warning ISUZU TF SERIES 2004 Repair Manual
[x] Cancel search | Manufacturer: ISUZU, Model Year: 2004, Model line: TF SERIES, Model: ISUZU TF SERIES 2004Pages: 4264, PDF Size: 72.63 MB
Page 130 of 4264
9A1-60 RESTRAINT CONTROL SYSTEM
DTC Chart Test Description
Refer to Charts B and C to diagnose warning lamp
circuit malfunctions.
DTC B0670 (Flash Code 63) Airbag Telltale Circuit Malfunction
Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to Step 2 Go to the “SRS
Diagnostic System
Check”
2
1. Malfunctions within the “AIR BAG” warning lamp circuitry will
set this diagnostic trouble code.
2. These malfunctions are addressed in the “SRS Diagnostic
System Check” via Chart B and Chart C.
3. Failure to properly perform the “SRS Diagnostic System
Check” may result in misdiagnosis.
4. Ignition switch “ON.”
5. Clear SRS diagnostic trouble codes.
Is DTC B0670 set? Ignition switch
“OFF.”
Go to Chart A Repeat the “SRS
Diagnostic System
Check”
Page 131 of 4264
RESTRAINT CONTROL 9A1-61
DTC B1000 (Flash Code 72) SDM Internal Fault (SDM=SRS control unit)
RTW49JLF000101
Circuit Description
DTC B1000 is an indication of a potential internal SRS
control unit malfunction and will set if any of the
following conditions are detected:
1) Microprocessor energy reverse time failure.
2) EEPROM read / write failure.
3) ROM check sum.
4) Calibration check sum fault.
5) Inflators reserve voltage low.
6) Inflators electronic sensor active signal not detected
during commanded deployment.
7) QSDD (High-side/Low-side) FET failure.
8) Frontal accelerometer failure.
9) Phase lock loop lost lock.
10) QSDD communication fault.
DTC Will Set When
Any of the above indicated malfunctions are detected by
the SRS control unit. The malfunctions described
above are tested mainly during “Continuous Monitoring”
and some ones run each ignition cycle.
Action Taken
SRS control unit turns “ON” the “AIR BAG” warning
lamp and sets a diagnostic trouble code.
DTC Will Clear When
SRS control unit is replaced.
Page 132 of 4264
9A1-62 RESTRAINT CONTROL SYSTEM
DTC B1000 (Flash Code 72) SDM Internal Fault (SDM=SRS control unit)
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SRS CONTROL
UNIT. NEVER STRIKE OR JAR THE SRS CONTROL UNIT. NEVER POWER UP THE SRS WHEN THE SRS
CONTROL UNIT IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SRS CONTROL UNIT AND MOUNTING
BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD
THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SRS CONTROL UNIT
COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH
COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY.
CAUTION: If DTC B1000 can not clear by Tech2, it is necessary to replace the SRS control unit.
Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Ignition switch
“OFF.”
Replace SRS
control unit.
Repeat the “SRS
Diagnostic System
Check” Go to the “SRS
Diagnostic System
Check”
Page 138 of 4264
4A-2 PROPELLER SHAFT
Service Precaution
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 PEREFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS
OR THE SRS WIRING, REFER TO THE SRS
SERVICE INFORMATION. FAILURE TO FOLLOW
WARNING COULD RESULT IN POSSIBLE AI
R
BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS. CAUTION : Always use the correct fastener in the
proper location. When you replace a fastener,
use ONLY the exact part number for that
application. ISUZU will call out those fasteners
that require a replacement after removal. ISUZU
will also call out the fasteners that require thread
lockers or thread sealant. UNLESS OTHERWISE
SPECIFIED, do not use supplemental coatings
(Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint
interfaces. Generally, such coatings adversely
affect the fastener torque and the joint clamping
force, and may damage the fastener. When you
install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts
and systems.
