glow ISUZU TF SERIES 2004 Workshop Manual

ELECTRICAL-BODY AND CHASSIS 8A-25
Light Name Rated Power
V-W Number of
Bulbs Lens
Color Remarks
W/O Tacho 5Illumination light 14-2
W/ Tacho 7White
Turn Signal 14-1.12 2 Green
High Beam 14-1.12 1 Blue
Low Fuel 14-1.12 1 Amber
A/T Oil Temp 14-1.12 1 Red
Brake system 14-1.12 1 Red
4WD 14-1.12 1 Green
Seat belt 14-1.12 1 Red
Oil pressure 14-1.12 1 Red
ABS 14-1.12 1 Amber
SEDIMENTER 14-1.12 1 Red
AIR BAG 14-1.12 1 Red
Brake 14-1.12 1 Red
Charge 14-1.12 1 Red
Check Trans 14-1.12 1 Red
Check 4WD 14-1.12 1 Red
Power drive 14-1.12 1 Amber
3rd start 14-1.12 1 Green
4L 14-1.12 1 Green
Cruise Set 14-1.12 1 Green
Check Engine 14-1.12 1 Amber
Front Fog 14-1.12 1 Green
Rear foglight 14-1. 12 1 Amber
Glow 14-1.12 1 Amber
P LED 1 Green
R LED 1 Green
N LED 1 Green
D LED 1 Green
3 LED 1 Green
2 LED 1 Green












Indicator/
Warning
light
A/T shift
indicator
L LED 1 Green

8A-28 ELECTRICAL-BODY AND CHASSIS

RELAY LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
RHD





















NO. RELAY (C24SE) RELAY (6VE1) RELAY
(4JA1-TC/4JH1-TC)RELAY (4JA1-L)
X-1 RELAY; TAIL LIGHT
  
X-2 RELAY; FUEL PUMP
 RELAY; FRT FOG RELAY; FRT FOG
LIGHT
X-3 RELAY; HORN
  
X-4 RELAY; DIMMER
  
X-5 RELAY; FOG LIGHT
 RELAY; GLOW RELAY; GLOW
X-6 RELAY; STARTER
 RELAY; COND, FAN RELAY; CSD
X-7 RELAY; COND, FAN
 RELAY; RR FOG

X-8
  RELAY; STARTER RELAY; STARTER
X-9 RELAY; HAZARD-RH
  
X-10 RELAY; HAZARD-LH
  
X-11 RELAY; HEATER
  
X-12 RELAY; HEAD
LIGHT   
X-13
 RELAY; ECM MAIN
 RELAY; COND, FAN
X-14 RELAY; A/C COMP
  
X-15 RELAY; THERMO
  

ELECTRICAL-BODY AND CHASSIS 8A-29

RELAY LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
LHD





















NO. RELAY (C24SE) RELAY (6VE1) RELAY
(4JA1-TC 4JH1-TC)RELAY (4JA1-L)
X-1 RELAY; TAIL LIGHT
  
X-2 RELAY; FUEL PUMP
 RELAY; FRT FOG RELAY; FRT FOG
LIGHT
X-3 RELAY; HORN
  
X-4 RELAY; DIMMER
  
X-5 RELAY; FRT FOG
LIGHT RELAY; FOG LIGHT RELAY; GLOW RELAY; GLOW
X-6 RELAY; STARTER
 RELAY; COND, FAN RELAY; CSD
X-7 RELAY; COND, FAN
 RELAY; RR FOG

X-8
  RELAY; STARTER

X-9
  SHORT
CONNECTOR
(with cooler) 
X-10
   
X-11 RELAY; HEATER
  
X-12 RELAY; HEAD
LIGHT   
X-13
 RELAY; ECM MAIN
 RELAY; COND, FAN
X-14 RELAY; A/C COMP
  
X-15 RELAY; THERMO
  

ELECTRICAL-BODY AND CHASSIS 8A-31
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
RHD

FUSE 
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
EB-1 15A ECM 20A ECM 10A ECM 
EB-2 
10A ECM (B) 10A RR FOG 
EB-3 15A FRT FOG
10A TCM 15A FRT FOG 
EB-4 10A ACG (S) 15A FRT FOG  10A ACG (S)
EB-5 10A ILLUMI  10A ILLUMI & TAIL-RH10A ILLUMI
EB-6 10A TAIL  10A TAIL-LH 10A TAIL
EB-7 10A H/LIGHT-RH  10A H/LIGHT RH-LOW10A H/LIGHT RH
EB-8 10A H/LIGHT-LH  10A H/LIGHT LH-LOW10A H/LIGHT LH
EB-9 20A FUEL PUMP 10A O2 SENSOR 10A TRA ILER 
EB-10 10A O2 SENSOR 20A FUEL PUMP 10A AC G (S) 
EB-11 
10A H/LIGHT RH-HIGH 
EB-12 
10A H/LIGHT LH-HIGH
EB-13 10A A/C 
 
EB-14 10A 4WD
10A 4WD  
EB-15 10A HORN   
EB-16 15A HAZARD 10A HAZARD  

SLOW BLOW FUSE
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
SBF-1 100A MAIN 
80A MAIN 
SBF-2  
20A COND, FAN 
SBF-3  
60A GLOW 20A COND, FAN
SBF-4 20A COND, FAN 
30A ECM 50A GLOW
SBF-5 40A IG 1   
SBF-6 
40A ABS-1  
SBF-7 
30A ABS-2  
SBF-8 30A BLOWER   
SBF-9 50A IG 2

