lights ISUZU TF SERIES 2004 Owner's Manual

ENGINE ELECTRICAL 6D1-5











































Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly rinse
the affected area with clean tap water.
Never allow metal tools or jumper cables to come in contact
with the positive battery terminal, or any other metal surface of
the vahicle. This will protect against a short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
1. Set the vehicle parking brake.
If the vahicle is equipped with an automatic transmission,
place the selector level in the "PARK" position.
If the vehicle is equipped with a manual transmission, place
the shift lever in the "NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is completely
clear, do not try to jump start.
3.
Attach the end of one jumper cable to the positive terminal
of the booster battery.

Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing the
charging procedure.
Be sure that the booster battery has a 12 volt rating.
4.
Attach one end of the remaining cable to the negative
terminal of the booster battery.

Attach the other end of the same cable to a solid engine
ground (such as the air conditioning compressor bracket o
r
the generator mounting bracket) of the vehicle with the
discharged battery.
The ground connection must be at least 450 mm (18 in.)
from the battery of the vehicle whose battery is being
charged.
WARNING: NEVER ATTACH THE END OF THE JUMPER
CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories have
been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in
reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.

STARTING AND CHARGING SYSTEM 6D3-13

5. During current output tests please make sure that the
ammeter is securely connceted into the charge circuit.
6. Some battery powered timing lights can produce high
transient voltages when connected or disconnected. Onl
y
disconnect or connect timing lights when the engine is
switched off.
7. Make sure the warning lamp circuit is functioning normall
y
before commencing tests.
8. Battery isolation switches must only be operated when the
engine is stopped.
9. To protect the charging system when using 240 vol
t
chargers it is recommeneded that the battery is
disconnected whilst charging.
10. Due to the very low resistance value of the stator winding i
t
may not be possible to obtain accurate readings withou
t
special equipment.
11. 12 volts must never be connected to the "L" terminal of the
regulator as this will damage the lamp driver circuit.
12. No loads apart from the warning lamp can be connected to
the "L" termainal. The "W" terminal is provided for this
purpose.

Disassembly
1. Mark the relative positions of the end housings in relation to
the stator assembly to aid reassembly. Use a permanen
t
marking pen do not use centre punched as this can cause
misalignmnet of the housings.
2. Remove the EP regulator from the slipring end housing b
y
removing the two screws. Tilt the regulator slightly from the
plug connection until the regulator clears the housing, then
lift clear.
3. Remove the four through bolts.
4. Carefully remove the stator assembly along with the slipring
end housing taking care not to put strain on the stator wires.
5. To disconnect the stator from the rectifier assembly, grasp
the stator wires close to the wire loop with a pair of long
nosed pliers, heat the joint with a soldering iron, when the
point becomes plastic apply a slight twisting motion to the
wires, then pull upwards to release the wires. Remove the
stator.
This procedure opens the wire loop to release the stato
r
connections easily.
6. To remove the rectifier remove the three retaining scre
w
and the B+ terminal nut and washers.

Note: the B+ bolt and the positive heatsink retaining screw are
fitted with mica insulating washers.
These must be discarded and replaced with new washers and
heatsink compound.

ENGINE DRIVEABILITY AND EMISSIONS 6E–65
Step 3: Simulate the symptom and isolate the
problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Nex t, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
Hints
You can isolate a circuit by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Substitute a known good part from the parts
department or the vehicle system
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the nex t page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
What resources you should use
Whenever appropriate, you should use the following
resources to assist in the diagnostic process:
Service manual
Bulletins
Digital multimeter (with a MIN/MAX feature)
Tech II and Tech II upload function
Circuit testing tools (including connector kits/
harnesses and jumper wires)
Ex perience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests
1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.For parts and sensors, apply slight vibration to the part
with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CA UTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
This method may be used when the complaint suggests
that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CA UTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed
This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
A lack of understanding by the customer
A conflict between customer ex pectations and
vehicle design intent
A system performance that is unacceptable to the
customer
What you should do
You can verify that a system is operating as designed
by:
Reviewing service manual functional/diagnostic
checks
Ex amining bulletins and other service information for
supplementary information
Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer ex pectation and system
operation, you should ex plain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.
What resources you should use
Whenever possible, you should use the following
resources to facilitate the diagnostic process:

