engine oil ISUZU TF SERIES 2004 Workshop Manual

11A-14 IMMOBILIZER SYSTEM

Pin-outs




RUW48HSF000201


No. Pin Function
1 Back up voltage supply
2 Voltage from ignition switch ON
3 Lamp
4


5


6 Antenna coil positive
7 Ground
8 Engine immobilizer unit
9 To Tech2
10


11

12


13 Antenna coil negative
14 Starter cut relay

IMMOBILIZER SYSTEM 11A-15

Immobilizer coil (Antenna)
Immobilizer coil is install in order that ICU may check
the security code memorized by the transponder (key).

RUW38HSH000301
Transponder (Key)
Transponder is installed in the inside of a key.
Transponder has memorized the security code of a
immobilizer system.

LTW3BASH000101

Legend


(1) Transponder (Key)



Check engine lamp
Check engine lamp displays failure or a system
operation of a immobilizer system by flash of a lamp.

LTW3BASH000201
Engine control module (ECM)
ECM will stop engine, if it communicates with ICU and
abnormalities are detected by a key and the immobilize
r
system.

LTW3BASH000301

Legend


(1) ECM (6VE1 engine)

(2) ECM (C24SE engine)

(3) ECM (4JH1-TC engine)

IMMOBILIZER SYSTEM 11A-31

Diagnostic procedure


Once the cause of DTC is repaired or gone,
engine can be operated normally, and present
DTC becomes history code.


History code is canceled by no repeat failure on 25
consequence ignition key on afterward.


History code cannot be canceled by batter
y
connector disconnected.
Clearing Diagnostic Trouble Codes
IMPORTANT:
Do not clear DTCs unless directed to do
so by the service information provided for each
diagnostic procedure. When DTCs are cleared, the
Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
Verifying Vehicle Repair
Verification of vehicle repair will be more
comprehensive for vehicles with immobilizer system
diagnostic. Following a repair, the technician should
perform the following steps:
1.
Review and record the Fail Records for the DTC
which has been diagnosed.
2.
Clear DTC(s).
3.
Operate the vehicle within conditions noted in the
Fail Records.
4.
Monitor the DTC status information for the DTC
which has been diagnosed until the diagnostic test
associated with that DTC runs.
Following these steps are very important in verifying
repairs on immobilizer systems. Failure to follow these
steps could result in unnecessary repairs.
Diagnostic Aids
Check the condition for system parts.



Installation condition, poor connection, damage,
system parts malfunction. Harness, Fuse, Relay,
Immobilizer coil (antenna), Key, Meter, Immobilize
r
control unit (ICU), Engine control module (ECM).
NOE: Breakage of immobilizer fuse does not operate
immobilizer system. Check engine lamp flashes at this
time.

Check the Electro-Magnetic Interference (EMI)



Location of vehicle check

Move the vehicle to a new location and perform
the check again.


Non-OEM Parts.

Switch is "OFF" or remove the Non-OEM parts and
perform the check again.


Other

Remove the accessory and another key from key.

Check the other items.



Battery voltage is low.


Immobilizer programming functions.

Must be programmed immobilizer system.


Registration for security code, immobilizer control
unit parts number.


Key switch operation.

Immobilizer system may detect a history DTC b
y
the timing of ON-OFF of a key switch.


Active the immobilizer system.


Keyless entry system is malfunction.


Anti theft system is malfunction.

Check the operation

Check the operation "Lock / unlock" by using transmitte
r
(key) on the vehicle.

11A-32 IMMOBILIZER SYSTEM

Diagnostic Trouble Code (DTC) list with ECM





Immobilizer Control Unit (ICU)
DTC
Description Note
B0001
REPLACE ELECTRONIC CONTROL UNIT
(ECU) (IMMOBILIZER FAULT) This error code appears if a RAM /ROM Error was
detected or the EEPROM is defect.
B0002 IMMOBILIZER NOT PROGRAMMED Immobilizer control unit is not programmed.
B0003 TRANSPONDER KEY PROBLEM

Reading of Transponder information failed with ignition
on transponder has a fault.


