wheel ISUZU TF SERIES 2004 Workshop Manual

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-129
Installation
Follow the removal procedure in the reverse order to install the
headlight.
Pay close attention to the important points mentioned in the
following paragraphs.


Connector
Be absolutely sure that the headlight connector is securely
connected.
This will prevent a contact and an open circuit.

This illustration is based on RHD model

LIGHTING SWITCH
Removal
1. Disconnect the battery ground cable.
2. Remove the steering wheel
1.
Refer to the “STEERING” Section of this manual.
3. Remove the Instrument panel lower cover
2.
4. Remove the steering column cover
3.


This illustration is based on RHD model
5. Disconnect the connector.
6. Remove the lighting switch from the steering shaft.





Installation
Follow the removal procedure in the reverse order to install the
lighting switch.
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that the lighting switch connector is securely
connected.
This will prevent a poor contact and an open circuit.


Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
Wire damage will result.

ELECTRICAL-BODY AND CHASSIS 8A-131


LICENSE PLATE LIGHT
Removal
1. Remove the lens cover 1 and the connector 2.
2. Pull the bulb
3 to remove it.



Installation
Follow the removal procedure in the reverse order to install the
license plate light.
Pay close attention to the important points mentioned in the
following paragraphs.



Bulb
Be absolutely sure that the license plate light bulb is correctly
installed.
This will prevent a poor contact and open circuit.



HEADLIGHT BEAM SWITCH
(COMBINATION SWITCH)
Removal
1. Disconnect the battery ground cable.
2. Remove the screws on the lower part of the steering wheel.
3. Remove the horn pad.
4. Remove the wiring connector.
5. Remove the steering wheel fixing nuts.
6. Remove the steering wheel.
Refer to the "STEERING" Section of this manual.
7. Remove the Instrument panel lower cover.
8. Remove the steering column cover.
9. Disconnect the connector.
10. Remove the headlight beam switch (lever) from the steering
shaft (combination switch).


Installation
Follow the removal procedure in the reverse order to install the
headlight beam switch (lever).
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that the headlight beam switch connector is
securely connected.
This will prevent a poor contact and an open circuit.

ELECTRICAL-BODY AND CHASSIS 8A-153

HEADLIGHT LEVELING SWITCH
Incorrect beam angle due to load change can be corrected.
A four position switch, 0-3, can alter the beam angle through
1.7 degrees on the long wheel base model and 2.17 degrees
on the short wheel base model.
825R300049

Inspection
Check to see if there is any continuity between the terminals of
the leveling switch.
Replace the switch when the result of inspection is found
abnormal.



Removal
Preparation:
Disconnect the battery ground cable.
1. Ventilation grille
2. Harness connector
3. Headlight leveling switch
To remove the switch, push the lock from the back side of
the cluster assembly.



Installation
To install, follow the removal steps in the reverse noting the
following point.
1. Push in the switch with your fingers until it locks securely.

ELECTRICAL-BODY AND CHASSIS 8A-171
HORN
1. Both sides of horn do not sound

Checkpoint Trouble Cause Countermeasure



Repair the grounding point

Poor ground contact
NG

Horn relay


Grounding point


Reinstall or replace fuse No.
EB-15 (10A)

Fuse No EB-15 (10A, Relay
and fuse box)

Poor fuse contact or blown
fuse
NG
OK OK

Reinstall or replace the horn
relay

Poor relay contact or faulty
horn relay
NG
Voltage between connector
3
X-3 - ground or 1 X-3
- ground (Should be battery
voltage present) OK

Repair open circuit or
reconnect the connector
Open circuit or poor connector
contact between fuse No. EB-
15 (10A) and horn relay
NG

Remove steering pad and
steering wheel
OK

Horn switch continuity
OK
Repair or replace the horn
switch

Poor switch point contact or
faulty switch
NG
Continuity between
4
X-3 - 10 B-60
2
X-3 - 1 C-20 (1 C-21) OK

Repair open circuit or
connector contact

Open circuit or poor connector
contact
NG

8A-176 ELECTRICAL-BODY AND CHASSIS
This illustration is based on RHD model
TURN SIGNAL SWITCH
Removal
1. Disconnect the battery ground cable.
2. Remove the steering wheel
1.
Refer to the “STEERING” Section of this Manual.
3. Remove the instruments panel lower cover
2.
4. Remove the steering column cover
3.

This illustration is based on RHD model
5. Disconnect the connector.
6. Remove the turn signal switch from the steering shaft.




Installation
Follow the removal procedure in the reverse order to install the
turn signal switch (lever).
Pay close attention to the important points mentioned in the
following paragraphs.



Connector
Be absolutely sure that the turn signal switch connector is
securely connected.
This will prevent a poor contact and at an open circuit.

