly the force to the bearing inner race only, otherwise
the bearing will be noisy and it's life will be shortened.
(b) Fit a new bearing to the drive end housing, fit the bearing
plate, and four retaining screws, press the rotor into the
bearing, using a support tool to take the thrust against the
bearing inner.
The support is fitted from the pulley side of the bearing. In
this way the thrust is not taken by the drive end housing.
(c) To fit pulley, mount an 8mm Allen key in the vice with the
short end upwards, place a 24mm ring spanner on the shaft
nut, position the internal hexagon of the rotor shaft onto the
Allen key, tighten the nut to the required torque(See torque
chart)
(d) Inspect the bearing support ring for signs of damage, if in
doubt replace the ring by pressing it into the housing by
hand, do not use excessive force.
(e) To refit the rectifier, fit new mica washers to the positive
heatsink B+ bolt and retaining screw each washer must
have heatsink compound applied to both surfaces before
fitting.
Fit the three retaining screws to the rectifier then install into
slipring end housing. Tighten the B+ bolt to the reuired
torque.
(f) To refit the stator, make sure the spigot surface are clean
and free from damage, fit the stator into the slipring end
housing noting the correct lead connection positioning. Fit
the stator leads into the wire loops in the recrifier. Using a
pair of pliers squeeze the loop to retain the stator lead prior
to soldering. Repeat for each lead in turn, solder the leads
into position using 60/40 resin cored solder. Make sure the
leads will be clear of the internal fan when the rotor is
assmebled into the stator.
(g) Carefully install the rotor into the stator/slipring end housing
assembly, noting the alignment of the housings and through
bolt holes. Fit the through bolts making sure the stator is
seated correctly, tighten the through bolts to the correct
torque setting (uneven torque can produce magnetic noise
levels above normal).
(h) Fitting the regulator. Compress the brushes into the brush
holder by hand, slip the regulator through the opening in the
rear of the slipring end housing until the brushes come in
contact with the slipring. Press the regulator towards the
slipring until the holes are aligned then fit the retaining
screws and tighten.

6E–100 ENGINE DRIVEABILITY AND EMISSIONS
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?—Go to Step 2Go to OBD
System Check
2 1. Turn the engine OFF.
NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Test
Description Number 2.
3. Connect the 5-8840-2618-0 Fuel Injector Tester to
B+ and ground, and to the 5-8840-2589-0 Injector
Adapter Cable.
4. Remove the harness connector of the Fuel
Injector and connect the 5-8840-2589-0 Injector
Adapter Cable for F/I check.
5. Set the amperage supply selector switch on the
fuel injector tester to the “Coil Test” 0.5 amp
position.
6. Connect the leads from the 5-8840-2392-0 Digital
Voltmeter (DVM) to the fuel injector tester. Refer
to the illustrations associated with the test
description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature.
Is the engine coolant temperature within the specified
values?10°C (50°F)
to
35°C (95°F) Go to Step 3Go to Step 5
3 1. Set the injector adapter cable to injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector adapter cable to the nex t injector
and repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values? 5.7-6.6V Go to Step 4Go to Step 7
4 Replace the faulty fuel injector(S). Refer to Fuel
Injector.
Is the action complete?—Go to Step 7—

ENGINE DRIVEABILITY AND EMISSIONS 6E–177
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT
Condition for setting the DTC and action taken when the DTC sets
Circuit Description
The ECM uses the Knock Sensor (KS) in order to detect
engine detonation. This allows the ECM to retard the
Ignition Control (IC) spark timing based on the KS signal
the ECM receives. The knock sensors produce an AC
signal that rides on the 1.3 volts DC. The signal’s
amplitude and frequency are dependent upon the
amount of the knock being ex perienced.
The ECM determines whether the knock is occurring by
comparing the signal level on the KS circuit with a
voltage level on the noise channel. The normal engine
noise varies depending on the engine speed and load.
Then the ECM determines that an abnormally high
noise channel voltage level is being ex perienced, a
Diagnostic Trouble Code P0327 sets.
Diagnostic Aids
Check for the following conditions:
A poor connection at the ECM. Inspect the knock
sensor and the ECM connectors for: , broken locks,
improperly formed or damaged terminals.
Backed out terminals
Broken locks
Improperly formed or damaged terminals
Also, check the wiring harness for: shorts to ground,
shorts to battery positive, and open circuits.
A misrouted harness. Inspect the knock sensor
harness in order to ensure that it is not routed too
close to high voltage wires such as spark plug leads.
Code Type DTC Name DTC Setting Condition Fail-Safe (Back Up)
P0327 A Knock Se nsor Circuit 1. No DTC re lating to MAP senso r.
2. Engine coolant temperature is more than
50 de g. C.
3. Engine speed is more than 1600rpm.
4. Knock sensor harness short to ground or
short to vo lta ge circuit.ECM re ta rds ignitio n timing 4 deg. C.