Hardware fault in reading circuit.
B0004
IMMOBILIZER COIL CIRCUIT (ANTENNA
COIL FAULT) Immobilizer coil has a fault.
B0005 COMMUNICATION LINE W VOLTAGE LOW Short circuit to ground or open circuit.
B0006 COMMUNICATION LINE W VOLTAGE HIGH Short circuit to 12V.
B0007 NO ENGINE REQUEST RECEIVED No ECM Challenge.
B0008 WRONG TRANSPONDER KEY Incorrect security code response received.
B0009 NO TRANSPONDER KEY PROGRAMMED Transponder security code table empty
B0010 UNKNOWN TRANSPONDER KEY Transponder security code not valid.






Engine Control Module (ECM: Gasoline Engine {6VE1, C24SE})

DTC Description
Note
P1626 No Response From Immobilizer Refer to Engine Control system section
P1631 Received Response Was Not Correct Refer to Engine Control system section
P1648 Received Incorrect Security Code Refer to Engine Control system section
P1649 Security Code & Security Key Not
Programmed Refer to Engine Control system section






Engine Control Module (ECM: Diesel Engine {4JH1-TC, 4JA1-TC})

DTC Description Note
P1610 Seeds and Key File Destroyed Refer to Engine Control system section
P1611 Wrong Security Code Entered Refer to Engine Control system section
P1612/
P1613 Immobilizer No or Wrong Signal Refer to Engine Control system section
P1649 Wrong Transponder Key Refer to Engine Control system section

IMMOBILIZER SYSTEM 11A-33

Diagnostic Trouble Code (DTC) list with Engine Immobilizer Unit (4JA1-T Diesel Engine)





Engine Immobilizer Unit
Code
(DTC) Description Detecting Condition
B0011 TRANSPONDER KEY PROBLEM Transponder code unsuccessfully read 5 consecutive
time. (No completely read in 500ms transponder code)
B0012 WRONG TRANSPONDER KEY Immobilizer program no executed.
B0013 IMMOBILIZER NOT PROGRAMMED Processing program no executed.
B0014 NO TRANSPONDER KEY PROGRAMMED Processing to save the transponder key in the control unit
not Executed.
B0015 FREQUENCY SIGNAL Lo Lo level (less than 2.5) input during the Hi level was being
output to the communication line.
B0016 FREQUENCY SIGNAL Hi (Diesel) Hi level (more than 2.5v) input during the Lo level was
being output to the communication line.
B0023 ANTENNA COIL OPEN Antenna coil not connected.
B0024 WRONG TRANSPONDER RESPONSE Transponder response signal with challenge is wrong.
B0055 EEPROM ERROR Write and read cannot be correctly made to and from the
EEPROM in the control unit.

11A-50 IMMOBILIZER SYSTEM

B0011 TRANSPONDER KEY PROBLEM (Only 4JA1-T Engine)
Step Action Value(s) Yes No
1
Was the "Immobilizer System Check" performed? 
Go to Step 2
Go to Immobilizer
System Check
2 Check the key.
Is a key peculiar to a vehicle? 
Go to Step 3
Refer to
Diagnostic Aids
3 Check the immobilizer programming functions.


All transponder (Key).
If a problem is found, repair as necessary.
(Refer to "Important information on Programming")
Was the action complete? 
Go to Step 4
Go to Step 5
4 Recheck the DTC.
1. Key position is “OFF” and keep the position for more
than 30 seconds.
2. Key position is “ON”.
3. Check the DTC on scan tool.
Is DTC B0011 stored? 
Go to Step 5
Verify repair
5 Recheck the DTC.
1. Non-OEM parts switch is "OFF" or remove the Non-
OEM parts.
2. Remove the accessory and another key from key.
3. Move the vehicle to a new location.
4. Key position is “OFF” and keep the position for more
than 30 seconds.
5. Key position is “ON”.
6. Check the DTC on scan tool.
Is DTC B0011 stored? 
Go to Step 6
Verify repair
6 Check the immobilizer coil (antenna) circuit.
1. Key position is “OFF”.
2. Disconnect the immobilizer control unit (ICU).
(immobilizer coil circuit : 3 pin connector)
3. Check the immobilizer coil circuit for an open, short
to ground, or short to voltage.
Also, check the ICU ignition feed circuit for an open or
short to ground and the ICU ground circuit for an open.
Was a problem found? 
Go to Step 7
Go to Step 8
7 Repair or replace the immobilizer coil (antenna) circuit.
Was the action complete? 
Verify repair 
8 Recheck the DTC.
1. Key position is “OFF” and keep the position for more
than 30 seconds.
2. Key position is “ON”.
3. Check the DTC on scan tool.
Is DTC B0011 stored? 
Go to Step 9
Verify repair

