ISUZU TF SERIES 2004 Repair Manual

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.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-43

NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.
RTW33BSH000601
14.Tighten the steering wheel fixing nut to the
specified torque.
Torque: 35 N




m (3.5 kg




m/25 lb ft)
15. Install the SRS air bag assembly. (Refer to “Drive
r
Air Bag Assembly in this section)

9A-44 SUPPLEMENTAL RESTRAINT SYSTEM

Passenger Air Bag Assembly
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AI
R
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY 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 POWER ON THE AIR BAG
ASSEMBLY 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.
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVE
R
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AI
R
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND RIM 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.
WARNING: IN THE EVENT DEPLOYMENT HAS
OCCURRED, INSPECT COIL ASSEMBLY WIRE
FOR ANY SIGNS OF SCORCHING, MELTING O
R
ANY OTHER DAMAGE DUE TO EXCESSIVE HEAT.
IF THE COIL HAS BEEN DAMAGED, REPLACE IT.

Removal
1. Disable the SRS. (Refer to “Disabling the SRS”in
this section)
2. Remove glove box.
3. Remove glove box cover.


4. Remove passenger air bag assembly fixing bolts
and nuts. Universal joint is used when removing a
nut.
060R300043
060R300044
5. Remove passenger air bag assembly.
6. Disconnect passenger air bag assembly harness
connector.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-45

Installation
1. Connect passenger air bag assembly harness
connector.
2. Install passenger air bag assembly.
3. Install passenger air bag assembly fixing bolts and
nuts. Universal joint is used when removing a nut.
Torque: 8 N




m (0.8 kg




m/78 lb in)
060R300043

060R300044
4. Install glove box cover.
5. Install glove box.
6. Enable the SRS. (Refer to “Enabling the SRS” in
this section)

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.

SUPPLEMENTAL RESTRAINT SYSTEM 9A-47

Main Data and Specifications
Fastener Tightening Specification
Application N




m kg




m Ft.lb
SRS control unit 7 0.7 5
Steering wheel fixing bolt 35 3.5 25
Steering column (dash panel side fixing bolts) 20 2.0 14
Steering column (Pedal bracket fixing bolt) 20 2.0 14
Steering column (Universal joint fixing bolt) 31 3.2 23
Passenger Air Bag fixing bolt & nut 8 0.8 5.8
Pretensioner seat belt bolt 55 5.6 40

9A-48 SUPPLEMENTAL RESTRAINT SYSTEM

Special Tools
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
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE
PERSONAL INJURY MAY RESULT.

5-8840-2421-0 SRS Driver/Passenger Load
Tool
901RS146
The SRS Driver/Passenger Load Tool 5-8840-2421-0
is used only when called for in this section. It is used
as a diagnostic aid and safety device to prevent
inadvertent air bag assembly deployment.
The load tool has three yellow connectors attached to
its case.
The three small connectors are electrically functional
and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of the small connectors is used to substitute for
the load of the driver air bag assembly when it is
connected at the top of the column to the SRS coil
assembly. Another small connector is used to
substitute for the load of the driver air bag assembly
and the SRS coil assembly when it is connected at the
base of the column to the SRS wiring harness. The
third small connector is used to substitute for the load
of the passenger air bag assembly when connected to
the passenger air bag assembly harness connector.
By substituting the resistance of the load tool when
called for, a determination can be made as to whether
an inflator circuit component is causing system
malfunction and which component is causing the
malfunction. The load tool should be used only when
specifically called for in the diagnostic procedures.

5-8840-0285-0 DVM
901RS163
The 5-8840-0285-0 DVM is the preferred DVM for use
in SRS diagnosis and repair. However, 5-8840-0366-
0 may be used if 5-8840-0285-0 is not available. No
other DVMs are approved for SRS diagnosis and
repair.

Scan Tool
901RW176

SUPPLEMENTAL RESTRAINT SYSTEM 9A-49

The Tech 2 is used to read and clear SRS Diagnostic
Trouble Codes (DTCs). Refer to the Tech 2
Operators, Manual for specific information on how to
use the Tech 2.

5-8840-0385-0 Connector Test Adapter Kit
901RS151
The 5-8840-0385-0 Connector Test Adapter Kit must
be used whenever a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the DVM prove, such as spreading or
bending. The adapter will also give an idea of
whether contact tension is sufficient, helping to find an
open or intermittent open due to poor terminal contact.

5-8840-2468-0 SRS Deployment Tool
901RW106
The 5-8840-2468-0 SRS Deployment Tool must be
used for deployment of the undeployed air bag.

5-8840-2420-0 SRS Deployment Fixture
901RV056
The 5-8840-2420-0 SRS Deployment Fixture must be
used for deployment of the undeployed passenger
side air bag.

5-8840-2796-0 SRS Adapter for Load Tool
901RW107
The 5-8840-2796-0 SRS Adapter for Load Tool must
be used with 5-8840-2421-0 SRS Driver/Passenger
Load Tool.

9A-50 SUPPLEMENTAL RESTRAINT SYSTEM

5-8840-2795-0 SRS Adapter for
Deployment Tool
901RW107
The 5-8840-2795-0 SRS Adapter for Deployment Tool
must be used with 5-8840-2468-0 SRS Deployment
Tool.

5-8521-0016-0 Steering Wheel remover
LNW28BSH003101