oil ISUZU TF SERIES 2004 Workshop 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 21 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-1
RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SERVICING
PAGE
Service Precaution ............................................................................................................ 9A- 3
General Description ...................................................................................................... 9A- 4
Restraint Devices ..................................................................................................... 9A- 4
System Description .................................................................................................. 9A- 5
SRS Component And Wiring Location View ............................................................... 9A- 6
Component Description ............................................................................................... 9A- 8
SRS Control Unit ...................................................................................................... 9A- 8
"Air Bag" Warning Lamp.......................................................................................... 9A- 8
SRS Coil Assembly................................................................................................... 9A- 9
Air Bag Assemblies .................................................................................................. 9A- 9
Seat Belt with Pretensioner (If so equipped) ......................................................... 9A- 10
Steering Column ....................................................................................................... 9A- 10
Knee Bolster ............................................................................................................. 9A- 10
Definitions...................................................................................................................... 9A- 10
Diagnosis .......................................................................................................................9A- 12
Diagnostic Trouble Codes ....................................................................................... 9A- 12
Scan Tool Diagnostics ............................................................................................. 9A- 12
Use Of Special Tools ................................................................................................ 9A- 12
SRS Connector Body Face Views................................................................................ 9A- 13
Repairs And Inspections Required After An Accident ............................................... 9A- 14
Accident With Deployment-Component Replacement And Inspections ............. 9A- 14
Accident With or Without Deployment-Component Inspection ........................... 9A- 14
SRS Control Unit Replacement Guidelines ............................................................ 9A- 14
Wiring Damage ......................................................................................................... 9A- 14
SRS Connector (Plastic Body And Terminal Metal Pin) Damage ......................... 9A- 14
SRS Wire Pigtail Damage......................................................................................... 9A- 14
Page 23 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-3
PAGE
Steering Wheel ................................................................................................................... 9A- 35
Service Precautions ...................................................................................................... 9A- 35
Removal .........................................................................................................................9A- 35
Installation ..................................................................................................................... 9A- 36
SRS Coil Assembly ............................................................................................................ 9A- 37
Service Precautions ...................................................................................................... 9A- 37
Removal. ........................................................................................................................9A- 37
Installation. .................................................................................................................... 9A- 38
Steering Column ................................................................................................................9A- 40
Service Precautions ...................................................................................................... 9A- 40
Removal .........................................................................................................................9A- 40
Installation ..................................................................................................................... 9A- 41
Passenger Air Bag Assembly ........................................................................................... 9A- 44
Service Precautions ...................................................................................................... 9A- 44
Removal .........................................................................................................................9A- 44
Installation ..................................................................................................................... 9A- 45
Pretensioner Seat Belt (If so quipped) ............................................................................. 9A- 46
Removal .........................................................................................................................9A- 46
Installation ..................................................................................................................... 9A- 46
Main Data and Specifications ........................................................................................... 9A- 47
Fastener Tightening Specification............................................................................... 9A- 47
Special Tools...................................................................................................................... 9A- 48
5-8840-2421-0 SRS Driver/Passenger Load Tool........................................................ 9A- 48
5-8840-0285-0 DVM........................................................................................................ 9A- 48
Scan Tool .......................................................................................................................9A- 48
5-8840-0385-0 Connector Test Adapter Kit ................................................................. 9A- 49
5-8840-2468-0 SRS Deployment Tool .......................................................................... 9A- 49
5-8840-2420-0 SRS Deployment Fixture ...................................................................... 9A- 49
5-8840-2796-0 SRS Adapter for Load Tool .................................................................. 9A- 49
5-8840-2795-0 SRS Adapter for Deployment Tool ...................................................... 9A- 50
5-8521-0016-0 Steering Wheel remover ...................................................................... 9A- 50
Page 25 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-5
System Description
The SRS consists of the SRS control unit, the driver
air bag assembly, the SRS coil assembly, the
passenger air bag assembly and the “AIR BAG”
warning lamp in the instrument cluster. The SRS
control unit, SRS coil assembly (driver side only),
driver air bag assembly, passenger air bag assembly
and connector wire make up the deployment loops.
The function of the deployment loops is to supply
current through air bag assembly, which will cause
deployment of the air bags in the event of a frontal
crash of sufficient force, up to 30 degrees off the
centerline of the vehicle. The air bag assemblies are
only supplied enough current to deploy when the SRS
control unit detects vehicle velocity changes severe
enough to warrant deployment.
The SRS control unit contains a sensing device which
converts vehicle velocity change to an electrical signal.
The electrical signal generated is processed by the
SRS control unit and then compared to a value stored
in memory. When the generated signal exceeds the
stored value, the SRS control unit will cause current to
flow through the air bag assembly deploying the air
bags.
