air condition ISUZU TF SERIES 2004 Repair Manual

5A-80 BRAKE CONTROL SYSTEM

DTC C0274 (Flash Code 74) ABS Operation Long Time


RTW45AMF000201

Step Action
Value(s) Yes No
1 Was the “Basic Diagnostic Flow Chart” performed?
- Go to Step 2 Go to Basic
Diagnostic
Flow Chart
2 Was the “Basic Inspection Procedure” performed?
- Go to Step 3 Go to Basic
Inspection
Procedure
3 1. Check for a poor connection at the wheel speed
sensor harness connector.
2. Check installation condition for wheel speed
sensor.
3. If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 4
4 1. Check condition for sensor rotor.
2. If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 5
5 1. Ignition “OFF,” disconnect the EHCU and wheel
speed sensor.
2. Check the circuit between EHCU and wheel speed
sensor.(short ground, or short to voltage.)
3. If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 6

BRAKE CONTROL SYSTEM 5A-89

Step Action Value(s) Yes No
4 1. Ignition "OFF".
2. Check for a poor condition at the EHCU harness
connector.
3. Check the EHCU circuit for an open, short to
ground, or short to voltage. Also, check the EHCU
ignition feed circuit for an open or short to ground
and the EHCU ground circuit for an open or short
to voltage.
4. If a problem is found, repair as necessary.
Was a problem found? - Verify repair Go to Step 9
5 1. Ignition "OFF," disconnect the EHCU and G-
sensor.
2. Check the circuit between EHCU and G-sensor.
(short to ground, or short to voltage.)
3. If a problem is found, repair as necessary.
Was a problem found? - Verify repair
Go to Step 6 Go to Step 6
6 1. Remove the G-sensor.
2. Reconnect G-sensor and EHCU
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Observe the G-sensor reading on Tech 2.
If G-sensor inclines, reading voltage will change.
Is the reading voltage between specified value? 1.0 – 4.0 V Go to Step 7 Go to Step 8
7 1. Ignition "OFF".
2. Install the G-sensor.
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Select "Display DTCs" with the Tech 2.
Are any DTCs stored? - Go to Step 8 Verify repair
8 1. Replace G-sensor.
2. Select "Display DTCs" with the Tech 2.
Note: Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech2.
Are any DTCs stored? - Go to Step 9 Verify repair
9 Replace EHCU.
Note : Check the EHCU type for specification, when
the EHCU is replaced.
(Specification ; 2WD model or 4WD model)
Was the action complete? - Verify repair -

5C-28 BRAKES


27. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in the
reservoir and replenish up to the “MAX" level as necessary.
28. Attach the reservoir cap.
29. Stop the engine.




05007-1


BRAKE LINE (HOSES AND PIPES)

Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or parts replacement if these
abnormal conditions are found through inspection.

All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and
bent when working with then, and pay special attention to all
the brake lines not to damage them when repairing o
r
replacing other parts (axle, suspension, etc).

Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints,
retighten or replace these parts.
This procedure must be performed whenever brake lines
are installed.

After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.

5C-40 BRAKES
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.





Rotor


Caliper body

Cylinder bore


Piston


Support bracket


Lock bolt


Guide pin



Visual Check
Inspect the following parts for wear, bending, distortion,
cracking, corrosion, or other abnormal conditions.




Rotor

Thickness (t) mm(in)

Standard Replacement
thickness (Discard)
4

2 26.0 (1.024) 24.6 (0.969)
4

2 HIGH RIDE
4
4 27.0 (1.063) 25.6 (1.008)



Run out
Limit mm(in)
0.075 (0.0029)

Before inspection, adjust the wheel bearing correctly.
Using a dial gauge, measure the run out at the 10mm inside
position from rotor out side edge of disc pad contact surface.




Parallelism (Total circumferential thickness variation)
Limit mm(in)
0.023 (0.0009)

Contact surface must be within 0.023mm at the 10mm inside
position from rotor out side edge.
(Measurement; shall be measure more than 8 position at
circumferential direction.)