IMMOBILIZER SYSTEM 11A-57

B0023 IMMOBILIZER COIL CIRCUIT (ANTENNA COIL FAULT)
(Only 4JA1-T Engine)
Step Action Value(s) Yes No
1
Was the "Immobilizer System Check" performed? 
Go to Step 2
Go to Immobilizer
System Check
2 Check the immobilizer coil (antenna) circuit.
1. Key position is “OFF”.
2. Disconnect the immobilizer control unit (ICU).
(immobilizer coil circuit : 3 pin connector)
3. Check the immobilizer coil circuit for an open, short
to ground, or short to voltage.
Also, check the ICU ignition feed circuit for an open or
short to ground and the ICU ground circuit for an
open.
Was a problem found? 
Go to Step 3
Go to Step 4
3 Repair or replace the immobilizer coil (antenna).
Was the action complete? 
Verify repair 
4 Recheck the DTC.
1. Key position is “OFF” and keep the position for
more than 30 seconds.
2. Key position is “ON”.
3. Check the DTC on scan tool.
Is DTC B0023 stored? 
Go to Step 5
Verify repair
5 Replace the immobilizer control unit (ICU).
IMPORTANT:
The replacement ICU must be
programmed the security data by scan tool.
Was the action complete? 
Verify repair 

POWER-ASSISTED STEERING SYSTEM 3B-7


Power Steering System Test
Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
(3) Power Steering Unit
(4) Power Steering Pump


Test of fluid pressure in the power steering system is
performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, i
f
necessary, must be made.


Inspect pump reservoir for proper fluid level.


Inspect pump belt for proper tension.


Inspect pump driver pulley condition.
1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2.
With the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
3. Check the fluid level. Fill the reservoir with powe
r
steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Powe
r
Steering System in this section.
5. Start the engine and check the fluid level. Add
power steering fluid if required. When the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.

3B-8 POWER-ASSISTED STEERING SYSTEM

6. Fully close the shutoff valve. Record the highest
pressures.


If the pressure recorded is within 9300-9800 kPa
(95-100 kg/cm
2/1350-1420 psi), the pump is
functioning within its specifications.


If the pressure recorded is higher than 9800 kPa
(100 kg/cm
2/1420 psi), the valve in the pump is
defective.


If the pressure recorded is lower than 9300 kPa (95
kg/cm
2/1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the powe
r
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and fron
t
suspension must be thoroughly examined.

Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regula
r
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.


Inspect belt for tightness.


Inspect pulley for looseness or damage. The pulle
y
should not wobble with the engine running.


Inspect hoses so they are not touching any othe
r
parts of the vehicle.


Inspect fluid level and fill to the proper level.

Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130
F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.

Bleeding The Power Steering System
When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the powe
r
steering fluid system, noisy and unsatisfactory operation
of the system may result.

Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only powe
r
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.

Flushing The Power Steering System
1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoi
r
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which ma
y
cause a sudden fluid overflow at the reservoir.

3B-24 POWER-ASSISTED STEERING SYSTEM

Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail. The parts with minor scores may be reused after
lapping the face.

Valve
The sliding face of the valve must be free from burrs
and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).

Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Needle bearing fitting
face must be free from damage and wear.

O-ring, Oil Seal, Retaining Ring
Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. I
f
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.

Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts fo
r
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install rotor and vanes to cam.
5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N




m (2.2-2.7 kg




m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 7.8-12 N




m (0.8-1.2 kg




m/6-9 lb ft)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N




m (5.0-7.0 kg




m/36-51 lb ft)
14. Install pressure switch assembly and tighten it to
specified torque.
Torque: 15-20 N




m (1.5-2.0 kg




m/11-14 lb ft)