ENGINE DRIVEABILITY AND EMISSIONS 6E–203
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0:
Diagnostic Trouble Code”.
Is the DTC P0562 stored as “Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”.
2. Select “Clear DTC Information” with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed
This Ignition” in “F2: DTC Information”.
Was the DTC P0562 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate enough ignition voltage? 10 - 14.5V Go to Step 6Go to Step 5
5 Using the DVM and check the battery voltage at the
battery terminal.
Does the tester indicate enough battery voltage?
10 - 14.5V Go to Step 6Check the
charging
system, charge
or replace the
battery
6 Check for poor/faulty connection at the ECM
connector. If a poor/faulty connection is found, repair
as necessary.
Was the problem found?
—Verify repair Go to Step 7
7 Check for poor/faulty connection of the ECM ground
at the inlet manifold. If a poor/faulty connection is
found, repair as necessary.
Was the problem found?
—Verify repair Go to Step 8
8 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 9
9 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step A ction Value(s) Yes No
16
2
17
12 C-56(J2)E-60(J1)
E-72

ENGINE DRIVEABILITY AND EMISSIONS 6E–205
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor By Priority” in “F0:
Diagnostic Trouble Code”.
Is the DTC P0563 stored as “Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech2, ignition “On” and engine “Off”.
2. Select “Clear DTC Information” with the Tech2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F5: Failed
This Ignition” in “F2: DTC Information”.
Was the DTC P0563 stored in this ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “Ignition Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage? Less than 16V Go to Step 5Check the
charging
system and Go
to Step 5
5 Is the battery jamp start cable incorrectly connecting?
—Verify
procedure Go to Step 6
6 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 7
7 Replace the ECM.
Is the action complete?
IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 “Immobilizer System-ECM replacement” for
the ECM/Immobilizer linking procedure.—Veri fy repai r— Step A ction Value(s) Yes No

TRANSFER CONTROL SYSTEM 7D1-39
Trouble diagnosis based on the operation switch, transfer indicator lamp and operating
sound “Check 4WD” indicator ON (operation guard based on the transfer actuator
position detection error)
This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator.
Detection (limit) switches detect the actuator operating angle based on their combinations.
The controller monitors transition of the actuator based on the combination of the detection (limit) switch output.
If the transition based on the combinations indicates some trouble, it is memorized, shifting operation is stopped
when the trouble is counted 5 times, and the “Check 4WD” indicator lights up. At this time, the system permits
operation to 2H only.
When such a condition results, inspection of the transfer shift actuator, check of harness related with the
detection (limit) switch, and erasure of the memory of the controller are required.
(Refer to the memory erasure procedure for the erasure of the memory.)
At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad
detected in the operation process shown by that position indicator (example: 4WD indicator when shifting from
2H to 4H).

Caution:
In the course of trouble diagnosis and correction, do not turn ON the ignition with the harness connector of
the transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator
when the ignition is ON.)
If the controller is connected at this condition, a limit SW trouble is judged and the above-described
“Check 4WD” condition is brought about.
This can be reset by clearing the memory.
When it is required to disconnect the harness connector of the actuator and turning the ignition ON,
remove the controller at the same time or remove the IG power fuse of the transfer controller.

TRANSFER CONTROL SYSTEM 7D1-41
Diagnosis from symptom
Check4WD lighting up
Step Action Yes No
1 Check what was done before
the trouble occurred.
Was the harness between the
transfer controller and actuator
disconnected with the ignition
kept ON for the purpose of
servicing the vehicle, etc.?
Or, was the ignition turned ON
(power supplied to the transfer
controller) with the harness of
the actuator removed? If the power is supplied with the
actuator not connected, faulty
position detection switch is
considered.
Clear the memory and trace this
chart from the beginning. Go to step 2.
2 Is the ignition switch ON? Go to step 3. Turn the ignition switch ON and
trace this chart from the
beginning.
3 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 4. Indicator lamp burnt out.
Disconnected harness wire .
After repairing, trace this chart
from the beginning.
4 Isn’t the harness between the
Check4WD indicator and
transfer controller GND shorted? GND (body) short of the indicator
harness.
After repairing, trace this chart
from the beginning. Go to step 5.
5 Check the continuity of harness
between the transfer controller
and transfer actuator. Check
the power short and GND short.
Check the GND harness of the
transfer actuator.
Is a trouble noticed? Repair the harness, clear the
memory and trace this chart from
the beginning. Go to step 6.
6 Check the limit switch of the
actuator.
Is a trouble noticed? Failed actuator. Replace the
actuator, clear the memory and
trace this chart from the
beginning. Clear the memory and trace this
chart from the beginning.
Failed controller.
Replace the controller, clear the
memory and trace this chart from
the beginning.
To check the operation after completing the repair and clearing the memory, shift between 2H and 4L 5 times at
least.
To judge the condition more quickly, ask the customer the situation when the Check4WD lamp lighted up.
When the position indicator blinks at a frequency of 4Hz immediately after occurrence of a trouble, position of
failure which the indicator shows may be limited.
(Since it indicates the situation immediately before detection of failure whether the vehicle is running or standstill so
that possibility of failure around that point is high.)
Status of the transfer when the Check4WD lights up is not always the same. Immediately after occurrence of the
failure, 2H can be operated.

