lock ISUZU TF SERIES 2004 Workshop Manual

CLUTCH 7C-31



Driven Plate Splined Hub Spline Wear
1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaf
t
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear mm(in)
Standard Limit
0.5 (0.020) 1.0 (0.039)



Rivet Head Depression
Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression

1 from the facing surface

2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression mm(in)

Standard
Fly wheel side P/Plate side Limit
4J 1.35-1.95
(0.053-0.077) 1.65-2.25
(0.065-0.089) 0.2
(0.008)
6VE1
C24SE 1.65-2.25
(0.065-0.089) 1.65-2.25
(0.065-0.089) 0.2
(0.008)

CLUTCH 7C-33
MASTER CYLINDER
DISASSEMBLY



Disassembly Steps
1. Bolt : reservoir tank
2. Reservoir tank Comp
3. Yoke
4. Lock nut
5. Body sub assembly

7C-34 CLUTCH
REASSEMBLY



Reassembly Steps
1. Body sub assembly
2. Lock nut
3. Yoke
4. Reservoir tank Comp
5. Bolt : Reservoir Tank

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

ELECTRICAL-BODY AND CHASSIS 8A-3
PAGE
Power Window ........................................................................................................... 8A- 310
Audio, Clock and Cigarette Lighter .......................................................................... 8A- 329
Power Door Mirror ...................................................................................................... 8A- 337
Rear Defogger ............................................................................................................ 8A- 349
SRS-Air Bag ................................................................................................................ 8A- 358
Transfer Case Control Module .................................................................................. 8A- 361
Anti-Lock Brake System ............................................................................................ 8A- 373
Immobilizer ................................................................................................................. 8A- 376
Keyless Entry ............................................................................................................. 8A- 385
Anti Theft ....................................................................................................................8A- 400
Auto Cruise ................................................................................................................. 8A- 412
Trailer Hitch ................................................................................................................ 8A- 415
Connector List ................................................................................................................8A- 418

ELECTRICAL-BODY AND CHASSIS 8A-5
NOTES FOR WORKING ON ELECTRICAL ITEMS
Battery

BATTERY CABLE
Disconnecting the Battery Cable
1. All switches should be "OFF" position.
2. Disconnect the battery ground cable.
3. Disconnect the battery positive cable.
CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result in
a short circuit.














Connecting the Battery Cable
Follow the disconnecting procedure in the reverse order to
connect the battery cables.
CAUTION:
Clean the battery terminal and apply light coat of grease to
prevent terminal corrosion.




CONNECTOR HANDLING
Disconnecting the Connectors
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards you
1.
Other tang locks are released by pressing them forward
2.
Determine which type of tang lock is on the connector being
handled.



Firmly grasp both sides (male and female) of the connector.
Release the tang lock and carefully pull the two halves of the
connector apart.
Never pull on the wires to separate the connectors.
This will result in wire breakage.

8A-6 ELECTRICAL-BODY AND CHASSIS


Connecting the Connectors
Firmly grasp both sides (male and female) of the connector.
Be sure that the connector pins and pin holes match.
Be sure that both sides of the connector are aligned with each
other.
Firmly but carefully push the two sides of the connector
together until a distinct click is heard.


Connector Inspection
Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.



CAUTION
Never insert the circuit tester test probes into the
connector open side to test the continuity.
Broken or open connector terminals will result.



Waterproof Connector Inspection
It is not possible to insert the test probes into the connector
wire side of a waterproof connector.
Use one side of a connector
1 with its wires cut to make the
test.
Connect the test connector to the connector
2 to be tested.
Connect the test probes to the cut wires to check the connecto
r
continuity.



Connector Pin Removal
Connector Housing Tang Lock Type
1. Insert a slender shaft 3into the connector housing open
end
4.
2. Push the tang lock
5up (in the direction of the arrow in the
illustration).
Pull the wire
6 with pin 7free from the wire side of the
connector.

ELECTRICAL-BODY AND CHASSIS 8A-7


Pin Tang Lock Type
1. Insert a slender shaft 3 into the connector housing open
end
4.
2. Push the tang lock
8flat (toward the wire side of the
connector).
Pull the wire
6 with pin 7free from the wire side of the
connector.



Connector Pin Insertion
1. Check that the tang lock 8 is fully up.
2. Insert the pin
7 from the connector wire side 9.
Push the pin in until the tang lock closes firmly.
3. Gently pull on the wires
6to make sure that connector pin
is firmly set in place.



Fuse Replacement
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a burn out fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious circuit
damage.



Parts Handling
Be careful for parts handling and any part should not be
dropped or thrown, otherwise short circuit or disorder may
result.



Wiring Harness
1. When assembling the parts, be careful not to bite or wedge
the wiring harness.
2. All electrical connections must be kept clean and tight.

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

ELECTRICAL-BODY AND CHASSIS 8A-35

FUSE BLOCK CIRCUIT C24SE Sheet 1/2




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