BRAKES 5C-45

P1010008


Important Operations
4. Spring ; shoe hold
Push the shoe hold spring toward the brake shoe and hold it.
Rotate the spring to remove it from the shoe hold pin.


6. Spring ; shoe to shoe, lower
Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.


INSPECTION AND REPAIR
Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.





Brake drum


Back plate


Brake lining


Wheel cylinder body


Piston

Piston cup

Return spring



Visual check
Inspect the following parts for wear scuffs, scratches,
corrosion, stains, deterioration, or other abnormal conditions.





Thickness of the Brake Lining
Thickness mm(in)
standard (T) Limit (t)
4

2 5.0 (0.197) 1.0 (0.039)
4

2 HIGH RIDE
4

4 5.0 (0.197) 1.0 (0.039)

BRAKES 5C-55
INSPECTION AND REPAIR

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.




Cylinder inside face


Piston


Piston cap


Piston cap spacer


Return port

Return spring


Visual Check
Inspect the following parts for wear, distortion, cuts, nicks,
corrosion, or other abnormal conditions.



Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.



Primary Piston
After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.

7C-26 CLUTCH
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.




PRESSURE PLATE ASSEMBLY
Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.



Pressure Plate Warpage
Use a straight edge and a feeler gauge to measure the
pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage mm(in)
Limit
0.3 (0.012)



Clutch Cover
Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.



1. Abrasion, scratches, cracks and deflection of friction face to
the disc, loose rivet and wear of ring

Grind small scratches, or replace the assembly if extreme
scratches are found.

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

8A-12 ELECTRICAL-BODY AND CHASSIS
ABBREVIATIONS
Abbreviation Meaning of abbreviation Abbreviation Meaning of abbreviation
A Ampere (S) LH Left hand
ABS Anti-lock brake system LWB Long wheel base
ASM Assembly MPI Multipart fuel injection
AC Alternating current M/T Manual transmission
A/C Air conditioner QOS Quick On Start system
ACC Accessories RH Right hand
CARB Carburetor RR Rear
C/B Circuit breaker RWAL Rear wheel anti-lock brake system
CSD Cold start device SRS Supplemental restraint system
DIS Direct ignition system ST Start
EBCM Electronic brake control module STD Standard
ECGI Electronic control gasoline injection SW Switch
ECM Engine control module SWB Short wheel base
ECU Electronic control unit TCM Transmission control module
EFE Early fuel evaporation V Volt
42 Two-wheel drive VSV Vacuum switching valve
44 Four-wheel drive W Watt (S)
FL Fusible link WOT Wide open throttle
FRT Front W/ With
H/L Headlight W/O Without
IC Integrated circuit
IG Ignition
kW Kilowatt

8A-20 ELECTRICAL-BODY AND CHASSIS

Caution:
Never push or tow the vehicle in an attempt to start it.
Extensive damage to the emission system and other
vehicle parts will result.
(Only catalytic converter vehicle)
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the procedure outlined below.
Always be aware of the dangers of sparking.
Failure to follow the following procedure can result in:
a. Serious personal injury, specially to your eyes.
b. Extensive property damage from a battery explosion,
battery acid discharge, or electrical file.
c. Extensive damage to the electronic components o
f
both vehicles.
Do not use a 24 volt booster battery.
Serious damage to the vehicle's electrical system and
electronic components will result.

Jump Starting Procedure
1. Set the parking brake on both vehicles.
2. If one or both vehicles is equipped with a manual
transmission, place the gear shift in the "NEUTRAL"
position.
3. Turn off the ignition on both vehicles.
4. Turn off all vehicle lights and accessories.
5 Be sure that the two vehicles are not touching.

Attach the end of one jumper cable to the booster battery
positive terminal.
6
Attach the other end of the same cable to the discharged
battery positive terminal.
7. Once again, check that the booster battery has a 12 vol
t
rating.
8.
Attach one end of the remaining booster cable to the
booster battery negative terminal.
9.
Attach the other end of the booster cable to a solid ground
(such as the air conditioner compressor mounting bracke
t
or the alternator mounting bracket) in the engine room o
f
the vehicle with the discharged battery.
Be sure that the ground connection is at least 500 mm (20
in) from the discharged battery.