Page 166 of 4264
4B-2 REAR AXLE
Service Precaution
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 REFORMING 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, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the prope
r
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers o
r
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints,
greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener torque
and the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.
Page 299 of 4264
SHIFT ON THE FLY SYSTEM 4C2-1
DRIVELINE/AXLE
SHIFT ON THE FLY SYSTEM
CONTENTS
Service Precaution............................................. 4C2-1
Shift On The Fly System .................................... 4C2-2
Outline of Shift on The Fly System ................. 4C2-2
Shift On The Fly Electrical Equipment ............... 4C2-3
Axle Shaft Connection and Disconnection ..... 4C2-3
Actuator Assembly.......................................... 4C2-3
Shift On The Fly System and Association
Parts ................................................................. 4C2-4
Disassembly ................................................... 4C2-5
Inspection and Repair..................................... 4C2-6
Reassembly .................................................... 4C2-9
Torque Specifications ..................................... 4C2-12
Special Service Tool ....................................... 4C2-13
Service Precaution
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, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, o
r
other corrosion inhibitors) on threaded fasteners o
r
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
Page 317 of 4264
BRAKE CONTROL SYSTEM 5A-1
SECTION 5A
BRAKE CONTROL SYSTEM
CONTENTS
Service Precaution ............................................................................................................. 5A-4
General Description ........................................................................................................... 5A-5
EHCU, Brake Pipe Diagram .......................................................................................... 5A-6
Hydraulic Unit (H/U)....................................................................................................... 5A-7
Normal Braking ......................................................................................................... 5A-8
Pressure Isolation (Pressure Maintain) .................................................................. 5A-9
Pressure Reduction .................................................................................................. 5A-10
Brake Release ........................................................................................................... 5A-11
Circuit Diagram.............................................................................................................. 5A-12
Connector List ............................................................................................................... 5A-13
Part Location ................................................................................................................. 5A-15
EHCU Pin-outs ............................................................................................................... 5A-17
System Components ..................................................................................................... 5A-19
Electronic Hydraulic Control Unit (EHCU) .............................................................. 5A-19
ABS Warning Lamp .................................................................................................. 5A-19
Wheel Speed Sensor (WSS)..................................................................................... 5A-19
G-Sensor ................................................................................................................... 5A-19
Normal and Anti-lock Braking ................................................................................. 5A-19
Electronic Brake-force Distribution (EBD) System ................................................ 5A-20
Brake Pedal Travel.................................................................................................... 5A-20
Acronyms and Abbreviations ....................................................................................... 5A-20
General Diagnosis ............................................................................................................. 5A-20
General Information ...................................................................................................... 5A-20
ABS Service Precautions.............................................................................................. 5A-20
Computer System Service Precautions....................................................................... 5A-21
General Service Precautions........................................................................................ 5A-21
Note on Intermittents .................................................................................................... 5A-21
Test Driving ABS Complaint Vehicles ......................................................................... 5A-21
"ABS and Brake" Warning Lamp ................................................................................. 5A-22