ELECTRICAL-BODY AND CHASSIS 8A-179

HORN SWITCH
Removal
1. Disconnect the battery ground cable.
2. Disable the SRS (Refer to “Disabling the SRS”in this
section).
3. Check the both side hole of the steering cover.


4. Check the position of the pins in a hole. Push the pin in the
direction of an arrow.


5. Push the four pins at 56 mm bar.

6. Cancel the lock four pins.
7. Disconnect the SRS air bag connector and horn lead
connector located behind the air bag assembly and remove
the air bag assembly.

Installation
1. Connect the SRS bag connector and horn lead connector.
2.
Align the each snap stud of driver air bag to the hole of
steering wheel.

6 – 8 TROUBLESHOOTING
5. Excessive Oil Consumption
Step Action Value(s) Yes No
1 Does the air cleaner element conditon OK? (Clogged
or not) —
Go to Step 2 Clean or
replace the air
cleaner
element
2 Does PCV (Positive Crankcase Ventilation) Valve
has problem? — Repair or
replace the
relation parts. Go to Step 3
3 Was the oil pressure value more than normal value? Less than
588 kPa (6.0
kg/cm
2, 85
psi) Repair or
replace the oil
relief valve Go to Step 4
4 Inspect the front and rear crankshaft oil seal.
Was the oil leakage found? —
Replace the
failure part. Go to Step 5
5 Was the oil leakage found from any gasket? — Replace the
wrong gasket Go to Step 6
6 Inspect the valve stem seal, the valve stem and the
valve guide for worn.
Were any worn found? —
Replace the
worn part. Go to Step 7
7 Was the oil leakage found from the turbocharger oil
seal? — Replace the oil
seal. Go to Step 8
8 Was the oil drain pipe of the turbocharger restricted?— Repair or
replace the oil
drain pipe. Go to Step 9
9 Was the oil drain passage in the turbocharger center
housing restricted? — Clean the
center housing Go to Step 10
10 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 11
11 Are any DTC stored? — Go to indicated
DTC Solved

6 – 10 TROUBLESHOOTING
8. Dark Exhaust Smoke
Step Action Value(s) Yes No
1 Was the air cleaner element normal condition? —
Go to Step 2 Clean or
replace the air
cleaner
element
2 Was the EGR valve sticking? — Replace the
EGR valve Go to Step 3
3 Was the injection nozzle pressure or the injection
spray pattern OK? —
Go to Step 4 Replace the
injection nozzle
4 Was the oil leakage found from the turbocharger oil
seal? — Replace the oil
seal Go to Step 5
5 Was the oil drain pipe of the turbocharger restricted?— Repair or
replace the oil
drain pipe Go to Step 6
6 Was restricted the oil drain passage in the
turbocharger center housing restricted? — Clean the
center housing Go to Step 7
7 Does turbine wheel has any impact damage? — Replace the
turbocharger Go to Step 8
8 Does PCV (Positive Crankcase Ventilation) Valve
has problem? — Repair or
replace the
relation parts Go to Step 9
9 Are any DTC stored? — Go to indicated
DTC Solved

TROUBLESHOOTING 6 – 13
10–3 Continuous noise
Step Action Value(s) Yes No
1 Was the fan belt tension OK? 9 – 13 mm
(0.35 – 0.51
in)
Go to Step 2 Adjust the fan
belt tension.
2 Was the cooling fan loose? — Tighten the
cooling fan Go to Step 3
3 Was noise coming from the generator? — Repair or
replace the
generator
and/or the
vacuum pump Go to Step 4
4 Was noise coming from the water pump? — Replace the
water pump Go to Step 5
5 Was noise coming from the cylinder head cover? — Readjust the
valve
clearance. Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

10-4 Slapping noise
Step Action Value(s) Yes No
1 Was noise coming from the cylinder head cover? — Go to Step 2 Go to Step 4
2 Were valve clearances correct? 0.4 mm
(0.016 in)
both intake
and exhaustAdjust the
valve
clearances Go to Step 3
3 Were the rocker arms damaged? — Replace the
rocker arms Go to Step 4
4 Was the flywheel fixing bolt loose? — Tighten the
fixing bolt. Go to Step 5
5 Was noise coming from the cylinder body? — Go to Step 6 Go to Step 10
6 Inspect the crankshaft bearing and/or crankshaft.
Was the crankshaft bearing and/or crankshaft worn?— Replace the
worn parts Go to Step 7
7 Inspect the connecting rod bearing and/or crankpin.
Was the connecting rod bearing and/or crankpin
worn? —
Replace the
worn parts Go to Step 8
8 Inspect the connecting rod small end bushing and/or
piston pin.
Was the connecting rod small end bushing and/or
piston pin worn? —
Replace the
worn parts Go to Step 9
9 Inspect the piston and/or cylinder liner.
Was the piston and/or cylinder liner worn or
damaged? — Replace the
worn or
damaged parts Go to Step 10
10 Are any DTC stored? — Go to indicated
DTC Solved