jump start ISUZU TF SERIES 2004 Workshop Manual

SUPPLEMENTAL RESTRAINT SYSTEM 9A-21

5. Remove passenger air bag assembly from vehicle.
Refer to “Passenger Air Bag Assembly Removal “.
6. Clear a space on the ground approximately 183
cm (six feet) in diameter where the fixture with
attached air bag assembly is to be placed fo
r
deployment. A paved outdoor location where
there is no activity is preferred. If an outdoo
r
location is not available, a space on the shop floor
where is no activity and sufficient ventilation is
recommended. Ensure that no loose o
r
flammable objects are within the deployment area.
7. Place the 5-8840-2420-0 on the bench vice. This
is necessary to provide sufficient stabilization o
f
the fixture during deployment.
8. Attach the passenger air bag assembly in the 5-
8840-2420-0.
An air bag assembly must be
mounted such that the bag will deploy upward.
SECURELY HAND–TIGHTEN ALL FASTENERS
PRIOR TO DEPLOYMENT.
901RW199
9. Stretch the SRS Deployment Harness and pigtail
adapter from the air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness. (Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.)
11. Connect the air bag assembly to the pigtail adapte
r
on the SRS deployment harness. The SRS
Deployment Harness shall remain shorted and no
t
be connected to a power source until the air bag is
to be deployed. The air bag assembly will
immediately deploy the air bag when a powe
r
source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated
into the air bag assembly connector. Failure to full
y
seat the connectors may leave the shorting bar located
in the air bag assembly connector functioning (shorting
the deployment circuit) and may result in
nondeployment of the air bag assembly.
12.
Verify that the area around the passenger air bag
assembly is clear of all people and loose o
r
flammable objects.
13.
Verify that the passenger air bag assembly is
firmly and properly in 5-8840-2420-0.
14. Notify all people in the immediate area of you
r
intention to deploy the passenger air bag
assembly. The deployment will be accompanied
by a substantial noise which may startle the
uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deplo
y
the air bag assembly.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the air bag
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18.Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembl
y
deployed as intended, proceed with Steps 20
through 23.

BRAKE CONTROL SYSTEM 5A-21

Computer System Service Precautions
The Anti-lock Brake System and Electronic Brake-force
Distribution interfaces directly with the Electronic
Hydraulic Control Unit (EHCU) which is a control
computer that is similar in some regards to the Engine
Control Module. These modules are designed to
withstand normal current draws associated with vehicle
operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the “ON”
position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the “OFF”
position.

General Service Precautions
The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System and Electronic Brake-force Distribution
damage.
 If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before
the welding operation begins.
 The EHCU and valve block connectors should
never be connected or disconnected with the
ignition “ON”.
Note:
 If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the “ABS and Brake” warning lamp
will illuminate. But actually no trouble exists. When
the DTC is not detected and the ABS and BRAKE
warning lamp is on, “How to erase code” is
performed and a ABS and BRAKE warning lamp
are off.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS) and
Electronic Brake-force Distribution (EBD) System
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS and EBD
to a non-operative state by removing the fuse for the
ABS. After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning Lamp does not light.
Note on Intermittents
As with virtually any electronic system, it is difficult to
identify an intermittent failure. In such a case
duplicating the system malfunction during a test drive or
a good description of vehicle behavior from the
customer may be helpful in locating a “most likely”
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most
intermittent problems are caused by faulty electrical
connections or wiring. When an intermittent failure is
encountered, check suspect circuits for:
 Suspected harness damage.
 Poor mating of connector halves or terminals not
fully seated in the connector body (backed out).
 Improperly formed or damaged terminals.

Test Driving ABS Complaint Vehicles
In case that there has been an abnormality in the
lighting pattern of “ABS” warning lamp, the fault can be
located in accordance with the “DIAGNOSIS BY “ABS”
WARNING LAMP ILLUMINATION PATTERN”. In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1.
Start the engine and make sure that the “ABS” W/L
goes OFF. If the W/L remains ON, it means that
the Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
Note: The DTC cannot be cleared if the vehicle speed
does not exceed about 6km/h (4mph) at DTC, even
though the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the
W/L is actuated while driving, read the DTC and
locate the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” .
Note:

Be sure to give a test drive on a wide, even road
with a small traffic.
 If an abnormality is detected, be sure to suspend
the test and start trouble diagnosis at once.

ELECTRICAL-BODY AND CHASSIS 8A-19
Battery-1

BATTERY
Inspection
1. Check the battery terminals 1 for corrosion.
2. Check the battery cables
2 for looseness.
3. Check the battery case
3 for cracks and other damage.
4. Check the battery electrolyte level.

Battery-2

Battery Replacement
1. Disconnect the battery ground cable 1.
2. Disconnect the battery positive cable
2.
3. Remove the battery clamp
3.
4. Remove the battery
Caution:
It is important that the battery ground cable be removed
first.
Removing the battery positive cable first can result in a
short circuit.