TRANSFER CONTROL SYSTEM 7D1-45
Transfer cannot shift to a position other than 4H.
When shifting from 4H to other position, indicator (4WD, 4Lo, Check4WD, neutral) does
not respond (Only 4WD keeps lighting).
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Failed 4WD indicator and
harness.
After repairing, trace this chart
from the beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON?
Then, only 4H lights up. Go to step 3. Indicator lamps other than the
4WD indicator are burnt out.
(Check for GND short circuit
between the 4WD indicator and
transfer controller.)
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 Press the 2H button.
Is the sound of relay heard from
under the seat, and the sound of
running motor heard? Failed controller.
After replacing the controller,
trace this chart from the
beginning. *Failed operation switch. Or
disconnected or shorted of the
harness for the operation switch.
* The operation switch is an analog type switch which reads the internal composite resistance value at the time of
operation. If an abnormal value is detected, it is judged to be an instruction to 4H.

TRANSFER CONTROL SYSTEM 7D1-47
Though the indicator responds when shifting from 4H to 2H(or other position), it returns
to 4H.
Step Action Yes No
1 Is the ignition switch ON? Go to step 2. Turn the ignition switch ON and
trace this chart from the
beginning.
2 Does the transfer-related
indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON? Go to step 3. Indicator lamp burnt out.
Disconnected harness wire.
After repairing, trace this chart
from the beginning.
3 After 2 seconds, check if the
Check4WD lamp lights up.
Is the Check4WD lamp OFF? Go to step 4. Failed actuator position detection
(limit) switch (LS1, LS2, LS3,
LS4, GND).
Short or disconnection of harness
of this detection switch.
Refer to paragraph of
Check4WD.
After repairing, trace this chart
from the beginning.
4 Press the 2H button.
Is the sound of relay heard from
the transfer controller? Go to step 5. Failed controller.
Replace the controller and trace
this chart from the beginning.
5 Is the sound of running motor
heart? Failed control system of the
transfer mechanism. Check and
repair and trace this chart from
the beginning. Failed actuator motor.
Disconnection of controller motor
drive output circuit or GND short.
After repairing, trace this chart
from the beginning.
If the motor does not or cannot run at all (stuck transfer mechanism, disconnected motor, failed drive circuit), the
lamp blinks at 4Hz when the position is shifted to other position by pressing the button for more 10 seconds (20
seconds in case of neutral position).

7A2-12 TRANSMISSION CONTROL SYSTEM (AW30 –40LE) (V6 3.5L)

Functions of Input / Output Components
Component Function
Transfer low signal Detects the transfer High/Low position.
OD Cancel signal Detects whether the cruise control unit is judged OD cancel mode.
Output revolution sensor
(Transmission) Detects the vehicle speed.
Input revolution sensor
(Transmission) Detects the input revolution (OD direct clutch drum revolution).
Engine revolution sensor Detects the engine revolution with CAN.
Throttle position signal Detects the throttle opening rate with CAN.
Neutral start switch Detects the select lever position.
Pattern select switch Detects whether the driver has selected "NORMAL" or "POWER" mode.
Brake lamp switch Detects whether the driver has pressed the brake pedal or not.
Oil temperature sensor Detects the oil temperature.




I
n
p
u t
Diagnostic start switch Starts self-diagnosis and displays a code for faulty part if any.
I
n
p
u t
/
O
u t
p
u t Data link connector When connected with Tech2 or tester, can communicate the data for function
check, etc.
Shift solenoid S1, S2 Selects shift point and gear position suited to the vehicle running condition on the
basis of TCM output.
Lock-up control solenoid SL Control the lock-up clutch suited to the vehicle running condition on the basis of TCM output.
Pressure control solenoid
STH Adjusts throttle pressure by energizing current of linear pressure control solenoid
to prevent the shift shock and to obtain shift smoothly.
"CHECK TRANS" lamp When trouble has occurred to throttle position sensor, vehicle speed sensor, or
solenoid, "CHECK TRANS" lamp is blinked to warn the driver. If also displays the
trouble code.
A/T OIL TEMP warning
lamp Lights when ATF oil temperature rises. (Turned on at greater than 146


C
(295

F). Turned off at less than 132

C (270

F).
POWER lamp Lights when POWER MODE detected.



O
u
t
p
u
t
3rd Start lamp Lights when 3rd Start MODE detected.
C
o
m
p
u t
e r Transmission Control
Module (TCM) Based on the signal from each switch and sensors, judges necessary shift point
and lock-up operation, and send signal to each solenoid.