RTW49JLF000101
Page 29 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-9
060R300007
SRS Coil Assembly
The SRS coil assembly consists of two current
carrying coils. This is attached to the steering column
and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver air bag assembly.
There is a shorting clip on the yellow connector near
the base of steering column which connects the SRS
coil to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air
bag assembly when the yellow connector is
disconnected. The circuit to the driver air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SRS components.
060R300047
Air Bag Assemblies
The air bag assembly consist of an inflatable air bag
assembly and an inflator. When the vehicle is in a
frontal crash of sufficient force.
The SRS control unit causes current flow through the
deployment loops. Current passing through the inflator
ignites the material in the air bag assembly. The gas
produced from this reaction rapidly inflates the air bag
assembly.
There is a shorting clip on the driver air bag assembly
connector which connects the SRS coil assembly. The
shorting clip shorts across the driver air bag assembly
circuits when driver air bag assembly connector is
disconnected.
The circuit to the driver air bag assembly is shorted in
this way to help prevent unwanted deployment of the
air bag when servicing the driver air bag assembly, the
steering column or other SRS components.
060R300012
There is a shorting clip on the passenger air bag
assembly connector which connects to the SRS
harness. The shorting clip shorts across the
passenger air bag assembly circuit when the
passenger air bag assembly connector is
disconnected. The circuit to the passenger air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the passenger air bag assembly, the instrument panel
or other SRS components.
Page 31 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-11
“Continuous Monitoring”
Tests performed by the SRS control unit on the SRS
every 100 milliseconds while “Ignition 1” voltage is in
the normal operating voltage range at the SRS control
unit.
Data Link Connector (DLC)
Formerly “DLC” a connector which allows
communication with an external computer, such as a
scan tool.
Datum Line
A base line parallel to the plane of the underbody or
frame from which all vertical measurements originate.
Deploy
To inflate the air bag.
Deployment Loops
The circuits which supply current to the air bag
assemblies to deploy the air bag.
Diagnostic Trouble Code (DTC)
Formerly “Code”, a numerical designator used by the
SRS control unit to indicate specific SRS malfunctions.
Driver Current Source
An output of the SRS control unit which applies current
into the driver air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
“Initiator Assembly Resistance Test”
Tests performed once each ignition cycle when no
malfunctions are detected during “Turn–ON” or
“Continuous Monitoring”. This test checks for the
correct SRS control unit configuration for the vehicle,
shorts to “Ignition 1” in the deployment loops, high
resistance or opens in the “Driver Side” and
“Passenger Side” circuits and measures the resistance
of the inflator assembly consisting of 1) Initiators, 2)
SRS coil assembly (driver side only), 3) Connectors
and associated wiring.
Normal Operating Voltage Range
The voltage measured between the SRS control unit
“Ignition 1” terminals and “Ground” terminals is
between 9 and 16 volts.
Passenger Current Source
An output of the SRS control unit which applies current
into the passenger air bag assembly circuit during the
“Initiator Assembly Resistance Test”.
Passenger Air Bag Assembly
An assembly located in the front of the passenger side
of the instrument panel consisting of an inflatable bag,
an inflator and an initiator.
Scan Tool
An external computer used to read diagnostic
information from on–board computers via the data link
connector.
SRS control unit
SRS control unit which provides reserve energy to the
deployment loops, deploys the air bags when required
and performs diagnostic monitoring of all SRS
components.
Serial Data
Information representing the status of the SRS.
SRS
Supplemental Restraint System.
SRS Coil Assembly
An assembly of two current–carrying coils in the driver
deployment loop that allows the rotation of the steering
wheel while maintaining the continuous contact of the
driver deployment loop to the driver air bag assembly.
SRS Wiring Harness
The wires and connectors that electrically connect the
components in the SRS.
“Turn–ON”
Test which the SRS control unit performs on the SRS
once during each ignition cycle immediately after
“Ignition 1” voltage is applied to the SRS control unit
and before “Continuous Monitoring”.
Page 34 of 4264
9A-14 SUPPLEMENTAL RESTRAINT SYSTEM
Repairs And Inspections Required
After An Accident
If any SRS components are damaged, they must be
replaced. If SRS component mounting points are
damaged, they must be replaced.
Never use SRS parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized dealer; they may be used fo
r
SRS repairs.
Do not attempt to service the SRS control unit, the
SRS coil assembly, or the air bag assembly.
Service of these items is by replacement only.
Verify the part number of replacement air bag
assembly.
CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
CAUTION: Proper operation of the sensors and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SRS
control unit, air bag assembly and dimensional
inspection of the steering column. Any visible
damage to the SRS control unit mounting bracket
(s) requires replacement, and the steering column
must be dimensionally inspected, whethe
r
deployment occurred or not.
Accident With Deployment – Component
Replacement And Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
Air bag assembly
SRS control unit
CAUTION: Refer to “SRS control unit
Replacement Guidelines” below for important
information on SRS control unit replacement in
both deployment and non deployment crashes.
SRS coil assembly — Inspect wiring and connecto
r
for any signs of scorching, melting, or damage due
to excessive heat. Replace if damaged. Refer to
section “SRS Coil Assembly” in this manual.
Accident With or Without Deployment –
Component Inspection
Certain SRS system components and rotation parts
must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Steering column —Refer to Inspection Required
“After an Accident” in this manual.
Knee bolsters and mounting points —Inspect fo
r
any distortion, bending, cracking, or other damage.
I/P steering column reinforcement plate —Inspect
for any distortion, bending, cracking, or othe
r
damage.
I/P braces —Inspect for any distortion, bending,
cracking, or other damage.
Seat belts and mounting points — Refer to “Seat
Belts” in Section “Seat Belt” of this workshop
manual.
SRS Control Unit Replacement Guidelines
SRS control unit replacement policy requires
replacement of SRS control unit, after crash involving
air bag deployment when “SRS Warning Lamp” turn
“ON”, “SRS Diagnosis” should be done according to
Section “Restraint Control System.”
Wiring Damage
If any SRS wire harness is damaged, it should be
replaced. Don't repair SRS harness. It is replace only.
SRS Connector (Plastic Body And
Terminal Metal Pin) Damage
If any connector or terminal in the SRS wire harness
(except pigtails) is damaged, it should be replaced.
SRS Wire Pigtail Damage
If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples
of “pigtail” components are the driver air bag
assembly, the passenger air bag assembly, and the
SRS coil assembly.
Page 48 of 4264
9A-28 SUPPLEMENTAL RESTRAINT SYSTEM
– Driver air bag assembly
– Passenger air bag assembly
– Steering wheel
– SRS coil assembly
– Steering column
– Knee bolster and instrument panel mounting
attachments
– Driver seat and belt
– Passenger seat and belt
– SRS control unit
SRS control unit always should be checked according
to “SRS Control Unit Replacement Guidelines.”
CAUTION: Refer to “SRS control unit Replacement
Guidelines” below for important information on
SRS control unit replacement in both deployment
and non–deployment crashes.
Inspect SRS coil assembly wiring and steering wheel
for any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to steering wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SRS control unit, the SRS
harness, the SRS coil assembly, the air bag assembly,
the steering wheel, or the steering column. Service of
these items is replacement only. Verify replacement
part numbers.
CAUTION: Proper operation of the SRS control
unit and supplemental restraint system (SRS)
requires that any repairs to the vehicle structure
return it to its original production configuration.
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.
Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
827RW028
Page 52 of 4264
9A-32 SUPPLEMENTAL RESTRAINT SYSTEM
Driver 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 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.
NOTE: In the event deployment has occurred, inspec
t
coil assembly wire for any signs of scorching, melting
or 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. Check the both side hole of the steering cover.
060R300025
3. Check the position of the pins in a hole. Push the
pin in the direction of an arrow.
060R300032
Page 55 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-35
Steering Wheel
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 O
R
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.
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. Remove the SRS air bag assembly. (Refer to
“Driver Air Bag Assembly” in this section)
2. Remove steering wheel attachment nut.
060R300009
3. Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the tires to the straight ahead position before
removing the steering wheel. Install steering wheel
puller onto steering wheel and remove steering
wheel with 5-8521-0016-0.
5. Feed wiring through the wheel and remove wheel.
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.
Page 57 of 4264
SUPPLEMENTAL RESTRAINT SYSTEM 9A-37
SRS Coil 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.
NOTE: In the event deployment has occurred, inspec
t
coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Remove the SRS air bag assembly. (Refer to
“Driver Air Bag Assembly” in this seciton)
2. Remove the steering wheel attachment nut.
060R300009
3. Apply a setting mark across the steering wheel
and shaft so parts can be reassembled in thei
r
original position.
060R300024
4. Move the tires to the straight ahead position before
removing the steering wheel and remove wheel
with 5-8521-0016-0.
5. Feed wiring though the wheel and remove wheel.
6. Remove the steering lower cover and engine hood
opening lever.
7. Remove the driver knee bolster assembly.
8. Remove the steering column cover.
9. Remove air conditioning lower duct.
10.Disconnect the wiring harness connectors located
at the base of steering column.