lock ISUZU TF SERIES 2004 User Guide

9A-28 SUPPLEMENTAL RESTRAINT SYSTEM

– Driver air bag assembly
– Passenger air bag assembly
– Steering wheel
– SRS coil assembly
– Steering column
– Knee bolster and instrument panel mounting
attachments
– Driver seat and belt
– Passenger seat and belt
– SRS control unit
SRS control unit always should be checked according
to “SRS Control Unit Replacement Guidelines.”
CAUTION: Refer to “SRS control unit Replacement
Guidelines” below for important information on
SRS control unit replacement in both deployment
and non–deployment crashes.
Inspect SRS coil assembly wiring and steering wheel
for any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to steering wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SRS control unit, the SRS
harness, the SRS coil assembly, the air bag assembly,
the steering wheel, or the steering column. Service of
these items is replacement only. Verify replacement
part numbers.
CAUTION: Proper operation of the SRS control
unit and supplemental restraint system (SRS)
requires that any repairs to the vehicle structure
return it to its original production configuration.

SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit. When removing the cable harness, do not
pull the cables otherwise, cable disconnection
may occur. When connect the SRS connector,
insert the connector completely. Imperfect locking
may cause malfunction of SRS circuit.


Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
827RW028

SUPPLEMENTAL RESTRAINT SYSTEM 9A-29

Installation
To install the connector, hold the socket insulator (1)
and insert it. The cover insulator slides and connector
will be locked. Do not hold the cover insulator (2).
827RW027

9A-30 SUPPLEMENTAL RESTRAINT SYSTEM

SRS Control Unit
5. Remove the three SRS control unit fixing bolts and
remove SRS control unit.


RTW49JSH000101
Legent
(1) SRS control unit
(2) SRS Harness
(3) Connector Position Assurance

Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SRS control
unit. NEVER STRIKE OR JAR SRS control unit.
UNDER SOME CIRCUMSTANCES, IT COULD
CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY OR IMPROPER OPERATION
OF THE SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . SRS control unit MOUNTING BRACKET
BOLTS MUST BE CAREFULLY TORQUED TO
ASSURE PROPER OPERATION. NEVER POWE
R
UP THE SRS WHEN SRS control unit IS NOT
RIGIDLY ATTACHED TO THE VEHICLE. THE SRS
control unit COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
WARNING: PROPER OPERATION OF THE SRS
CONTROL UNIT REQUIRES THE SRS CONTROL
UNIT TO BE RIGIDLY ATTACHED TO THE
VEHICLE STRUCTURE AND THAT THE ARROW
ON THE SENSOR BE POINTING TOWARD THE
FRONT OF THE VEHICLE.
SRS control unit is specifically calibrated and is keyed
to the SRS control unit location SRS wiring harness.
Caution should be used to ensure proper location of
the SRS control unit. The keying of the SRS control
unit to its location and wiring harness connectors
should never be modified in the field.

Removal
1. Disable the SRS (Refer to “Disabling the SRS” in
this section).
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. Remove the front console assembly and
disconnect wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SRS
control unit harness connector.

Installation
1. Install the SRS control unit on bracket and fixing
bolts and tighten the fixing bolts to the specified
torque.
Torque: 7




2 N
 m (0.7




0.2 kg
 m/61 lb in)
2. Connect the SRS control unit harness connecto
r
and after that, put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfe
r
lever knob.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-33

4. Push the four pins at 56 mm bar.
060R300045
5. Cancel the lock four pins.
6. Disconnect the SRS air bag connector pin.

060R300042


7. Disconnect the SRS air bag connector and horn
lead connector located behind the air bag
assembly and remove the air bag assembly.
060R300041

Installation
1. Connect the SRS air bag connector and horn lead
connector.
060R300041

9A-38 SUPPLEMENTAL RESTRAINT SYSTEM

CAUTION: Never apply force to the steering wheel
in the direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
11. Remove the combination switch assembly with
SRS coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from
the combination switch assembly.