3B-34 POWER-ASSISTED STEERING SYSTEM

10. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
430R300009
11. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag assembl
y
and remove the air bag assembly. (with SRS air
bag)
060R300041


12. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It removes previosly from the spoke bottom.


RTW43BSH000201
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE COVER SIDE
UP. THIS IS NECESSARY BECAUSE A FREE SPACE
IS PROVIDED TO ALLOW THE AIR CUSHION TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY MAY RESULT. (with SRS ai
r
bag)
430R300007

POWER-ASSISTED STEERING SYSTEM 3B-35

Inspection and Repair (with SRS air
bag)
The inflator module consists of a cover, air bag, inflator,
and retainer. Inspect the inflator module mainly for the
following:


Check for holes, cracks, severe blemishes and
deformation on the cover.


Check that the retainer is not deformed.


Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.

Installation
1. Support the inflator module and carefully connect the
SRS connector and horn lead. (with SRS air bag)
060R300041


2. Connect the horn leads at center of wheel. (without
SRS air bag)
NOTE: Horn leads is letting a bracket top pass.
(Plastic type steering wheel only)



RTW43BSH000301
3. Push the born pad area 1-4.
Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
Torque: 2 - 4 N





m (0.2 – 0.4 kg





m/17 - 35 lb ft)
NOTE: A horn pad is not struck at the time o
f
attachment.



RTW43BSH000401

POWER-ASSISTED STEERING SYSTEM 3B-39

11. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag assembl
y
and remove the air bag assembly. (with SRS air
bag)
060R300041
12. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It removes previously from the spoke bottom.



RTW33BSH000401
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE COVER SIDE
UP. THIS IS NECESSARY BECAUSE A FREE SPACE
IS PROVIDED TO ALLOW THE AIR CUSHION TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY MAY RESULT. (with SRS ai
r
bag)


430R300007
13. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in thei
r
original position. Move the front wheels to the
straight ahead position, then use steering wheel
remover 5-8521-0016-0 to remove the steering
wheel.
430R300008
CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.

3B-40 POWER-ASSISTED STEERING SYSTEM



430RX005-X
14. Remove steering column cover.
15. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly.

Installation
1. Align the setting marks made when removing then
install steering wheel.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601

CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N





m (3.2 – 4.0 kg





m/23 - 29 lb ft)
3. Support the inflator module and carefully connect the
SRS connector and horn lead. (with SRS air bag)
060R300041
4. Connect the horn leads at center of wheel. (without
SRS air bag)
NOTE: Horn leads is letting a bracket top pass.
(Plastic type steering wheel only)



RTW43BSH000301

POWER-ASSISTED STEERING SYSTEM 3B-45

13. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag assembl
y
and remove the air bag assembly. (with SRS air
bag)
060R300041
14. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It removes previously from the spoke bottom.



RTW43BSH00201

WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE COVER SIDE
UP. THIS IS NECESSARY BECAUSE A FREE SPACE
IS PROVIDED TO ALLOW THE AIR CUSHION TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY MAY RESULT. (with SRS ai
r
bag)


430R300007
15. Apply a setting mark (1) across the steering wheel
and shaft so parts can be reassembled in thei
r
original position. Move the front wheels to the
straight ahead position, then use steering wheel
remover 5-8521-0016-0 to remove the steering
wheel.
430R300008
CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.

POWER-ASSISTED STEERING SYSTEM 3B-47

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.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601
CAUTION: Never apply force to the steering wheel in
direction of the shaft by using a hammer or othe
r
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
9. Tighten the steering wheel fixing nut to the specified
torque.
Torque: 31 - 39 N




m (3.2 – 4.0 kg




m/23 - 29 lb ft)
10. Support the inflator module and carefully connec
t
the SRS connector and horn lead. (with SRS air
bag)
060R300010

11. Connect the horn leads at center of wheel. (without
SRS air bag)
NOTE: Horn leads is letting a bracket top pass.
(Plastic type steering wheel only)



RTW43BSH000301
12. Push the born pad area 1-4.
Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
Torque: 2 - 4 N





m (0.2 – 0.4 kg





m/17 - 35 lb ft)
NOTE: A horn pad is not struck at the time o
f
attachment.



RTW43BSH00040