lock ISUZU TF SERIES 2004 Workshop Manual

11B – 60 ANTITHEFT SYSTEM
DTC 50 A/D Converter Defect Or Battery Voltage Less Than 9 Volt
Step Action Value (s) Yes No
1
2
3
4
5
6Was the Antitheft System Check
performed?
Recheck the DTC.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Check the DTC on the Tech-2.
Is DTC 50 stored?
Check the antilock system voltage.
1. Key position is “OFF”.
2. Install the Tech-2 on vehicle.
3. Key position is “ON”.
4. Observe to display system voltage data with
the Tech-2.
Is the voltage near the specified value ?
1. Key position is “OFF”.
2. Check the battery voltage.
3. If a problem found, repair as necessary.
(Chage battery)
Was the problem found?
1. Check the ignition feed circuit for an open,
short to ground.
Also, check the ACU ground circuit for
damage.
2. If a problem found, repair as necessary.
Was the problem found?
Replace the antitheft control unit (ACU).
IMPORTANT:The replacement ACU must be
programmed the security data by the Tech-2.
Was the action complete?—
—
12V
—
—
—Go to Step 2
Go to Step 3
Go to Step 7
Verify repair
Verify repair
Verify repairGo to antitheft
System Check
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Refer to
Diagnostic Aids
—

3A-8 FRONT ALIGNMENT




Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel a
t
front end.
3.
Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks
reach the rear end position.
5. Take measurement of distance B between the cente
r
marks at rear end.
The toe-in can be calculated with next formula.
Toe-in = B - A
Toe-in mm (in)

4

2
(Except high ride suspension) 0
2 (0
0.08)





To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque N
m (kgf
m/lb
ft)
986.0 (10.00.6 / 72.34.3)

RTW330SH000101

Trim Height
Trim Height : at Curb Weight (Reference Data)
Trim height (Z) = A - B
Front mm (in)

Z
105(4.13)

3A-12 FRONT ALIGNMENT




Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel a
t
front end.
3.
Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks
reach the rear end position.
5. Take measurement of distance B between the cente
r
marks at rear end.
The toe-in can be calculated with next formula.
Toe-in = B - A
Toe-in mm (in)

4
2 (High ride suspension)
4
4 02 (00.08)






To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque N
m (kgf
m/lb
ft)
986.0 (10.00.6 / 72.34.3)

RTW330SH000201

Trim Height
Trim Height : at Curb Weight
Trim height (Z) = A - B
mm (in)

Z
140
5 (5.51)

POWER-ASSISTED STEERING SYSTEM 3B-3


PAGE
Combination Switch ........................................................................................................ 3B – 43
Combination Switch and Associated Parts .............................................................. 3B – 43
Removal ....................................................................................................................... 3B – 43
Installation ................................................................................................................... 3B – 46
Lock Cylinder ................................................................................................................... 3B – 49
Lock Cylinder and Associated Parts ......................................................................... 3B – 49
Removal ....................................................................................................................... 3B – 49
Installation ................................................................................................................... 3B – 52
System Inspection (with SRS air bag) ....................................................................... 3B – 54
Steering Column .............................................................................................................. 3B – 55
Steering Column and Associated Parts .................................................................... 3B – 55
Removal ....................................................................................................................... 3B – 55
Inspection .................................................................................................................... 3B – 58
Installation ................................................................................................................... 3B – 59
System Inspection (with SRS air bag) ....................................................................... 3B – 61
Supplemental Restraint System Steering Wheel & Column and Associated Parts ... 3B – 62
Main Data and Specifications ..................................................................................... 3B – 62
Special Tools ............................................................................................................... 3B – 62

3B-6 POWER-ASSISTED STEERING SYSTEM

Steering Column


This illustration is based on the RHD model.
RTW43BLF000101
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLT-
METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED
IN THIS MANUAL. DO NOT USE A NON-POWERED
PROBE-TYPE TESTER.
INSTRUCTION IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft o
f
the vehicle.
The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use
only the specified screws, bolts and nuts as designated,
and tighten them to the specified torque.
Handle the column with care when it is removed from
the vehicle. A sharp blow on the end of steering shaft o
r
shift lever, or dropping the assembly could shear o
r
loosen the fastenens that maintain column rigidity.