Jump Starting the Engine with a Booster Battery
The following description assumes that you are using a booster
battery mounted on a second vehicle.
The listed steps (with some minor modifications) are also
applicable if you are using a naked booster battery or special
battery charging equipment.

8A-20 ELECTRICAL-BODY AND CHASSIS

Caution:
Never push or tow the vehicle in an attempt to start it.
Extensive damage to the emission system and other
vehicle parts will result.
(Only catalytic converter vehicle)
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the procedure outlined below.
Always be aware of the dangers of sparking.
Failure to follow the following procedure can result in:
a. Serious personal injury, specially to your eyes.
b. Extensive property damage from a battery explosion,
battery acid discharge, or electrical file.
c. Extensive damage to the electronic components o
f
both vehicles.
Do not use a 24 volt booster battery.
Serious damage to the vehicle's electrical system and
electronic components will result.

Jump Starting Procedure
1. Set the parking brake on both vehicles.
2. If one or both vehicles is equipped with a manual
transmission, place the gear shift in the "NEUTRAL"
position.
3. Turn off the ignition on both vehicles.
4. Turn off all vehicle lights and accessories.
5 Be sure that the two vehicles are not touching.

Attach the end of one jumper cable to the booster battery
positive terminal.
6
Attach the other end of the same cable to the discharged
battery positive terminal.
7. Once again, check that the booster battery has a 12 vol
t
rating.
8.
Attach one end of the remaining booster cable to the
booster battery negative terminal.
9.
Attach the other end of the booster cable to a solid ground
(such as the air conditioner compressor mounting bracke
t
or the alternator mounting bracket) in the engine room o
f
the vehicle with the discharged battery.
Be sure that the ground connection is at least 500 mm (20
in) from the discharged battery.

ELECTRICAL-BODY AND CHASSIS 8A-21

Caution:
Do not attach the booster cable to the discharged battery
negative terminal.

11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.

8A-256 ELECTRICAL-BODY AND CHASSIS
3. Speedometer pointer jumps erratically

Checkpoint Trouble Cause Countermeasure

Replace the vehicle speed
sensor, or repair an open
circuit in the circuit or a poor
connection at the connectors Vehicle speed sensor
malfunction, or open circuit or
poor connector contact
NG

Replace the case baseboard
assy

Use meter tester to check the
speedometer function

Speedometer malfunction
NG OK
Check the vehicle speed
sensor output by using the
oscilloscope





Inspection of a waveform by oscilloscope
1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 30 B-24 and 9

B-24 of the meter.


2. Install a speedometer tester.
2. Turn on the starter SW.
3. Check the waveform at the time when the vehicle speed is at 60km/h.





4. Trip odometer does not reset


Replace the case baseboard
assy

Faulty reset mechanism
NG Check at other kilometer
figures given by meter tester
(Reset should be made to
zero kilometer)

4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS 6E–121
24 P0500 1 ON
at
next
igniti
on
cycleVehicle Speed Sensor Circuit
High InputVehicle speed is more than
200km/h.ECM uses vehicle speed
5km/h condition as
substitute.Vehicle speed is below
200km/h.1. VSS signal circuit open,
short to ground or short
t o v o l t a g e c i r c u i t .
2. VSS malfunction.
3. Speed meter
m a l f u n c t i o n .
4. TCM malfunction (AT
2 W D ) .
5. ECM malfunction.68 —
A O N
at
next
igniti
on
cycleVehicle Speed Sensor Input
Signal Frequency Too HighInput signal frequency is too
high.ECM uses vehicle speed
5km/h condition as
substitute.Correct vehicle speed signal
frequency. 1. VSS malfunction.
2. Speed meter
m a l f u n c t i o n .
3. Electrical interference.
4. Magnetic interference.
5. ECM malfunction.68 —
B O N
at
next
igniti
on
cycleVehicle Speed Sensor
Incorrect Signal1. Engine speed is more
than 3200rpm (4JA1-TC)
or 3600rpm (4JH1-TC).
2. Fuel injection quantity is
more than 30mg/strk
(4JA1-TC) or 41mg/strk
( 4 J H 1 - T C ) .
3. Vehicle speed is below
1.5km/h.Fuel injection quantity is
reduced.Vehicle speed is more than
1.5km/h.1. VSS open circuit, short
to ground or short to
voltage.
2. Poor connector
c o n n e c t i o n .
3. VSS malfunction.
4. Speed meter
m a l f u n c t i o n .
5. ECM malfunction.68 —
35 P0560 1 OFF System Voltage Too High System voltage is more than
20V.ECM uses 9V conditions as
substitute.System voltage is below 20V. 1. Charge system
m a l f u n c t i o n .
2. Battery jump start cable
misconnect.
3. ECM malfunction.3 /
39—
2 OFF System Voltage Too Low System voltage is below 7V. System voltage is more than
7V.1. Battery power feed
harness open circuit or
short to ground circuit.
2. ECM ground harness
open or poor connection.
3. Poor connector
c o n n e c t i o n .
4 . B a t t e r y m a l f u n c t i o n .
5. Charge system
m a l f u n c t i o n .
6. ECM malfunction.3 /
39— Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