8A-32 ELECTRICAL-BODY AND CHASSIS
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
LHD

FUSE  Saudi Arabia
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
EB-1 15A ECM 20A ECM 10A ECM 
EB-2 
10A ECM (B) 10A RR FOG 
EB-3 15A FRT FOG
10A TCM 15A FRT FOG 
EB-4 10A ACG (S) 15A FRT FOG  10A ACG (S)
EB-5 10A ILLUMI & TAIL-RH  10A ILLUMI & TAIL-RH 
EB-6 10A TAIL-LH  10A TAIL-LH

EB-7 10A H/LIGHT-RH 10A H/LIGHT-RH
10A H/LIGHT-RH-LOW
 10A H/LIGHT RH-LOW
10A H/LIGHT-RH-LOW
EB-8 10A H/LIGHT-LH 10A H/LIGHT-LH
10A H/LIGHT-LH-LOW
 10A H/LIGHT LH-LOW
10A H/LIGHT-LH-LOW
EB-9 20A FUEL PUMP 10A O2 SENSOR 10A TRA ILER 
EB-10 10A O2 SENSOR 20A FUEL PUMP 10A AC G (S) 
EB-11
10A H/LIGHT-RH-HIGH
10A H/LIGHT RH-HIGH 
EB-12 10A H/LIGHT-LH-HIGH
10A H/LIGHT LH-HIGH 
EB-13 10A A/C 
 
EB-14 10A 4WD
10A 4WD  
EB-15 10A HORN   
EB-16 15A HAZARD 10A HAZARD  
SLOW BLOW FUSE
ENGINE MODEL
FUSE NO. C24SE 6VE1 4JA1-TC / 4JH1-TC4JA1-L
SBF-1 100A MAIN 
80A MAIN 
SBF-2  
20A COND, FAN 
SBF-3  
60A GLOW 20A COND, FAN
SBF-4 20A COND, FAN 
30A ECM 50A GLOW
SBF-5 40A IG 1   
SBF-6 
40A ABS-1  
SBF-7 
30A ABS-2  
SBF-8 30A BLOWER   
SBF-9 50A IG 2

8A-276 ELECTRICAL-BODY AND CHASSIS


Connector No. B-24
Terminal Connector place SOUTH
AFRICA SAUDI
ARABIA ISRAEL EC UK OTHER
1
SEDIMENTER
2
4LO
3
OIL PRESS
4
4WD
5
CHECK 4WD
6
GLOW
7
POWER DRIVE
8








9
SPEED (+)
10
4P OUTPUT
11
TACHO
12
STARTER
13
TEMP
14
FUEL
RR FOG


15
FRONT FOG






16
ABS CONT. (ABS)
17
CHECK ENGINE
18
AIR BAG
SEAT BELT 19
LOW COOLANT





CRUISE SET



20
BEAM (+)




21
TURN (LEFT)
22
BEAM (-)
BEAM (+)


23
FRONT FOG




24
3rd START (A/T)
25








26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN

ELECTRICAL-BODY AND CHASSIS 8A-429


No. Connector face No. Connector face
E-23
(4JH1-TC)
Gray TPS 2 main E-44
Gray Vehicle speed sensor
E-24
~
E-29 NOT USED E-45
(4JH1-TC)
Gray 2WD-4WD switch
E-30
(4JH1-TC)
Gray A/T speed sensor E-46
(4JH1-TC)
BrownH-L neutral switch
E-31
(4JH1-TC)
Gray Turbine sensor E-47
~
E-48 NOT USED
E-32
~
E-34 NOT USED E-49
(4JH1-TC)
Glow plug
E-35
(4JH1-TC)
(C24SE)
Black Motor actuator E-50

NOT USED
E-36
~
E-40 NOT USED E-51
(6VE1)
Fuel injector
E-41
(4JH1-TC)
Black Coolant temp sensor E-51
(4JH1-TC)
BlackInhibiter switch
E-42
Natural
green
Backup lamp switch E-52
(6VE1)
Fuel injector
E-43
Natural
green
Backup lamp switch E-53
(6VE1)
Ignition coil

6A – 26 ENGINE MECHANICAL



041RY00011
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.





1. Place the drain pan under the drain plug.
2. Loosen the drain plug and drain water.
3. After draining the water, tighten the drain plug.
4. Operate the priming pump on the fuel filter several
times and check for fuel leakage.
5. Check the water separator indicator light. It should be
off.



Except EURO III model
RTW46ASH002901




For EURO III model
RTW46ASH000501


Air Bleeding
1. Operate the priming pump until strong resistance is
felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait until
the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and
crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.

ENGINE ELECTRICAL 6D – 1


SECTION 6D
ENGINE ELECTRICAL


TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description......................................................................................................... 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator.......................................................................................................................... 6D - 7
Removal and Installation ............................................................................................ 6D - 7
Disassembly................................................................................................................. 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly.................................................................................................................. 6D - 18
Starter Motor .................................................................................................................... 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly................................................................................................................. 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly.................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug ..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33

ENGINE ELECTRICAL 6D – 33
PRE-HEATING SYSTEM
INSPECTION AND REPAIR
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.

VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.



825R300046




Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance Ohms
94  114

GLOW PLUG


LNW21KSH001401
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference) Ohms
Approximately 0.9

EGR SYSTEM 4JA1T (L)
Refer to 6F-9. (EGR system diagram)