air condition ISUZU TF SERIES 2004 Repair Manual

8A-172 ELECTRICAL-BODY AND CHASSIS
2. One side of horn does not blow

Checkpoint Trouble Cause Countermeasure

Repair open circuit or
reconnect the connectorOpen circuit or poor connector
contact NG
Voltage between 1 C-20
(1 C-21) - ground with
horn switch depressed
(Should be battery voltage
present)
Replace the horn assemblyHorn continuity between
connectorsFaulty horn assembly NG
OK



3. Insufficient horn volume

Clfean and/or remove the
foreign materialStain foreign material in the
horn NGHorn
Recharge or replace the
batteryBattery conditionDischarged battery NG
OK

ELECTRICAL-BODY AND CHASSIS 8A-195
INSPECTION AND REPAIR




R-9 R-10
R-1 R-6



DOOR SWITCH
Door Switch Connections

Connector
SW No.
R-9 R-10
R-1 R-6
position Terminal No.
1 Body Ground
PUSHED
RELEASED





WARNING BUZZER
1. Warning Buzzer Circuit


Warning function Operational conditions
Taillights left on The buzzer sounds when both the tail relay and the FRT door switch-drive
side are turned on. To stop the sound of the buzzer, turn on the starter
switch.




Harness side
B-45


2. Warning Buzzer Harness Side Connector Circuit
Disconnect the warning buzzer connector and check
continuity and voltage between the warning buzzer harness
side connector terminals.

Terminal
NO. Wire
color Connecting to Check itemConnecting
terminal Check condition Standard
3 G/R Tail relay 3-Ground Lighting SW “ON” Approx. 12V
6 Y Fuse CB-5 Voltage
6-Ground Starter SW “ON” Approx. 12V

Door SW Open Continuity
(FRT-LH)
Continuity Close No continuity
2 B Ground 2-Ground - Continuity
FRT door-LH 1-Ground 1
B/W

ELECTRICAL-BODY AND CHASSIS 8A-205
6. Auto-stop function of the wiper motor does not operate

Checkpoint Trouble Cause Countermeasure


Repair open circuit or
connector contact

Open circuit or poor connector
contact
NG

Repair open circuit or
connector contact

Open circuit or poor connector
contact
NG Continuity between the
intermittent relay harness side
connector 6
C-3 and the
wiper motor harness side
connector 6
C-4

Replace the intermittent relay

Relay malfunction
NG
Intermittent relay function

Wiper motor function
1. Disconnect the wiper motor
connector
2. Connect the motor
connector 5
B-59 to the
battery (+) terminal and 1
C-4 to the (-) terminal,
and then change the
connection of the battery (+)
terminal to the connector 4
C-4 while the motor
rotating at a low speed
3. Check to see if the wiper
motor stops at the auto stop
position when connecting
the connector terminals 3
C-4 and 1 C-4 in this
condition
Continuity between the wiper
& washer SW. connector
terminals 5
B-59 and 6 B-59
at the “OFF” position
OK

Replace the wiper motor

Wiper motor malfunction
NG
Repair an open circuit or a
poor connection of the
connectors between the fuse
No. RHD: C-9 (20A) and 4

C-4
Voltage between the wiper
motor harness side connector
terminal 4
C-4 and the
ground (Should be battery
voltage present)

Open circuit or poor connector
contact
NG
OK OK
OK

ELECTRICAL-BODY AND CHASSIS 8A-281
HEATER AND AIR CONDITIONING
PARTS LOCATION (RHD)







RTW48AXF018801 & RTW48AXF018901

ELECTRICAL-BODY AND CHASSIS 8A-307
INSPECTION AND REPAIR








Harness side
D-20 D-5

Driver Seat Side Power Window & Door Lock
Switch
1. Harness Side Connector Circuit
Check voltage and continuity between the switch harness
side connector terminals as shown in the following table.


Terminal
No. Wire
color Connecting to Check itemConnectin
g terminalCheck condition Standard
Door lock SW
Driver seat Lock Continuity
(Lock) side door
Unlock No continuity
Door lock SW
Driver seat Lock No continuity
(Unlock) side door
Unlock Continuity
3 (D-5) L/R Ground
Continuity 3-Ground - Continuity

4 (D-5)
L/R Door lock
actuator (Lock) (Resistance)

4-5
- Continuity
There is some
resistance

5 (D-5)
L Door lock
actuator
(Unlock)
5-4
- Continuity
There is some
resistance
1 (D-5) LG/W Fuse
C-14 (20A) Voltage 1- Ground - Battery voltage
(Approx. 12V)
14-Ground L/R 14 (D-20)
13-Ground L/Y
13 (D-20)

ELECTRICAL-BODY AND CHASSIS 8A-323
INSPECTION AND REPAIR

B-8


Power Window Relay
Check continuity between the relay terminals.
2- 1......................... No continuity
(When battery voltage is applied between
3 and 4)
2- 1......................... Continuity






Harness side
D-20 D-5


Driver Seat Side Power Window & Door Lock
Switch
1. Harness Side Connector Circuit
Disconnect the switch connector, and check voltage and
continuity between the harness side connector terminals as
shown in the following table.


