power ISUZU TF SERIES 2004 Owners Manual

ELECTRICAL-BODY AND CHASSIS 8A-357


(5) If there is a place where the voltage suddenly changes to
0V, there is a broken wire between there and the powe
r
side.
(6) Move the tester probe from the position where the voltage
changes to 0V toward the power side and find where the
voltage suddenly increases.



REPAIR OF BROKEN HEAT WIRE
(1) Clean broken wire tips with white gasoline.
(2) Place masking tape along both sides of wire to be repaired.



(3) Thoroughly mix the repair agent (Dupont paste No. 4817 or
equivalent).
(4) Using a fine tip brush, apply a small amount to the wire.
(5) After a couple of minutes, remove the masking tape.
(6) Allow to stand at least 24 hours.

8A-394 ELECTRICAL-BODY AND CHASSIS
060R100102

Operating Procedure
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card.
Follow the operating procedure.

8A-418 ELECTRICAL-BODY AND CHASSIS

CONNECTOR LIST
No. Connector face No. Connector face
B-1
~
B-6 NOT USED B-17
~
B-19 NOT USED
B-7
Black
Rear defogger relay B-20
WhiteCigar lighter illumination
B-8
Black
Power Window Relay B-21
WhiteCigar lighter
B-9
NOT USED B-22
Black
Cigar lighter
B-10
White
Clock B-23
GreenMeter-A
B-11


B-12 NOT USED B-24
Green
Meter-B
B-13
White
Fan switch B-25
~
B-27 NOT USED
B-14
Gray
Audio B-24
GreenGround Driver Side
B-15
NOT USED B-30
~
B-29 NOT USED
B-16
White
Hazard switch B-31
SDM

ELECTRICAL-BODY AND CHASSIS 8A-419


No. Connector face No. Connector face
B-32
NOT USED B-44

Keyless Entry (B)
B-33

Illumination control B-45
WhiteAlarmer control unit
B-34
NOT USED B-46
Gray
Rear defogger timer
B-35
Yellow
Infrator; passenger side B-47
WhiteGlove box illumination
B-36
Yellow
Infrator; Driver side B-48
BlackG/sensor
B-37
~
B-39 NOT USED B-49
White
A/T Lever
B-40
Black
Acc socket relay B-50
WhitePower/3rd start switch
B-41
Natural
Acc socket B-51
~
B-52 NOT USED
B-42
White
Acc socket B-53
WhiteJ/B I1
B-43

Keyless Entry (A) B-54
WhiteJ/B I2

8A-426 ELECTRICAL-BODY AND CHASSIS


No. Connector face No. Connector face
D-1
Brown
Power window motor-RH D-10
WhitePower window switch passenger side
D-2
White
Remote mirror-RH D-11
BrownPower window motor Rear-LH
D-3
Black
Front speaker-RH D-12
WhitePower window switch Rear-LH
D-4
Black
Door lock actuator driver side D-13
BlackRear speaker-LH
D-5
White
Power window driver side D-14
BlackDoor lock actuator Rear-LH
D-6
Brown
Power window motor-LH D-15
BrownPower window motor Rear-RH
D-7
White
Remote mirror-LH D-16
WhitePower window switch-RH
D-8
Black
Speaker-LH D-17
BlackRear speaker-RH
D-9
Black
Door lock actuator passenger side
(keyless & antitheft) D-18
BlackDoor lock actuator Rear-RH
D-9
Black
Door lock actuator passenger side D-19
WhiteRemote mirror switch driver side

ELECTRICAL-BODY AND CHASSIS 8A-427


No. Connector face No. Connector face
D-20
White
Power window switch driver side


D-21
White
Tweeter-RH


D-22
White
Tweeter-LH


D-23
White
Door lock & super actuator front (RH)


D-24
White
Key cylinder switch front –(RH)


D-25
White
Door lock & super lock actuator front (LH)


D-26
White
Key cylinder switch front – (LH)


D-27
White
Door lock & super lock actuator RR (RH)


D-28
White
Door lock & super lock actuator RR (LH)

8B-6 CRUISE CONTROL SYSTEM
Adjustment
1. Check to be sure that the brake pedal has been completely
returned by the return spring.
2. Disconnect the switch connector.



RTW3A0SH001201

3. Release the lock (2) by turning the switch (1) counter-clock-
wise.
4. After doing so, pull the pedal arm (3) to you a little so tha
t
the pedal arm is not pushed in.
5. Making the pedal arm not movable with one hand, push in
the whole switch with the other hand until the plunger of the
switch is pushed in and the switch itself hits the rubber o
f
the pedal arm.
In the condition, turn the switch clock-wise until "click"
sound is made and lock it.
By doing this, the switch is adjusted at 0.2 to 1.2mm (0.01-
0.06 in.) clearance.

Clutch Switch


Removal and Installation
Refer to the Clutch Control removal and installation steps in
Clutch section.

Adjustment
1. Turn the clutch switch or stopper bolt 1 until the switch bolt
or stopper bolt just touches the clutch pedal arm.
2. Adjust clutch switch or stopper bolt by backing it out half a
turn, and measure the clearance (L) between the clutch
pedal arm and the clutch switch bolt end or stopper bolt.
3. Lock the lock nut
2.
4. Connect the clutch switch connector.