6E–122 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
35 P0560 A OFF System Voltage Malfunction System voltage of PSG
(pump control unit) is below
4.5V or more than 27V.PSG uses default voltage as
substitute.System voltage of PSG is
between 4.5V and 27V.1. Battery power feed
harness open circuit or
short to ground circuit.
2. PSG (pump control unit)
ground harness open or
p o o r c o n n e c t i o n .
3. Poor connector
c o n n e c t i o n .
4 . B a t t e r y m a l f u n c t i o n .
5. Charge system
m a l f u n c t i o n .
6. Battery jump start cable
misconnect.
7. PSG (pump control unit)
malfunction.——
18 P0561 A OFF Ignition Switch Circuit
MalfunctionThe ECM recognized ignition
switch turn off signal during
ECM is activated.ECM stops engine. No recovery until condition
match in the next ignition key
cycle.1. Ignition switch circuit
open or short to ground
c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. Ignition switch
m a l f u n c t i o n .
4. ECM malfunction.39 —
B OFF Ignition Switch Circuit
MalfunctionIgnition switch circuit is
malfunction.1. Ignition switch circuit
open or short to ground
c i r c u i t .
2. Poor connector
c o n n e c t i o n .
3. Ignition switch
m a l f u n c t i o n .
4. ECM malfunction.39 —
- P0602 - Control Module
Programming ErrorECM memory area error. Engine control disabled. Memory are is OK. ECM is not programmed.
——
28 P0606 A ON ECU Malfunction Gate Array communication
error.1. MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d .
2. Desired injection quantity
becomes 0mg/strk.No recovery. ECM malfunction.
——
B ON ECU Malfunction 1. Throttle position is below
1 % .
2. Desired injection quantity
is more than 0mg/strk.
3. Engine speed is more
t h a n 2 0 0 0 r p m . MAB (fuel cutoff solenoid
v a l v e ) i s o p e r a t e d . Desired injection quantity is
b e l o w 0 m g / s t r k . 1 . E C M m a l f u n c t i o n .
2. PSG (pump control unit)
malfunction.
—— Flash
CodeCodeSymptom
CodeMILDTC Name DTC Setting Condition Fail-Safe (Back Up) Recovery Condition Related Failure PartsRelated
ECM Pin
No.Related
Multiple
DTC4JA1-TC
(MT)4JH1-TC
(MT)4JH1-TC
(AT)

6E–254 4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
or low, DTC P0560 (Symptom Code A) will be stored.
Diagnostic Aids
An intermittent may be caused by the following:
Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the “System Voltage” display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0560 (Symptom Code 1) (Flash Code 35)
System Voltage Too High
Step Action Value(s) Yes No
1Was the “On-Board Diagnostic (OBD) System Check”
performed?
—Go to Step 2Go to On Board
Diagnostic
(OBD) System
Check
2 1. Connect the Tech 2.
2. Review and record the failure information.
3. Select “F0: Read DTC Infor As Stored By ECU” in
“F0: Diagnostic Trouble Codes”.
Is the DTC P0560 (Symptom Code 1) stored as
“Present Failure”?—Go to Step 3Refer to
Diagnostic Aids
and Go to Step
3
3 1. Using the Tech 2, ignition “On” and engine “Off”.
2. Select “F1: Clear DTC Information” in “F0:
Diagnostic Trouble Codes” with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the “F0: Read
DTC Infor As Stored By ECU” in the “F0:
Diagnostic Trouble Codes”.
Was the DTC P0560 (Symptom Code 1) stored in this
ignition cycle?—Go to Step 4Refer to
Diagnostic Aids
and Go to Step
4
4 Was the battery jump start cable incorrectly
connecting?—Verify
procedure Go to Step 5
5 1. Using the Tech 2, ignition “On” and engine “On”.
2. Monitor the “System Voltage” in the data display.
3. Load the electrical system by turning on the
headlights, etc..
Does the Tech 2 indicate correct ignition voltage? 10 - 14.5V Go to Step 6Check the
charging
system
6 Is the ECM programmed with the latest software
release?
If not, download the latest software to the ECM using
the “SPS (Service Programming System)”.
Was the problem solved?—Verify repair Go to Step 7

6A-4 ENGINE MECHANICAL (6VE1 3.5L)
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.


Symptom Possible Cause Action
Headlights go out or dim considerably Battery run down or under charged Recharge or replace battery
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace

2. Ignition Trouble




Starting Motor Turns Over But
Engine Does Not Start Spark Test
Disconnect an ignition coil from any spark plug.
Connect the spark plug tester 5884003830, start the
engine, and check if a spark is generated in the spark
plug tester. Before starting the engine, make sure that
the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the part where insulation
of the ignition coil is broken while the engine is running.


Symptom Possible Cause Action
Spark jumps across gap Spark plug defective Clean or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or
engine Refer to item 3 (Trouble in fuel
system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with
module Replace
Poor connections in engine harness Correct
Engine Control Module cable
disconnected or defective Correct or replace