Terminal
No. Wire
color Connecting to Check item Connectin
g terminal Check condition Standard
6 G/R Power window
relay Voltage 6-Ground Starter SW “ON” Approx.
12V
7 BR/R
Power window
8 BR/W motor

3 B Ground Continuity 3-Ground - Continuity






Harness side
D-10


Front Passenger’s Power Window & Door Lock
Switch
1. Harness Side Connector Circuit
Disconnect the switch connector, and check voltage and
continuity between the harness side connector terminals as
shown in the following table.

Continuity
- 7-8 Continuity

6 – 2 TROUBLESHOOTING
Basic Inspection Procedure
Follow the under inspection procedure, when the problem vehicle comes workshop.
Step Inspection point Inspection result YES NO
1 Check the check engine lamp Is the check engine lamp turn
ON ? Go to section
6E “On Board
Diagnostic
(OBD) System
Check" Go to Step 2
2 The battery fluid level and the
gravity Was the problem found? Re-charge the
battery or
replace the
battery Go to Step 3
3 The engine coolant capacity Was the problem found? Replenish the
engine coolant Go to Step 4
4 The engine oil level Was the problem found? Replenish the
engine oil Go to Step 5
5 The air cleaner element Was the problem found? Clean or
replace Go to Step 6
6 The piping fixing condition (oil,
vacuum and fuel piping) Was the problem found? Return normal
condition Go to Step 7
7 The drive belt tension and break Was the problem found? Re-adjust the
tension or
replace Go to Step 8
8 Go to section 6E “On Board
Diagnostic (OBD) System
Check” Was the problem found?
Verify repair Go to Step 9
9 Go to mechanical
troubleshooting chart Was the problem found?
Verify repair —

TROUBLESHOOTING 6 – 3
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
1–1 Starter motor inoperative
Step Action Value(s) Yes No
1 Check the starter switch.
Does the starter switch work? —
Go to Step 2 Repair or
replace the
starter switch
2 Check the starter relay.
Does the starter relay work? —
Go to Step 3 Repair or
replace the
starter relay
3 Check the magnetic switch.
Does the magnetic switch work? —
Go to Step 4 Repair or
replace the
magnetic
switch
4 Check the pinion gear condition on the starter motor.
Was the condition normal? —
Go to Step 5 Replace the
pinion gear
5 Check the brush wear or brush spring weakness.
Was the condition normal? —
Replace the
starter motor
assembly Repair or
replace the
brush or brush
spring

1-2 Starter motor operates but engine does not turn over
Step Action Value(s) Yes No
1 Check the engine internal seizure.
Was the engine seized? —
Repair or
replace seized
parts Check other
DTC by Tech
2 and go to
indicated DTC

6 – 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine
Incase of the fuel not being delivered to the injection pump
Step Action Value(s) Yes No
1 Check clogged, damaged the fuel piping or the
connector loosen.
Was any problem found? —
Repair replace
problem parts. Go to Step 2
2 Was the over flow valve on the fuel filter closed? — Repair replace
the over flow
valve Go to Step 3
3 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 4
4 Was the fuel line air bled? — Go to Step 5 Bleed the air
5 Are any DTC stored? — Go to indicated
DTC Solved

Incase of the fuel is being delivered to the injection pump
Step Action Value(s) Yes No
1 Was the water contain in the fuel? — Replace the
fuel Go to Step 2
2 Was the fuel line air bled? — Go to Step 5 Bleed the air
3 Was the injection spray condition complete? —
Go to Step 4 Replace the
injection nozzle
4 Was the injection nozzle injection starting pressure
OK? (See below)
Go to Step 5 Replace the
injection nozzle
5 Was the injection nozzle sticking? — Replace the
injection nozzle Go to Step 6
6 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)

TROUBLESHOOTING 6 – 5
2. Unstable Idling
Step Action Value(s) Yes No
1 Was the fuel line air bled completely? — Go to Step 3 Bleed the air
2 Was the fuel line leakage or blockage found? — Repair or
replace relation
parts. Go to Step 4
3 Was the water contained in the fuel? — Replace the
fuel Go to Step 5
4 Was the fuel filter element clogged? — Replace the
fuel filter
element Go to Step 6
5 Was the injection starting pressure or the injection
spray condition OK? (See below)
Go to Step 7 Replace the
injection nozzle
6 Was the injection nozzle sticking? See Step 6 Replace the
injection nozzle Go to Step 8
7 Check the throttle valve condition.
Was the idling port clogged in the throttle valve? — Repair or
replace the
throttle valve Go to Step 9
8 Was the valve clearance improper adjusted? 0.4 mm
(0.016 in)
both intake
and exhaust
valves Adjust the
valve clearance Go to Step 10
9 Was the compression pressure OK? 3,040 kPa
(31 kg/cm2,
441 psi) at
200rpm
Go to Step 11 Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
10 Are any DTC stored? — Go to indicated
DTC Solved

Injection nozzle opening pressure
1st = 19.5 MPa (199 kg/cm2, 2828 psi)