Installation
1. Install the combination switch assembly with SRS
coil.
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage the
cable in the SRS coil.
826RW014
Legend
(1) Neutral mark

3. Connect the wiring harness connectors located at
the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
825RS048
6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood
opening lever.
8. Install the steering wheel and align the setting
marks.
060R300024

SUPPLEMENTAL RESTRAINT SYSTEM 9A-41

7. Remove the driver knee bolster assembly.


RTW49JSH000401
Legend
(1) RHD
(2) LHD

8. Remove the steering column cover.
9. Disconnect the wiring harness connectors located
at the base of steering column.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer o
r
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
10. Remove the combination switch assembly with
SRS coil.
SRS coil is a part of combination switch assembly,
which cannot be replaced separately. Therefore, be
sure not to remove the SRS coil from the combination
switch assembly.
11.Remove the snap ring.
12. Remove the cushion rubber.
13. Disconnect shift lock cable (A/T only).
14.Disconnect the starter switch harness connecto
r
located base of steering column.
15. Remove steering lock cylinder assembly.



16.Apply a setting mark across the universal joint and
steering shaft to reassemble the parts in thei
r
original position.
060R300038
17.Remove steering column assembly.

Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
060R300038
2. Tighten the steering column fixing bolts (dash
panel side) to the specified torque.
Torque: 20 N




m (2.0 kg




m/14 lb ft)
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
Torque: 20 N





m (2.0 kg





m/14 lb ft)

9A-42 SUPPLEMENTAL RESTRAINT SYSTEM

4. Tighten the universal joint to the specified torque.
Torque: 31 N




m (3.2 kg




m/23 lb ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
8. Install snap ring.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on
the base of steering column.
11. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage to the
cable in the SRS coil.
826RW014
Legend
(1) Neutral mark

12.Install steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.


825RS048
13.Install the steering wheel and align the setting
marks.

9A-46 SUPPLEMENTAL RESTRAINT SYSTEM

Pretensioner Seat Belt (If so quipped)
Service Precaution
WARNING: WHEN PERFORMING SERVICE ON OR
AROUND THE PRETENSIONER SEAT BELT O
R
THE PRETENSIONER SEAT BELT WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE PRETENSIONE
R
SEAT BELT.
FAILURE TO FOLLOW PROCEDURES COULD
RESULT IN POSSIBLE THE PRETENSIONER SEAT
BELT DEPLOYMENT, PERSONAL INJURY O
R
OTHERWISE UNNEEDED THE PRETENSIONE
R
SEAT BELT REPAIR.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN PERFORMING THE
PRETENSIONER SEAT BELT. WHEN DEPLOY A
LIVE PRETENSIONER SEAT BELT AT OUTSIDE
THE VEHICLE, DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE PRETENSIONE
R
SEAT BELT IS TO BE DEPLOYED. THE
PRETENSIONER SEAT BELT WILL IMMEDIATELY
DEPLOY WHEN A POWER SOURCE IS
CONNECTED TO IT. CONNECTING THE
DEPLOYMENT HARNESS SHOULED ALWAYS BE
THE FINAL STEP IN THE PRETENSIONER SEAT
BELT DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
COULD RESULT IN PERSONAL INJURY.
Parts Location


RTW49JSH000301
Legend
(1) Seat
(2) Bolt
(3) Pretensioner Harness
(4) Pretensioner

Removal
1. Turn ignition switch to “LOCK”, remove key.
2. Remove the foot rest located behind the seat.
3. Remove the cover on seat slide.
4. Disconnect the pretensioner connector at the
base of the seat.
5. Remove four fixing bolts the seat slide and
remove seat.
6. Remove the seat cover.
7. Remove the pretensioner seat belt assembly.
Installation
1. Install the pretensioner seat belt assembly.
2. Install the seat cover.
3. Install the seat on seat slide and four fixing bolts.
4. Connect the yellow pretensioner connector at the
base of the seat.
5. Install the cover on seat slide.
6. Install the foot rest located behind the seat.