Clutch switch and clutch and clutch pedal clearance
mm (in)

Limit 0.5-1.5 (0.020-0.059)


Starter Switch

431R300001
Removal
1. Steering Lock Assembly

Refer to the Steering Lock assembly removal steps o
f
"Steering Column" in Power-Assisted Steering System
section.
2. Starter Switch

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

TROUBLESHOOTING 6 – 1


SECTION 6
TROUBLESHOOTING


TABLE OF CONTENTS
PAGE PAGE
BASIC INSPECTION PROCEDURE ... 6– 2

1. HARD STARTING ........................... 6– 3

1-1.Starter Motor Inoperative ......... 6– 3

1-2. Starter Motor Operates But
Engine Does Not Turn Over .......... 6– 3

1-3. Engine Turns Over But Does
Not Start Engine ............................. 6– 4

2. UNSTABLE IDLING ........................ 6– 5

3. INSUFFICIENT POWER ................. 6– 6

4. EXCESSIVE FUEL
CONSUMPTION ................................. 6– 7

5. EXCESSIVE OIL CONSUMPTION.. 6– 8

6. OVERHEATING............................... 6– 9

7. WHITE EXHAUST SMOKE ............. 6– 9

8. DARK EXHAUST SMOKE .............. 6– 10

9. OIL PRESSURE DOES NOT RISE . 6– 11

10. ABNORMAL ENGINE NOISE ....... 6– 12

10-1. Engine Knocking.................... 6– 12

10-2. Gas Leakage Noise ................ 6– 12

10-3. Continuous Noise .................. 6– 13

10-4. Slapping Noise ....................... 6– 13

10-5. Excessive Turbocharger
Noise ............................................... 6– 14
11. ROTATING PART WEAR OF
TURBOCHARGER ............................. 6– 14

12. OIL LEAKAGE FROM
TURBOCHRGER ............................... 6– 15

13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER ....................... 6– 15

14. BATTERY CHARGING AND
NOISE PROBLEM.............................. 6– 16

14-1. Battery No Charging .............. 6– 16

14-2. Battery Overcharging ............ 6– 16

14-3. Battery Under Charging......... 6– 17

14-4. Battery Unstable Charging
Current ............................................ 6– 17

14-5. Charging System Noise ......... 6– 18

15. STARTER MOTOR PROBLEM..... 6– 19

15-1. Starter Motor Pinion Engages
to Ring Gear But Engine Does
Not Turn Over ................................. 6– 19

15-2. Incorrect Pinion And Ring
Gear Engagement .......................... 6– 19

15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off ....................................... 6– 20

15-4. Excessive Commutator
Sparking .......................................... 6– 20

TROUBLESHOOTING 6 – 3
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1–1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch.
Does the starter switch work? —
Go to Step 2 Repair or
replace the
starter switch
2 Check the starter relay.
Does the starter relay work? —
Go to Step 3 Repair or
replace the
starter relay
3 Check the magnetic switch.
Does the magnetic switch work? —
Go to Step 4 Repair or
replace the
magnetic
switch
4 Check the pinion gear condition on the starter motor.
Was the condition normal? —
Go to Step 5 Replace the
pinion gear
5 Check the brush wear or brush spring weakness.
Was the condition normal? —
Replace the
starter motor
assembly Repair or
replace the
brush or brush
spring

1-2 Starter motor operates but engine does not turn over
Step Action Value(s) Yes No
1 Check the engine internal seizure.
Was the engine seized? —
Repair or
replace seized
parts Check other
DTC by Tech
2 and go to
indicated DTC

6 – 6 TROUBLESHOOTING
3. Insufficient Power
Step Action Value(s) Yes No
1 Was the air cleaner element condition OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element.
2 Was the intake air leakage found from intake
system? — Repair or
replace the
intake air
system. Go to Step 3
3 Was the fuel filter element condition OK? (Clogged
or not) —
Go to Step 4 Clean or
replace the fuel
filter element.
4 Check the fuel injection pipes.
Does the injection pipes have obstruction or any
damage? — Repair or
replace the fuel
injection pipes. Go to Step 5
5 Was the water contained in the fuel? — Replace the
fuel Go to Step 6
6 Was the injection nozzle pressure or spray pattern
normal? —
Go to Step 7 Readjust the
injection nozzle
pressure or
replace the
nozzle.
7 Was the compression pressure OK? 3.0 MPa
(31.0 kg/cm2,
441 psi) at
200 rpm
Go to Step 8 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
8 Was the exhaust pipe clogged? — Repair or
replace the
exhaust pipe. Go to Step 9
9 Was the exhaust gas leakage found from exhaust
system? — Repair or
replace the
exhaust
system. Go to Step 10
10 Was the waste gate control actuator hose broken or
cracked? — Replace the
hose. Go to Step 11
11 Was the waste gate working completely? —
Go to Step 12 Replace the
turbocharger
assembly.
12 Was turbocharger working completely? —
Go to Step 13 Replace the
turbocharger
assembly.
13 Are any DTC stored? — Go to indicated
DTC Solved