POWER-ASSISTED STEERING SYSTEM 3B-9

4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the powe
r
steering system components. Do not re-use any
drained power steering fluid.

Steering Wheel Free Play Inspection
060R300016
1. With the tires in the straight-ahead position, check
the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 - 30 mm (0 - 1.18 in)
2.
Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. When test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.

Front End Alignment Inspection and
Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. To adjust the toe-in angle, loosen the lock nuts (2)
on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
This illustration is based on the RHD model.
431R30006
2. Tighten the lock nut to the specified torque.
Torque:
92 - 104 N




m (9.4 - 10.6 kg




m/68 - 77 lb ft)

POWER-ASSISTED STEERING SYSTEM 3B-13

Power Steering Unit Disassembled View

This illustration is based on the RHD model. 440R300003
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line
(8) Inner Ball Joint Assembly
(9) Tab Washer
(10) Mounting Rubber
(11) Housing Assembly



Disassembly
NOTE: The valve housing is made of aluminum and
care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
4. Remove oil line, mounting rubber and dust cover.
Inspection and Repair
Inspect the following parts for wear, damage or any
abnormal conditions.

3B-14 POWER-ASSISTED STEERING SYSTEM


Tie-rod End
If looseness or play is found when checked by moving
the end of ball joint at tie-rod end, replace tie-rod end.

Tie-rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.

Rubber Parts
If wear or damage is found through inspection, replace
with new ones.

Reassembly
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Torque: 10 - 15 N




m (1.0 – 1.5 kg




m/87 - 130 lb in)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
Torque: 69 - 98 N




m (7.0 – 10.0 kg




m/51 - 72 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4.
Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque:
92 - 104 N




m (9.4 – 10.6 kg




m/68 - 77 lb ft)

Main Data and Specifications
General Specifications
2WD 4WD
Power steering Without With
Type Rack and pinion
Rack stroke mm (in) 138 (5.43) 138 (5.43) 152 (5.98)
Steering unit
Lock to lock 4.84 3.38 3.26

POWER-ASSISTED STEERING SYSTEM 3B-31

Supplemental Restraint System Steering Wheel & Column
Service Precaution
This steering wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific to
SRS components. When servicing a vehicle equipped
with Supplemental Restraint System, pay close attention
to all WARNINGS and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
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, REFE
R
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, O
R
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES FOLLOWING THE PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY
CONTAIN A SMALL AMOUNT OF SODIUM
HYDROXIDE, A BY-PRODUCT OF THE
DEPLOYMENT REACTION, THAT IS IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY, AND WASH YOUR HANDS WITH MILD
SOAP AND WATER AFTERWARDS.

WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN AI
R
BAG ASSEMBLY BY THE WIRES OR CONNECTO
R
ON THE UNDERSIDE OF MODULE. IN THE CASE OF
AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A
BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.
NEVER REST A STEERING COLUMN ASSEMBLY
ON THE STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN VERTICAL.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG ASSEMBLY
TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT. OTHERWISE,
PERSONAL INJURY COULD RESULT.
TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLT-
METER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN 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.

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.

POWER-ASSISTED STEERING SYSTEM 3B-33

Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait a
t
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
5. Disable the SRS (Refer to "Disabling the SRS" in
this section). (with SRS air bag)
6. Check the both side hole of the steering cover. (with
SRS air bag)
060R300025


7. Check the position of the pins in a hole. Push the
pin in the direction of an arrow. (with SRS air bag)
060R300032
8. Push the four pins at 
5
6 mm bar. (with SRS air
bag)
060R300031
9. Cancel the lock four pins. (with SRS air bag)