9A1-2 RESTRAINT CONTROL SYSTEM

DTC B0051 (Flash Code 51) Squib Circuit Activated (Clash) .........................................9A1-37
DTC B0053 (Flash Code 53) Deployment Command Despite Present Trouble
Code ..................................................................................................................................9A1-39
DTC B0057 (Flash Code 57) Passenger Pretensioner Squib Circuit Low
Resistance ........................................................................................................................9A1-41
DTC B0058 (Flash Code 58) Passenger Pretensioner Squib Circuit High
Resistance ........................................................................................................................9A1-44
DTC B0059 (Flash Code 59) Passenger Pretensioner Squib Circuit Voltage
Range/Performance .........................................................................................................9A1-47
DTC B0064 (Flash Code 64) Driver Pretensioner Squib Circuit Low Resistance .........9A1-50
DTC B0065 (Flash Code 65) Driver Pretensioner Squib Circuit High Resistance ........9A1-53
DTC B0066 (Flash Code 66) Driver Pretensioner Squib Circuit Voltage Range/
Performance .....................................................................................................................9A1-56
DTC B0670 (Flash Code 63) Airbag Telltale Circuit Malfunction ...................................9A1-59
DTC B1000 (Flash Code 72) SDM Internal Fault ..............................................................9A1-61


Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.

CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.

RESTRAINT CONTROL 9A1-3

Diagnostic Information
CAUTION: When fasteners are removed, always
reinstall them at the same location from which they
were removed. if a fastener needs to be replaced,
use the correct part number fastener for that
application. if the correct part number fastener is
not available, a fastener of equal size and strength
(or stronger) may be used. fasteners that are not
reused, and those requiring thread locking
compound will be called out. the correct torque
value must be used when installing fasteners that
require it. if the above conditions are not followed,
parts or system damage could result.


Diagnostic Procedures
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY-POWERED OR AC-POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED, PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
The diagnostic procedures used in this section are
designed to aid in finding and repairing SRS problems.
Outlined below are the steps to find and repair SRS
problems quickly and effectively. Failure to carefully
follow these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect parts
replacement.
1. Perform The “SRS Diagnostic System Check”.
The “SRS Diagnostic System Check” should always
be the starting point of any SRS diagnostics. The
“SRS Diagnostic System Check” checks for prope
r
“AIR BAG” warning lamp operation and checks for
SRS trouble codes using both “Flash Code” and
“Scan Tool” Methods.
2. Refer To The Proper Diagnostic Chart As
Directed By The “SRS Diagnostic System
Check”.
The “SRS Diagnostic System Check” will lead you to
the correct chart to diagnose any SRS problems.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect
parts replacement.

3. Repeat The “SRS Diagnostic System Check”
After Any Repair Or Diagnostic Procedures Have
Been Performed.
Preforming the “SRS Diagnostic System Check”
after all repair or diagnostic procedures will assure
that the repair has been made correctly and that no
other conditions exist.

Diagnostic Codes
The SRS control unit maintains a history record of all
diagnostic codes that have been detected since the
SRS codes were last cleared during service.
1. Active Codes - Faults that are presently detected this
ignition cycle. Active codes are stored in RAM
(Random Access Memory).
2. History Codes - All faults detected since the last time
the history fault memory was cleared. History codes
are stored in EEPROM. (Electronically Erasable
Programmable Read only Memory)

How To Read Trouble Codes
All codes (Active and history) can be read (or cleared)
by using a scan tool or equivalent.
If a PDT is not available, have the vehicle serviced by
HOLDEN dealer.

How To Clear Trouble Codes
Trouble codes can only be cleared by using a Scan
Tool. If a “scan tool” is not available then inform the
owner of the stored codes and suggest that the codes
are cleared upon the next visit to an Isuzu dealership.

Scan Tool Diagnostics
A scan tool can be used to read current and history
codes and to clear all history codes after a repair is
complete. The scan tool must be updated to
communicate with the SRS through a replaceable
cartridge or a manufacturer's update before it can be
used for SRS diagnostics. To use the scan tool,
connect it to the DLC connector and turn the ignition
switch “ON”. Then follow the manufacturer's directions
for communication with the SRS. The scan tool reads
serial data from the SRS control unitSRS control unit
“Serial Data” output (terminal 21) to the DLC connector
(terminal 2).

Basic Knowledge Required
Before using this section of the Service Manual, there is
some basic knowledge which will be required. Without
this knowledge, you will have trouble using the
diagnostic procedures in this section. Use care to
prevent harm or unwanted deployment. Read all