instrument panel ISUZU TF SERIES 2004 Owner's Manual

CAB 10-33
Important Operations
15. Instrument Panel & Crass Beam Assembly
1) Tighten the 4 bolts fixing the cross beam and body panel
to the specified torque.
Torque N
m (kgf
m/lb
ft)
19 (1.9/14)

2) A Bolt: Steering Column to Cross Beam
Torque N
m (kgf
m/lb
ft)
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
Torque N
m (kgf
m/lb
ft)
15 (1.5/11)


3) C Bolt: Parking Brake Bracket to Cross Beam
Torque Nm (kgfm/lbft)
15 (1.5/11)

21. Steering Wheel/Steering Cowl

Tighten the steering wheel fixing nut to the specified
truque.
Torque N
m (kgf
m/lb
ft)
35 (3.6/26)

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-160 ELECTRICAL-BODY AND CHASSIS


RTU4Z0SH000901
ILLUMINATION SWITCH




RTW48ASH000601

Inspection
Check to see if there is any continuity between the terminals of
the switch.
Replace the switch when the result of inspection is found
abnormal.




RTW48ASH000501

Removal
Preparation:
Disconnect the battery ground cable.
1. Instrument panel driver lower cover assembly
Refer to the removal steps Sec.10
2. Harness switch
3. Illumination control
To remove the switch, push the lock from the back side of
the cluster assembly.
4. Remove the bulb.

8A-176 ELECTRICAL-BODY AND CHASSIS
This illustration is based on RHD model
TURN SIGNAL 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 instruments 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 turn signal switch from the steering shaft.




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



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

ELECTRICAL-BODY AND CHASSIS 8A-177

REAR COMBINATION LIGHT
Back Up Light
Removal
1. Open the rear gate.
2. Remove the screws.
3. Remove the rear combination light assembly.

4. Turn the bulb
3 counterclockwise to remove it.



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



Bulbs
Be absolutely sure that each bulb is correctly installed.
This will prevent a poor contact and an open circuit.

This illustration is based on RHD model

HAZARD WARNING FLASHER SWITCH
Removal
1. Disconnect the battery ground cable.
2. Instrument Panel Cluster Assembly

Refer to Section 10 “BODY” for instrument panel cluste
r
assembly removal steps.
3. Hazard Warning Switch

Disconnect the switch connector.

To remove the switch, push the lock from the back side
of the cluster assembly.


Installation
To install, follow the removal procedure in the reverse order.



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

8A-262 ELECTRICAL-BODY AND CHASSIS
REMOVAL AND INSTALLATION

This illustration is based on RHD model
METER ASSEMBLY
Removal
1. Meter Cluster Assembly

Refer to the removal steps of “INSTRUMENT PANEL” in
Section 10 “CAB”
2. Meter Assembly

Remove three screws of the meter assembly.

Disconnect the meter connectors.






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



Connector
Be absolutely sure that the meter connectors are securely
connected.
This will prevent a poor contact and an open circuit.



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

ELECTRICAL-BODY AND CHASSIS 8A-355
REMOVAL AND INSTALLATION

865R300008


REAR DEFOGGER SWITCH
Removal
1. Instrument Panel Cluster Assembly

Refer to Section 10 “BODY” for center cluster panel
assembly removal steps.
2. Rear Defogger Switch (With HVAC control unit)
Refer to Section 1 “HVAC” HVAC control unit assembly
removal steps.



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

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–83
ECM detects a DTC that will impact the vehicle
emissions.
When the check engine lamp remains “ON” while the
engine is running, or when a malfunction is
suspected due to a driveability or emissions problem,
a Powertrain On-Board Diagnostic (OBD) System
Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
System Check. These checks will ex pose faults
which may not be detected if other diagnostics are
performed first.
Data Link Connector (DLC)
The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
behind the lower front instrument panel. The DLC is
used to connect to a Tech 2. Some common uses of the
Tech 2 are listed below:
Identifying stored Diagnostic Trouble Codes (DTCs).
Clearing DTCs.
Reading serial data.
Verifying Vehicle Repair
Verification of vehicle repair will be more
comprehensive for vehicles with OBD system
diagnostic. Following a repair, the technician should
perform the following steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the
Fail Records.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps is very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
Reading Flash Diagnostic Trouble Codes
The provision for communicating with the Engine
Control Module (ECM) is the Data Link Connector
(DLC). The DLC is located in the front console box . It is
used in the assembly plant to receive information in
checking that the engine is operating properly before it
leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECM’s memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
DLC terminal “6” (diagnostic request) is pulled “Low”
(grounded) by jumping to DLC terminal “4 or 5”, which is
a ground wire.
This will signal the ECM that you want to “flash” DTC(s),
if any are present. Once terminals “4 or 5” and “6” have
been connected, the ignition switch must be moved to
the “ON” position, with the engine not running.
The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
stored in the ECM’s memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a
Tech 2
The procedure for reading diagnostic trouble code(s) is
to used a diagnostic Tech 2. When reading DTC(s),
follow instructions supplied by Tech 2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech 2.
Clearing Diagnostic Trouble Codes
To clear Diagnostic Trouble Codes (DTCs), use the
Te c h 2 “clear DTCs” or “clear information” function.
When clearing DTCs follow instructions supplied by the
Tech 2 manufacturer.
History DTC
History DTC can be candeled after 40 cycle driving with
no defect. Or history code can be deleted by Tech 2
“Clear DTCs” function.

6E–92 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
mechanical trouble and an electrical trouble.
Connect Tech 2 and select "Powertrain", "4JA1-TC
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
F0: Lamps
F0: Glow Time Telltale Test
When the Tech 2 is operated, "Glow Time Indicator
Lamp" is turned on or off.
The circuit is correct if the "Glow Time Indicator Lamp"
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
accordance with this operation.
Press "Active" key.
Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%F3: Engine Speed (RPM) Control
When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is correct if engine speed is changed in
accordance with this operation.
Press "Increase" key.
Then, Desired Idle speed is increases
50rpm-by-50rpm up to 1200rpm. Engine speed is
also
EGR Solenoid Test
Desired Mass Air Flow 470 mg/strk
Mass Air Flow 450 mg/strk
Engine Speed 700 rpm
Exhaust Gas Recirculation 95%
Engine Speed (RPM) Control
Engine Speed 850 rpm
Desired Idle Speed 850 rpm
Injection Quantity 7.5 mg/ strk