Normal Operation .......................................................................................................... 5A-22
Page 318 of 4264
5A-2 BRAKE CONTROL SYSTEM
Brake (EBD) Warning Lamp.......................................................................................... 5A-22
Tech 2 Scan Tool ........................................................................................................... 5A-23
DATA LIST (Tech 2) ....................................................................................................... 5A-26
Actuator Test (Tech 2)................................................................................................... 5A-27
Diagnostic Trouble Codes................................................................................................. 5A-30
Diagnosis By "ABS" Warning Lamp Illumination Pattern .............................................. 5A-32
Basic Diagnostic Flow Chart ............................................................................................ 5A-35
Basic Inspection Procedure .............................................................................................. 5A-37
1. Basic Inspection of Service Brake ........................................................................... 5A-37
2. Ground Inspection .................................................................................................... 5A-37
Wheel Speed Sensor Inspection Procedure .................................................................... 5A-38
Symptom Diagnosis........................................................................................................... 5A-39
ABS Works Frequently But Vehicle Does Not Decelerate ......................................... 5A-39
Uneven Braking Occurs While ABS Works ................................................................. 5A-40
The Wheels Are Locked ................................................................................................ 5A-40
Brake Pedal Feed Is Abnormal ..................................................................................... 5A-41
Braking Sound (From EHCU) Is Heard
While Not Braking ....................................................................................................... 5A-42
No ABS Warning Lamp ................................................................................................. 5A-43
DTC C0221 (Flash Code 21) Front Right Wheel Speed Sensor
Short Circuit or Circuit Open ......................................................................................... 5A-44
DTC C0222 (Flash Code 22) Front Right Wheel Speed Sensor Incorrect Signal.......... 5A-46
DTC C0223 (Flash Code 23) Front Right Wheel Speed Sensor
Signal - Tooth Chipping................................................................................................... 5A-48
DTC C0225 (Flash Code 25) Front Left Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-50
DTC C0226 (Flash Code 26) Front Left Wheel Speed Sensor Incorrect Signal ............ 5A-52
DTC C0227 (Flash Code 27) Front Left Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-54
DTC C0231 (Flash Code 31) Rear Right Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-56
DTC C0232 (Flash Code 32) Rear Right Wheel Speed Sensor Incorrect Signal ........... 5A-58
DTC C0233 (Flash Code 33) Rear Right Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-60
Page 320 of 4264
5A-4 BRAKE CONTROL SYSTEM
DTC C0277 (Flash Code 77) Power Supply Low Input .................................................... 5A-84
DTC C0278 (Flash Code 78) Power Supply High Input ................................................... 5A-84
DTC C0282 (Flash Code 82) 4 Wheel Drive State Input Signal Failure .......................... 5A-86
DTC C0285 (Flash Code 85) Assembly Error (G-sensor) ................................................ 5A-88
Special Tools ...................................................................................................................... 5A-90
Service Precaution
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, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the
proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
Page 334 of 4264
5A-18 BRAKE CONTROL SYSTEM
EHCU Side
Pin No.
(Harness
side
Pin No.) Pin Function Wire
Color Typical Value Note
14
(C67-17) ABS Warning Lamp YEL More than 10V
15
(C67-16) Not Used - -
16
(C67-15) Not Used - -
17
(C67-14) G-Sensor Signal YEL/BLK 2.0~3.0V
(MAX4.0V,MIN1.0V) 4WD Only
It checks in a flat place
(0G:2.5V)
DTC C0276, C0285
18
(C67-13) Front Left Wheel Speed Sensor (+) RED 12
1.5V DTC C0225, C0226,
C0227
19
(C67-12) Rear Right Wheel Speed Sensor (+) ORN 12
1.5V DTC C0231,C0232,
C0233
20
(C67-26) EBD (Brake) Warning Lamp LT BLU More than 10V
21
(C67-25) Starter Switch ON
(Power Supply and Switch Position) BLU/WHT Battery Voltage Control Unit
DTC C0277,C0278
22
(C67-22) Not Used - -
23
(C67-23) Not Used - -
24
(C67-22) Not Used - -
25
(C67-21) Transfer (2-4WD Control Unit) GRY Pulse Signal
(High 4.5V, Low 1.5V) 4WD Only
DTC C0282
26
(C67-20) Front Left Wheel Speed Sensor (-) WHT High Level: 1.28~2.2V
Low Level: 0.5~0.86V DTC C0225, C0226,
C0227
27
(C67-19) Rear Left Wheel Speed Sensor (+) GRY/BLU 12
1.5V
DTC C0235, C0236,
C0237
28
(C67-18) Rear Left Wheel Speed Sensor (-) WHT/BLU High Level: 1.28~2.2V
Low Level: 0.5~0.86V DTC C0235, C0236,
C0237